Edition: May 2001 Revision: December 2001 (01) Publication No.: SM1A00-1P11E0E
QUICK REFERENCE INDEX
GENERAL INFORMATI...
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Edition: May 2001 Revision: December 2001 (01) Publication No.: SM1A00-1P11E0E
QUICK REFERENCE INDEX
GENERAL INFORMATION
GI
MAINTENANCE
MA
ENGINE MECHANICAL
EM
PRIMERA
ENGINE LUBRICATION & COOLING SYSTEMS
LC
MODEL P11-144 SERIES
ENGINE CONTROL SYSTEM
QG16/18DE
ENGINE CONTROL SYSTEM
SR20DE
ENGINE CONTROL SYSTEM
CD20T
ACCELERATOR CONTROL, FUEL & EXHAUST SYSTEMS
FE
CLUTCH
CL
MANUAL TRANSAXLE
MT
AUTOMATIC TRANSAXLE
AT
FRONT AXLE & FRONT SUSPENSION
FA
REAR AXLE & REAR SUSPENSION
RA
BRAKE SYSTEM
BR
STEERING SYSTEM
ST
RESTRAINT SYSTEM
RS
BODY & TRIM
BT
HEATER & AIR CONDITIONER
HA
ELECTRICAL SYSTEM
EL
ALPHABETICAL INDEX
IDX
NISSAN EUROPE N.V. © 2001 NISSAN EUROPE N.V. Produced in The Netherlands Not to be reproduced in whole or in part without the prior written permission of Nissan Europe N.V., Amsterdam, the Netherlands.
FOREWORD This manual contains maintenance and repair procedures for NISSAN PRIMERA, model P11-144 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 completely satisfy himself that neither his safety nor the vehicle’s safety will be jeopardized by the service method selected.
NISSAN EUROPE N.V. Service Operations Section Amsterdam, The Netherlands
GENERAL INFORMATION SECTION
GI
CONTENTS MODIFICATIONS ........................................................... 2 PRECAUTIONS ............................................................. 3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 3 Precautions for NATS ................................................ 3 Precautions for Super Lock System.......................... 4 General Precautions .................................................. 4 Precautions for Multiport Fuel Injection System or Engine Control Module.......................................... 6 Precautions for Three Way Catalyst.......................... 6 Precautions for Turbocharger .................................... 6 Precautions for Engine Oils....................................... 6 Precautions for Fuel .................................................. 7 Precautions for Air Conditioning ................................ 8 HOW TO USE THIS MANUAL...................................... 9 HOW TO READ WIRING DIAGRAMS.........................11 Sample/Wiring Diagram - EXAMPL - .......................11 Description ............................................................... 13 Wiring Diagram Codes (Cell Codes) ....................... 20 HOW TO CHECK TERMINAL..................................... 21 How to Probe Connectors ....................................... 21 How to Check Enlarged Contact Spring of Terminal ................................................................... 22 Waterproof Connector Inspection ............................ 23 Terminal Lock Inspection ......................................... 23
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT ...................................... 24 Work Flow................................................................ 24 Incident Simulation Tests......................................... 25 Circuit Inspection ..................................................... 29 HOW TO FOLLOW TROUBLE DIAGNOSES ............ 35 How to Follow Test Groups in Trouble Diagnoses.. 35 CONSULT-II CHECKING SYSTEM ............................. 39 Function and System Application ............................ 39 Nickel Metal Hydride Battery Replacement............. 39 Checking Equipment................................................ 39 CONSULT-II Data Link Connector (DLC) Circuit .... 40 IDENTIFICATION INFORMATION............................... 41 Model Variation ........................................................ 41 Identification Number............................................... 43 Dimensions .............................................................. 45 Wheels and Tires..................................................... 45 LIFTING POINTS AND TOW TRUCK TOWING......... 46 Preparation .............................................................. 46 Board-on Lift ............................................................ 46 Garage Jack and Safety Stand ............................... 47 2-pole Lift ................................................................. 48 Tow Truck Towing .................................................... 49 TIGHTENING TORQUE OF STANDARD BOLTS ...... 50 ISO 15031-2 TERMINOLOGY LIST ............................ 51 ISO 15031-2 Terminology List ................................. 51
GI
MODIFICATIONS APPLIED FROM: SJN *** P11U 0526000 * : Any of the possibilities. See Vehicle Identification Number Arrangement.
OUTLINE OF MODIFICATIONS GENERAL ●
Various running changes on engine control system, electrical systems, body etc. Note that the introduction timing of some of the running changes may not be entirely in line with the above mentioned VIN.
●
For some running changes, the VIN (Vehicle Identification Number) is mentioned to specify the timing of the change implemention. The VIN No. may not be an exact number, there is an error range of approx. ±50 cars.
GI-2
PRECAUTIONS Observe the following precautions to ensure safe and proper servicing.
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System “Air Bag” and “Seat Belt Pre-tensioner”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pretensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. If the vehicle is equipped with side air bag as the Supplemental Restraint System, the side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (which is one of components of air bags for a frontal collision), wiring harness, warning lamp (which is one of components of air bags for a frontal collision). 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 dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to do so in this Service Manual. SRS wiring harnesses are covered with yellow insulation (either just before the harness connectors or for the complete harness), for easy identification.
Precautions for NATS NATS (Nissan Anti-Theft System)
SGI916
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 NATS security indicator is located on the instrument panel. The indicator flashes when the ignition switch is in “LOCK” or “Acc” position. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system. ● When NATS detects trouble, the malfunction indicator (MI) flashes. This flashing indicates that the anti-theft is not functioning, so prompt service is required. ● When servicing NATS (trouble diagnoses, system initialisation and additional registration of other NATS ignition key IDs), CONSULT-II hardware and CONSULT-II NATS software is necessary.
GI-3
PRECAUTIONS Precautions for NATS (Cont’d) Regarding the procedures of NATS initialisation and NATS ignition key ID registration, refer to CONSULT-II operation manual for 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 initialisation and additional registration of other NATS ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to obtain all keys from vehicle owner. A maximum of four key IDs can be registered into NATS.
Precautions for Super Lock System Locking the driver’s door or front passenger’s door with the key or remote control will lock all doors and activate the Super Lock System. The Super Lock System is designed to prevent theft as it can only be released when a front door is unlocked using a key or remote control. This means, none of the door locks can be operated from the inside using the door lock knob when the Super Lock System is activated.
General Precautions ●
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 flammable materials. Special care should be taken when handling any flammable 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.
●
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.
SGI285
●
SGI231
GI-4
PRECAUTIONS General Precautions (Cont’d) ●
Before starting repairs which do not require battery power: Turn off ignition switch. Disconnect the negative battery terminal.
●
To prevent serious burns: Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot.
●
Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers. Take care that keys, buckles or buttons do not scratch paint.
●
Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 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. 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 ECMs). Static electricity may damage internal electronic components. 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. 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. Dispose of drained oil or solvent used for cleaning parts in an appropriate manner.
SEF289H
SGI233
Seat cover
Fender cover SGI234
● ● ● ●
● ● ● ● ● ●
GI-5
PRECAUTIONS Precautions for Multiport Fuel Injection System or Engine Control Module ●
● SGI787
●
Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM (Engine Control Module): Turn ignition switch to “LOCK” 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.
Precautions for Three Way Catalyst If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions below: ● 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 Turbocharger Cold engine
SGI292
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 it off.
Precautions for Engine Oils 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-6
PRECAUTIONS Precautions for Engine Oils (Cont’d) ● ● ● ● ● ● ●
● ● ● ●
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, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. If skin disorders develop, obtain medical advice without delay. Where practicable, 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 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 courses. The regulations concerning the pollution of the environment will vary between regions.
Precautions for Fuel GASOLINE ENGINE: Unleaded gasoline of at least 95 octane (RON) CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the catalytic converter.
DIESEL ENGINE*: Diesel fuel of at least 50 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.
GI-7
PRECAUTIONS Precautions for Fuel (Cont’d) 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 temperatures below −7°C (20°F). Cold temperatures 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 alternative fuels to diesel fuel.
Precautions for Air Conditioning Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA section (“HFC134a (R134a) Service Procedure”, “SERVICE PROCEDURES”) for specific instructions.
GI-8
HOW TO USE THIS MANUAL ● ● ● ● ● ●
ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and page you are searching for. 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 mating 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 letters which designate the particular section and a number (e.g. “BR-5”). THE LARGE ILLUSTRATIONS are exploded views (See below) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (MICROFICHE) or (EURO)FAST system (E.g. SEC440) 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. “Example” SEC. 440 Pad retainer (Upper side) 54 - 64 (5.5 - 6.5, 40 - 47)
Main pin Torque member
to sliding portion
Pin boot
Inner shim
Copper washer 17 - 20 (1.7 - 2.0, 12 - 14)
Pad retainer (Lower side)
Brake hose
Outer shim Cylinder body Piston seal
Pad Dust seal Piston
Air bleeder 7 - 9 (0.7 - 0.9, 62 - 80) Pin bolt 22 - 31 (2.2 - 3.2, 16 - 23)
N·m (kg-m, ft-lb) N·m (kg-m, in-lb) SBR364AC
●
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.
GI-9
HOW TO USE THIS MANUAL The following SYMBOLS AND ABBREVIATIONS are used: : Tightening torque M/T : Should be lubricated with grease. A/T Unless otherwise indicated, use A/C recommended multi-purpose P/S grease. SST : Should be lubricated with oil. SAE : Sealing point : Checking point SMJ ATF : Always replace after every disasD1 sembly. D2 P : Apply petroleum jelly. p : Apply ATF. D3 ★ : Select with proper thickness. D4 ✩ : Adjustment is required. OD SDS : Service Data and Specifications 22 LH, RH : Left-Hand, Right-Hand 21 LHD, RHD : Left-Hand Drive, Right-Hand Drive 12 FR, RR : Front, Rear 11
●
,
●
● ● ●
: : : : : : : : : : : : : : : : :
Manual Transaxle/Transmission Automatic Transaxle/Transmission Air Conditioner Power Steering Special Service Tools Society of Automotive Engineers, Inc. Super Multiple Junction Automatic Transmission Fluid Drive range 1st gear Drive range 2nd gear Drive range 3rd gear Drive range 4th gear Overdrive 2nd range 2nd gear 2nd range 1st gear 1st range 2nd gear 1st range 1st gear
The UNITS given in this manual are primarily expressed as an SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. “Example” Tightening torque: 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb) TROUBLE DIAGNOSES are included in sections dealing with complicated components and systems. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. 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.
GI-10
HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL — ●
For Description, refer to GI-13. BATTERY
Refer to optional splice.
JOINT CONNECTOR-1 To ELEXAMPL Preceding page Next page
To GIEXAMPL-04
SWITCH
DIODE
RELAY
POWER POSITION A
GND
MOTOR
POSITION B
SIGNAL UNIT
GND
MOTOR CONTROL MODULE
A/T models M/T models
.
REFER TO THE FOLLOWING M1 , E103 FUSE BLOCK Junction Box (J/B) M2 FUSE BLOCK Junction Box (J/B) E127 FUSE BLOCK Junction Box (J/B)
YGI001
GI-11
HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL — (Cont’d) OPTIONAL SPLICE Optional splice
M/T models
A/T models
BATTERY
BATTERY
RELAY
RELAY
SGI858
GI-12
HOW TO READ WIRING DIAGRAMS Description Number
Item
1 p
Power condition
2 p
Fusible link
3 p
Fusible link/fuse location
4 p
Fuse
5 p
Current rating
6 p
Connectors
7 p
Optional splice
8 p
Splice
9 p
Page crossing
10 p
Common connector
11 p
Option abbreviation
12 p
Relay
13 p
Connectors
14 p
Wire color
15 p
Option description
16 p
Switch
17 p
Assembly parts
18 p
Cell code
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 EL 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 alphanumeric reference (1A, 5B, etc.) indicates that the connector is an SMJ connector.
● ●
●
The open circle shows that the splice is optional depending on vehicle application.
●
The shaded circle shows that the splice is always on the vehicle.
●
This arrow shows that the circuit continues to an adjacent page. The A will match with the A on the preceding or next page.
● ●
The dotted lines between terminals show that these terminals are part of the same connector.
●
This shows that the circuit is optional depending on vehicle application.
●
This shows an internal representation of the relay. For details, refer to EL section (“STANDARDIZED RELAY”).
●
This shows that the connector is connected to the body or a terminal with bolt or nut.
●
This shows a code for the color of the wire. B = Black BR = Brown W = White OR = Orange R = Red P = Pink G = Green PU = Purple L = Blue GY = Gray Y = Yellow SB = Sky Blue LG = Light Green CH = Dark Brown DG = Dark 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
●
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.
GI-13
HOW TO READ WIRING DIAGRAMS Description (Cont’d) Number
Item
Description ●
19 p
Current flow arrow
20 p
System branch
●
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 “F—E” shows that current can flow in either direction depending on circuit operation.
●
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.
21 p
Page crossing
22 p
Shielded line
●
The line enclosed by broken line circle shows shield wire.
23 p
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 p
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 details and to locate the connector, refer to EL section (“Main Harness”, “HARNESS LAYOUT”). A coordinate grid is included for complex harnesses to aid in locating connectors.
●
●
25 p
Connector number
26 p
Ground (GND)
27 p
Ground (GND)
28 p
Connector views
29 p
Common component
30 p
Connector color
31 p
Fusible link and fuse box
32 p
Reference area
●
The line spliced and grounded under wire color shows that ground line is spliced at the grounded connector.
●
This shows the ground connection.
●
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 14 of this chart. wire color codes, Number p
●
This shows the arrangement of fusible link(s) and fuse(s), used for connector views of “POWER SUPPLY ROUTING” in EL 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 foldout page.
GI-14
HOW TO READ WIRING DIAGRAMS Description (Cont’d) Example View from terminal side
CONNECTOR SYMBOLS Connector symbol
Single line Connector
View from harness side
Direction mark
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 .
●
Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.
Connector symbol
Double line Direction mark
Connector
SGI364
Example Male terminal
Guide
Connector
Connector symbol
Female terminal
Guide
Connector Connector symbol SGI363
GI-15
HOW TO READ WIRING DIAGRAMS Description (Cont’d) ●
Example: Harness indication
● BCM connector
Single line
Connector numbers that indicate the harness side are enclosed by a single line. Connector numbers that indicate components are enclosed by a double line.
Component indication
A/C mode switch connector
Double line
SGI940
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 in the “LOCK” position, ● doors, hood and trunk lid/back door are closed, ● pedals are not depressed, and ● parking brake is released.
Normally open
Normally closed
SGI860
GI-16
HOW TO READ WIRING DIAGRAMS Description (Cont’d) DETECTABLE LINES AND NON-DETECTABLE LINES IGNITION SWITCH ON or START
VEHICLE SPEED SENSOR
SPEED OMETER M27
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 (Engine Control Module) 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.
Detectable line for DTC Non-detectable line for DTC
ECM (ENGINE CONTROL MODULE) SGI862
GI-17
HOW TO READ WIRING DIAGRAMS Description (Cont’d) MULTIPLE SWITCH The continuity of a 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. Example
(SWITCH CHART)
(SWITCH DIAGRAM)
WIPER SWITCH
INT
HI
INT
LO OFF
WASH
OFF
LO
HI WASH
WIPER SWITCH
Both switches are turned in combination
Continuity circuit of wiper switch SWITCH POSITION
CONTINUITY CIRCUIT
OFF INT LO HI WASH
SGI875
GI-18
HOW TO READ WIRING DIAGRAMS Description (Cont’d) REFERENCE AREA The Reference Area of the wiring diagram contains references to additional electrical reference pages at the 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. Example Super Multiple Junction (SMJ)
(Main harness)
(Engine room harness)
(Main harness)
(Engine room harness)
Connector Area Reference Area: Refer to the electrical reference pages at the end of the manual for the terminal arrangement of the connectors shown here in the “Reference Area”.
SGI092A
Super multiple junction (SMJ) In a wiring diagram, the SMJ connectors include a letter of the alphabet in the terminal number. SMJ connector numbers are shown in the Reference Area of the wiring diagram. SMJ terminal arrangement can be found on the electrical reference pages at the end of the manual. For terminal arrangement of these connectors, refer to “SUPER MULTIPLE JUNCTION (SMJ)” electrical reference page at the end of the manual.
GI-19
HOW TO READ WIRING DIAGRAMS Wiring Diagram Codes (Cell Codes) Use the chart below to find out what each wiring diagram code stands for. Code
Section
Wiring Diagram Name
Code
Section
Wiring Diagram Name
AAC/V
EC
IACV-AAC Valve
ILL
EL
Illumination
ABS ACL/SW
BR EC
Anti-lock Brake System Accelerator Position Switch
INJECT
EC
Injector
INT/L
EL
ADJRES
EC
Adjustment Resistor
A/C
HA
Manual Air Conditioner
KS
EC
Interior, Spot and Trunk Room Lamps Knock Sensor
A/CCUT ACC/SW
EC EC
Air Conditioner Cut Control Accelerator Switch (FC)
LOAD
EC
Load Signal
LKUP
EC
A/T
AT
Automatic Transmission
Torque Converter Clutch Solenoid Valve
AIM
EL
Headlamp Aiming Control
LOAD
EC
Load Signal
APS AIRREG AT/C AUDIO BACK/L BUZZER CHARGE CKPS CHIME CMPS COOL/F CSPS
EC EC EC EL EL EL EL EC EL EC EC EC
EC
MAIN
EC
METER
EL
MI MIRROR NATS NLS O2S
EC EL EL EC EC
PGC/V
EC
DTRL
EL
PLA PNP/SW POWER
EC EC EL
DEF D/LOCK
EL EL
PST/SW
EC
DTRL
EL
ECTS
EC
EGRC/V
EC
FCUT F/FOG FICD F/PUMP FTS GLOW GOVNR
EC EL EC EC EC EC EC
R/FOG SROOF SRS S/LOCK S/SIG START STOP/L
EL EL RS EL EC EL EL
TAIL/L
EL
TCV TPS
EC EC
TURN
EL
H/LAMP
EL
H/SEAT HEAT HLC HO2S HORN IATS IGN/SG
EL HA EL EC EL EC EC
Accelerator Position Sensor IACV-Air Regulator A/T Control Audio Back-up Lamp Warning Buzzer Charging System Crankshaft Position Sensor Warning Chime Camshaft Position Sensor Cooling Fan Control Control Sleeve Position Sensor Headlamp — With Daytime Light System Rear Window Defogger Power Door Lock Headlamp — With Daytime Light System Engine Coolant Temperature Sensor EGR and canister Control Solenoid Valve Fuel Cut Solenoid Valve Front Fog Lamp IACV-FICD Solenoid Valve Fuel Pump Fuel Temperature Sensor Quick-glow system Electric Governor Headlamp — Without Daytime Light System Heated Seat Heater Headlamp Washer Heated Oxygen Sensor Horn, Cigarette Lighter, Clock Intake Air Temperature Sensor Ignition Signal
MAFS
VSS VTC WARN WINDOW WIPER WIP/R
EC EC EL EL EL EL
Mass Air Flow Sensor Main Power Supply and Ground Circuit Speedometer, Tachometer, Temp. and Fuel Gauges Malfunction Indicator Door Mirror Nissan Anti-Theft System Needle Lift Sensor Oxygen Sensor EVAP Canister Purge Control Solenoid Valve Partial Load Advance Control Park/Neutral Position Switch Power Supply Routing Power Steering Oil Pressure Switch Rear Fog Lamp Sun Roof Supplemental Restraint System Power Door Lock — Super Lock Start Signal Starting System Stop Lamp Clearance, License, and Tail Lamps Injection Timing Control Valve Throttle Position Sensor Turn Signal and Hazard Warning Lamps Vehicle Speed Sensor VTC Solenoid Valve Warning Lamps Power Window Front Wiper and Washer Rear Wiper and Washer
GI-20
HOW TO CHECK TERMINAL How to Probe Connectors Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks. The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip.
PROBING FROM HARNESS SIDE
Connector
Alligator clip
Standard type (not waterproof type) connector should be probed from harness side with “T” pin. ● If the connector has a rear cover such as a ECM connector, remove the rear cover before probing the terminal. ● Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result.
DMM
“T” pin SGI841
PROBING FROM TERMINAL SIDE Female Terminal ● There is a small notch above each female terminal. Probe each terminal with the “T” pin through the notch. Do not insert any object other than the same type male terminal into female terminal.
“T” pin
Sectional view (Female)
SEL265V
●
Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing.
Retainer
SEL266V
Male Terminal Carefully probe the contact surface of each terminal using a “T” pin. Do not bend terminal.
Sectional view (Male)
“T” pin
Male terminal
SEL267V
GI-21
HOW TO CHECK TERMINAL How to Check Enlarged Contact Spring of Terminal An enlarged contact spring of a terminal may create intermittent signals in the circuit. If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal.
1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire. Use a male terminal which matches the female terminal. 2. Disconnect the suspected faulty connector and hold it terminal side up. Male terminal
Wire
SEL270V
3. While holding the wire of the male terminal, try to insert the male terminal into the female terminal. Do not force the male terminal into the female terminal with your hands. Do not apply force against the terminal.
SEL271V
4. While moving the connector, check whether the male terminal can be easily inserted or not.
SEL272V
●
OK
If the male terminal can be easily inserted into the female terminal, replace the female terminal.
NG
SEL273V
GI-22
HOW TO CHECK TERMINAL Waterproof Connector Inspection
Wire seal
If water enters the connector, it can short interior circuits. This may lead to intermittent problems. Check the following items to maintain the original waterproof characteristics.
Connector housing
RUBBER SEAL INSPECTION ●
Rubber seal SEL275V
●
Most waterproof connectors are provided with a rubber seal between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications. The rubber seal may come off when connectors are disconnected. Whenever connectors are reconnected, make sure the rubber seal is properly installed on either side of male or female connector.
WIRE SEAL INSPECTION The wire seal must be installed on the wire insertion area of a waterproof connector. Be sure that the seal is installed properly.
Terminal Lock Inspection
Male connector Female connector
Locked terminal
Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit.
Intermittent contact Unlocked terminal SEL330V
GI-23
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Work Flow
START
LISTEN TO CUSTOMER COMPLAINTS
STEP 1
VERIFY THE SYMPTOM
STEP 2 SYMPTOM SIMULATION
NARROW THE POSSIBLE CAUSE
STEP 3
INSPECT THE CIRCUIT
STEP 4
REPAIR THE CIRCUIT
STEP 5
STEP 6
MAKE SURE THE CIRCUIT WORKS
END SGI838
STEP STEP 1
DESCRIPTION Get detailed information about the conditions and the environment when the incident occurred. The following are key pieces of information required to make a good analysis: WHAT
Vehicle Model, Engine, Transmission and the System (i.e. Radio).
WHEN
Date, Time of Day, Weather Conditions, Frequency.
WHERE
Road Conditions, Altitude and Traffic Situation.
HOW
System Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories have been installed.
STEP 2
Operate the system, road test if necessary. Verify the parameter of the incident. If the problem can not be duplicated, refer to “Incident Simulation Tests” next page.
STEP 3
Get the proper diagnosis materials together including: POWER SUPPLY ROUTING System Operation Descriptions Applicable Service Manual Sections 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.
GI-24
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT 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 ● 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 illustration below.
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. Vibration test
Tap gently.
Shake gently. Bend gently.
GI-25
SGI839
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d) Possible cause Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Intermittent signals through pierced insulation
Enlarged
Proper crimp
Normal
Insulation not removed
Wire strands missing
DEFORMED (ENLARGED) FEMALE TERMINALS DEFECTIVE INSULATION STRIPPING Male half Female half Seal
Locked terminal
Loose
Seal Unlocked terminal (Hidden by wire seal)
Intermittent contact
Check for unlocked terminals by pulling each wire at the end of the connector.
TERMINAL NOT PROPERLY SEATED SGI840
Tester probe
Connector
Alligator clip “T” pin
DMM SGI841
When probing a connector it is possible to enlarge the contact spring opening. If this occurs it may create an intermittent signal in the circuit. When probing a connector, use care not to enlarge the opening. The probe of the Digital Multimeter (DMM) may not fit into the connector cavity. In such cases make an extension of a “T” pin and probe it from the harness side of the connector. Most DMMs have accessory alligator clips. Slide these over the probe to allow clipping the “T” pin for a better contact. If you have any difficulty probing a terminal, inspect the terminal. Ensure you have not accidentally opened the contact spring or pulled a wire loose.
GI-26
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d) 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.
Under seating areas 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.
HEAT SENSITIVE
Heating test
The owner’s problem 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.
Heat gun
Do not heat above 60°C (140°F). SGI842
GI-27
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d) FREEZING
Freezing test
Water in connector
Short
Solenoid SGI843
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.
WATER INTRUSION
Water intrusion test
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.
SGI844
ELECTRICAL LOAD
Electrical load test
The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on.
“ON”
COLD OR HOT START UP A/C
Rear window defogger
Light switch
SGI845
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.
GI-28
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT 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.
SHORT
There are two types of shorts. ●
SHORT CIRCUIT
When a circuit contacts another circuit and causes the normal resistance to change.
●
SHORT TO GROUND
When a circuit contacts a ground source and grounds the circuit.
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. Inspection for opens (Voltage check) DMM
FUSE BLOCK
N.C. RELAY
SOLENOID
SW1 OPEN A B+
SIDE
OPEN B
OPEN C DMM
DMM (Continuity check)
SW2 SGI846
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 (OL, 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 schematic above. 1. 2. 3. 4.
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) 5. 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) 6. 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 above example.
GI-29
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) Voltage check method To help in understanding the diagnosis of open circuits please refer to the previous schematic. 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. 1. Connect one probe of the DMM to a known good ground. 2. Begin probing at one end of the circuit and work your way to the other end. 3. With SW1 open, probe at SW1 to check for voltage. voltage; open is further down the circuit than SW1. no voltage; open is between fuse block and SW1 (point A). 4. Close SW1 and probe at relay. voltage; open is further down the circuit than the relay. no voltage; open is between SW1 and relay (point B). 5. Close the relay and probe at the solenoid. voltage; open is further down the circuit than the solenoid. no voltage; open is between relay and solenoid (point C). Any powered circuit can be diagnosed using the approach in the above example.
TESTING FOR “SHORTS” IN THE CIRCUIT To simplify the discussion of shorts in the system please refer to the schematic below. Inspection for shorts IGN “ON” OR “START”
(Resistance check) FUSE BLOCK
DMM
RELAY
SOLENOID
SW1 B+
SIDE SHORT A
SHORT B
DMM (Voltage check)
SW2
SHORT C SGI847
Resistance check method 1. Disconnect the battery negative cable and remove the blown fuse. 2. Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. 3. Connect one probe of the ohmmeter to the load side of the fuse terminal. Connect the other probe to a known good ground. 4. 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. 5. 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. 6. 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.
GI-30
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) Voltage check method 1. Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. 2. Turn the ignition key to the ON or START position. Verify battery voltage at the B + side of the fuse terminal (one lead on the B + terminal side of the fuse block and one lead on a known good ground). 3. With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage; short is between fuse block and SW1 (point A). no voltage; short is further down the circuit than SW1. 4. 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. 5. 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: 1. Remove the ground bolt screw or clip. 2. Inspect all mating surfaces for tarnish, dirt, rust, etc. 3. Clean as required to assure good contact. 4. Reinstall bolt or screw securely. 5. Inspect for “add-on” accessories which may be interfering with the ground circuit. 6. 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. Ground Inspection
Remove bolt (screw).
Inspect mating surfaces for tarnish, dirt, rust, etc. Clean as required to assure good contact.
Reinstall bolt (screw) securely.
SGI853
GI-31
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) 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 ohmmeter, 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. If repairs are needed always use wire that is of the same or larger gauge.
Measuring voltage drop — Accumulated method 1. Connect the voltmeter across the connector or part of the circuit you want to check. The positive lead of the voltmeter should be closer to power and the negative lead closer to ground. 2. Operate the circuit. 3. The voltmeter 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. Symptom: Dim bulb or no operation 0 (zero) ohm resistance between switch and bulb DMM
Load Switch Power
Ground
Connection with high resistance
Battery
Ground
SGI848
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.
GI-32
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) 1. Connect the voltmeter as shown, starting at the battery and working your way around the circuit. 2. An unusually large voltage drop will indicate a component or wire that needs to be repaired. The illustration shows a poor connection causes a 4 volt drop. Switch
Battery Connection with high resistance
The chart that follows illustrates some maximum allowable voltage drops. These values are given as a guideline, the exact value for each component may vary. COMPONENT Wire Ground Connections Switch Contacts
VOLTAGE DROP Negligible <.001 volts Approx. 0.1 volts Approx. 0.3 volts
SGI854
GI-33
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) Relationship between open/short (high resistance) circuit and the ECM pin control System Description: When the switch is ON, the ECM lights up the lamp. Case 1 Switch FUSE
TERMINAL: 1 Monitoring of the switch operation (ON/OFF)
TERMINAL: 2 Power supply to light up the lamp
Lamp
Battery
Short: Open:
FUSE blows. Inoperative lamp
Short: FUSE blows when switch is ON. Open: Inoperative lamp
ECM
Short: Open:
Short & Open: Inoperative lamp
No problem Inoperative lamp
High resistance: (Single strand) See below.*
Input-output voltage chart Pin No.
Item
Condition
Voltage value [V]
In case of high resistance such as single strand [V] *
1
Switch
Switch ON
Battery voltage
Lower than battery voltage Approx. 8 (Example)
Approx. 0
Approx. 0
Battery voltage
Approx. 0 (Inoperative lamp)
Approx. 0
Approx. 0
OFF 2
Lamp
Switch ON OFF
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. ECM does not detect the switch is ON even if the switch does turn ON. Therefore, the ECM does not supply power to light up the lamp.
Case 2 Lamp FUSE
TERMINAL: 2 Monitoring of the switch operation (ON/OFF)
TERMINAL: 1 Ground control to light up the lamp
Switch
Battery
ECM Short: Open:
FUSE blows. Inoperative lamp
Short: Open:
Lamp stays ON. Inoperative lamp
Short: Lamp stays ON. (Same as the switch ON) Open: Inoperative lamp
Short: Open:
No problem Inoperative lamp
High resistance: See below. (Single strand)*
Input-output voltage chart Pin No.
Item
Condition
Voltage value [V]
In case of high resistance such as single strand [V] *
1
Lamp
Switch ON
Approx. 0
Battery voltage (Inoperative lamp)
Battery voltage
Battery voltage
Approx. 0
Higher than 0 Approx. 4 (Example)
Approx. 5
Approx. 5
OFF 2
Switch
Switch ON OFF
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. ECM does not detect the switch is ON even if the switch does turn ON. Therefore, the ECM does not control ground to light up the lamp.
SGI849-A
GI-34
HOW TO FOLLOW TROUBLE DIAGNOSES NOTICE Trouble diagnoses indicates 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 EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be in the “LOCK” position. 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 Example Type A
INSPECTION START
H
CHECK POWER SUPPLY. 1) Turn ignition switch to “ON” position. 2) Check voltage between terminal b and ground. p
NG
E
Check the following items. 1) Harness continuity between camshaft position sensor and battery 2) Engine relay-1 3) “BR” fusible link 4) Power source for ECM 5) Ignition switch
E
Check the following items. 1) Harness continuity between camshaft position sensor and ground 2) Ground circuit for ECM
Battery voltage should exist OK
H
CHECK GROUND CIRCUIT. 1) Turn ignition switch to “OFF” position. 2) Disconnect camshaft position sensor harness connector. 3) Check resistance between terminal p d and ground. Resistance:
NG
Approximately 0Ω H
OK SGI800-C
GI-35
HOW TO FOLLOW TROUBLE DIAGNOSES How to Follow Test Groups in Trouble Diagnoses (Cont’d) HOW TO FOLLOW THIS FLOW CHART Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed blocks, as shown in the following example. CHECK POWER SUPPLY. 1) Turn ignition switch to “ON” position. 2) Check voltage between terminal b and ground. p Battery voltage should exist.
F
Check item being performed. Procedure, steps or measurement results
Measurement results Required results are indicated in bold type in the corresponding block, as shown below: These have the following meanings: Battery voltage → 11 - 14V or approximately 12V Voltage: Approximately 0V → Less than 1V
Cross reference of work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures. indicated in the left upper portion of For example, symbol each illustration corresponds with the symbol in the flow chart for easy identification. More precisely, the procedure under the “CHECK POWER SUPPLY” outlined previously is indicated by an illustration .
Symbols used in illustrations Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol.
Direction mark Refer to “CONNECTOR SYMBOLS” on GI-15.
GI-36
HOW TO FOLLOW TROUBLE DIAGNOSES How to Follow Test Groups in Trouble Diagnoses (Cont’d) Example Type B Example CHECK POWER SUPPLY CIRCUIT
CHECK GAUGE OPERATION
1. Turn ignition switch “ON”. 2. Check voltage between combination meter terminal 15 and ground. Battery voltage should exist.
1. Turn ignition switch “ON”. 2. Connect terminals B (Fuel), C (Temp.) and ground with wire for less than 10 seconds.
Fuel gauge Water temperature gauge
3. Check operation of gauge. Gauge should move smoothly to full scale. OK or NG
OK or NG OK NG
GO TO 2. Check the following. ● 10A fuse [No. 7, located in the fuse
block (J/B)]
OK
GO TO 4.
NG
Repair or replace gauge.
● Harness for open or short between
fuse and combination meter
CHECK GROUND CIRCUIT FOR GAUGES Check continuity between combination meter terminal 23 and ground. Continuity should exist.
CHECK GROUND CIRCUIT FOR FUEL TANK GAUGE UNIT Check harness continuity between fuel tank gauge unit terminal 2 and ground. Continuity should exist.
SGI975
1) Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups. 2) Questions and required results. Questions and required results are indicated in bold type in test group. The meaning of are as follows: a. Battery voltage → 11 - 14V or approximately 12V b. Voltage: Approximately 0V → Less than 1V 3) Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. For symbols, refer to “CONNECTOR SYMBOLS” (GI-15) and “Key to Symbols Signifying Measurements or Procedures” (GI-38). 4) 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.
GI-37
HOW TO FOLLOW TROUBLE DIAGNOSES How to Follow Test Groups in Trouble Diagnoses (Cont’d) Key to symbols signifying measurements or procedures Symbol
Symbol explanation
Symbol
Symbol explanation
Check after disconnecting the connector to be measured.
Procedure with CONSULT-II.
Check after connecting the connector to be measured.
Procedure without CONSULT-II.
Insert key into ignition switch.
Procedure with Generic Scan Tool (GST, E-OBD scan tool)
Remove key from ignition switch.
Procedure without CONSULT-II or GST
Turn ignition switch to “LOCK” position.
A/C switch is “OFF”.
Turn ignition switch to “ON” position.
A/C switch is “ON”.
Turn ignition switch to “START” position.
Fan switch is “ON”. (At any position except for “OFF” position)
Turn ignition switch from “LOCK” to “ACC” position.
Fan switch is “OFF”.
Turn ignition switch from “ACC” to “LOCK” position.
Apply positive voltage from battery with fuse directly to components.
Turn ignition switch from “LOCK” to “ON” position.
Drive vehicle.
Turn ignition switch from “ON” to “LOCK” position.
Disconnect battery negative cable.
Do not start engine, or check with engine stopped.
Depress brake pedal.
Start engine, or check with engine running.
Release brake pedal.
Apply parking brake.
Depress accelerator pedal.
Release parking brake.
Release accelerator pedal.
Check after engine is warmed up sufficiently.
Pin terminal check for SMJ type ECM and A/T control unit connectors. For details regarding the terminal arrangement, refer to the foldout page.
Voltage should be measured with a voltmeter. Circuit resistance should be measured with an ohmmeter. Current should be measured with an ammeter.
GI-38
CONSULT-II CHECKING SYSTEM Function and System Application Diagnostic test mode
Function
ENGINE
H⋅CVT
ABS
AIR BAG
NATS
Work support
This mode enables a technician to adjust some devices faster and more accurate by following the indications on CONSULT-II.
×
—
—
—
—
Self-diagnostic results
Self-diagnostic results can be read and erased quickly.
×
x
x
×
×
Trouble diagnostic record
Current self-diagnostic results and all trouble diagnostic records previously stored can be read.
—
—
—
x
—
ECU discriminated No.
Classification number of a replacement ECU can be read to prevent an incorrect ECU from being installed.
—
—
—
×
—
Data monitor
Input/Output data in the ECM can be read.
×
x
x
—
—
DTC work support
This mode enables a technician to set operating conditions to confirm self-diagnosis status/results.
x
x
—
—
—
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.
×
—
x
—
—
ECM part number
ECM part number can be read.
×
x
x
—
—
Control unit initialisation
All registered ignition key IDs in NATS components can be initialised and new IDs can be registered.
—
—
—
—
x
x
—
—
—
—
DTC & SRT confirma- The results of SRT (System Readiness Test) and the self-diagtion nosis status/results can be confirmed.
×: Applicable *1: NATS: Nissan Anti-Theft System
Nickel Metal Hydride Battery Replacement 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 of dispose of in fire. Keep the battery out of reach of children and discard used battery conforming to the local regulations.
Checking Equipment When ordering the equipment below, contact your NISSAN distributor.
Tool name NISSAN CONSULT-II 1 CONSULT-II unit p and accessories 2 Program card p AED00B-1 and AEN00A (for NATS) Refer to the CONSULT-II operation manual to confirm the best combination of the tester internal software and the software mentioned above.
Description 1 p
2 p
NGI045
GI-39
CONSULT-II CHECKING SYSTEM Checking Equipment (Cont’d) NOTE: ● The CONSULT-II must be used in conjunction with a program card. CONSULT-II does not require loading (Initialisation) procedure. ● Be sure the CONSULT-II is turned off before installing or removing a program card.
CONSULT-II Data Link Connector (DLC) Circuit Example IGNITION SWITCH ON or START
ECM
AIR BAG DIAGNOSIS SENSOR UNIT
DATA LINK CONNECTOR (DLC-II FOR CONSULT-II AND GST)
To each diagnosed system : DDL2 communication line (J1962)
SGI084A
INSPECTION PROCEDURE If the CONSULT-II cannot diagnose the system properly, check the following items. Symptom
Check item
CONSULT-II cannot access ● CONSULT-II DLC power supply circuit (Terminal 9) and ground circuit (Terminal 13) any system. (For detailed circuit, refer to “MIL & Data Link Connectors Wiring Diagram” in EC section.) ● CONSULT-II DDL cable CONSULT-II cannot access ● CONSULT-II program card (Check the appropriate CONSULT-II program card for the sysindividual system. (Other tem.) systems can be accessed.) ● 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.)
GI-40
IDENTIFICATION INFORMATION Model Variation Body
Engine
Transaxle
QG16DE
RS5F70A
QG18DE
Grade
RHD
LHD
Low
BDGARBF-EEA
BDGALBF-EGA
High
BDGARUF-EEA
BDGALUF-EGA
Low
BATARBF-EEA
BATALBF-EGA
RS5F70A High
BATARUF-EEA
BATALUF-EGA
Low
BBYARBF-EEA
BBYALBF-EGA
High
BBYARUF-EEA
BBYALUF-EGA
Low
BBYARBZ-EEA
BBYALBZ-EGA
High
BBYARUZ-EEA
BBYALUZ-EGA
High
BBYARUW-EEA
BBYALUW-EGA
Low
BVCARBF-TEA
BVCALBF-TGA
High
BVCARUF-TEA
BVCALUF-TGA
Low
FDGARBF-EEA
FDGALBF-EGA
High
FDGARUF-EEA
FDGALUF-EGA
RS5F70A 4 Door SR20DE RE0F06A RE0F06A (M6) CD20T
QG16DE
QG18DE
RS5F32A
RS5F70A Low
FATARBF-EEA
FATALBF-EGA
High
FATARUF-EEA
FATALUF-EGA
Low
FBYARBF-EEA
FBYALBF-EGA
High
FBYARUF-EEA
FBYALUF-EGA
Low
FBYARBZ-EEA
FBYALBZ-EGA
RS5F70A
RS5F70A 5 Door SR20DE RE0F06A RE0F06A (M6) CD20T
QG18DE
High
FBYARUZ-EEA
FBYALUZ-EGA
High
FBYARUW-EEA
FBYALUW-EGA
Low
FVCARBF-TEA
FVCALBF-TGA
High
FVCARUF-TEA
FVCALUF-TGA
Low
TATARBF-EEA
TATALBF-EGA
RS5F32A
RS5F70A High
TATARUF-EEA
TATALUF-EGA
Low
TBYARBF-EEA
TBYALBF-EGA
High
TBYARUF-EEA
TBYALUF-EGA
Low
TBYARBZ-EEA
TBYALBZ-EGA
High
TBYARUZ-EEA
TBYALUZ-EGA
High
TBYARUW-EEA
TBYALUW-EGA
Low
TVCARBF-TEA
TVCALBF-TGA
High
TVCARUF-TEA
TVCALUF-TGA
RS5F70A WAGON
SR20DE RE0F06A RE0F06A (M6) CD20T
RS5F32A
GI-41
IDENTIFICATION INFORMATION Model Variation (Cont’d) Prefix and suffix designations: B
DG
A
L
B
F
P11
E
G
A A: Standard
E: RHD models G: LHD models E: EGI T: Turbo (CD20T) Model F: 5-speed manual transaxle Z: H-CVT W: H-CVT (M6) B: LOW U: HIGH L: Left-hand drive R: Right-hand drive A: 2-wheel drive models DG: QG16DE engine AT: QG18DE engine BY: SR20DE engine VC: CD20T engine B: 4-door Sedan F: 5-door Hatchback T: Wagon
GI-42
IDENTIFICATION INFORMATION Identification Number
Vehicle identification number Vehicle identification plate Air conditioner specification label
NGI046
VEHICLE IDENTIFICATION NUMBER ARRANGEMENT For Europe SJN
B
F
A
P11
U
0
XXXXXX Vehicle serial number
0 : Stopgap (no meaning) Destination U : Europe Model A : 2-wheel drive Engine type F : QG16DE engine E : QG18DE engine C : SR20DE engine D : CD20T engine Body type B : 4-door Sedan F : 5-door Hatchback T: Wagon Manufacturer SJN : Nissan, Passenger vehicle
GI-43
IDENTIFICATION INFORMATION Identification Number (Cont’d) IDENTIFICATION PLATE
A B C D E F G H I J
Type approval number Vehicle identification number (chassis number) Gross vehicle weight (GVW) Gross combination weight (GCW) Gross axle weight (Front) Gross axle weight (Rear) Vehicle type specification Body colour code Trim colour code Model
NGI011
ENGINE SERIAL NUMBER SR20DE engine
QG16DE/QG18DE engine
Front
CD20T engine
Front Front
MANUAL TRANSAXLE NUMBER
NGI060
H⋅CVT NUMBER
RS5F32A and RS5F70A
RE0F06A Transaxle type
NGI048
NGI061
GI-44
IDENTIFICATION INFORMATION Dimensions Unit: mm (in)
H/B & Sedan
Wagon
Overall length
4522 (178.03)
4566 (179.76)
Overall width
1715 (67.52) *1
1715 (67.52) *1
Overall height
1410 (55.51) *2
1410 (55.51) *2
Front tread
1470 (57.87)
1470 (57.87)
Rear tread
1450 (57.09)
1450 (57.09)
Wheelbase
2600 (102.36)
2600 (102.36)
*1: Without mirrors. *2: Without roof mounted antenna.
Wheels and Tires Steel Offset mm (in)
Road wheel Aluminum
Offset mm (in) Tire size
Conventional Spare
GI-45
15 x 6J 45 (1.77)
—
—
—
—
15 x 6J
15 x 6J
16 x 7J
45 (1.77)
45 (1.77)
45 (1.77)
185/65HR15 195/60VR15 195/60R15 205/50R16 Conventional
Conventional
Conventional
185/65 HR15
LIFTING POINTS AND TOW TRUCK TOWING Preparation SPECIAL SERVICE TOOLS Tool number Tool name
Description
LM4086-0200 Board on attachment
NT001
LM4519-0000 Safety stand attachment
NT002
Board-on Lift Front
Pantograph jack point
Attachment
Side sill
CAUTION: Make sure vehicle is empty when lifting. ● The board-on lift attachment (LM4086-0200) 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.
Attachment (SST. No. LM4086-0200) AGI016
GI-46
LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand WARNING: ● 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. Garage jack points
Note: Safety stand points are the same as pantograph jack points.
Safety stand points Use safety stand adapter as shown for stable support.
Fit the lower side sill into groove.
Attachment SST No. LM4519-0000
Safety stand NGI021
GI-47
LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift WARNING: 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 and fuel lines.
Note: Lift-up points are the same as pantograph jack points.
Lift pad
Put the sill in the groove of the lift pad to prevent the sill from deforming. If the pad does not have a groove, prepare a suitable attachment with one.
Sill
NGI022
GI-48
LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing 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. ● When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral position. NISSAN recommends that vehicle be towed with the driving (front) wheels off the ground as illustrated.
TOWING A H⋅CVT MODEL WITH FOUR WHEELS ON GROUND
SGI805
H⋅CVT model
Observe the following restricted towing speeds and distances. Speed: Below 50 km/h (30 mph) Distance: Less than 65 km (40 miles) CAUTION: Never tow a H⋅CVT model from the rear (i.e., backward) with four wheels on the ground as this may cause serious and expensive damage to the transaxle.
TOWING A H⋅CVT MODEL WITH REAR WHEELS RAISED (With front wheels on ground) Never tow a H⋅CVT model with rear wheels raised (with front wheels on ground) as this may cause serious and expensive damage to the transaxle. If it is necessary to tow it with rear wheels raised, always use a towing dolly under the front wheels. SGI806-A
TOWING POINT Always pull the cable straight out from the vehicle. Never pull on the hook at a sideways angle. CAUTION: Remove the front spoiler when towing the vehicle forward. Otherwise, the towing device may damage the front spoiler.
Removable towing hook
Towing hook
GI-49
NGI049
TIGHTENING TORQUE OF STANDARD BOLTS
Grade
4T
Bolt size
Pitch mm N·m
kg-m
ft-lb
in-lb
N·m
kg-m
ft-lb
in-lb
M6
6.0
1.0
5.1
0.52
3.8
45.1
6.1
0.62
4.5
53.8
1.25
13
1.3
9
—
15
1.5
11
—
M8
8.0 1.0
13
1.3
9
—
16
1.6
12
—
1.5
25
2.5
18
—
29
3.0
22
—
1.25
25
2.6
19
—
30
3.1
22
—
1.75
42
4.3
31
—
51
5.2
38
—
1.25
46
4.7
34
—
56
5.7
41
—
M10
M12
7T
9T
Tightening torque (Without lubricant)
Bolt diameter* mm
Hexagon head bolt
Hexagon flange bolt
10.0
12.0
M14
14.0
1.5
74
7.5
54
—
88
9.0
65
—
M6
6.0
1.0
8.4
0.86
6.2
74.6
10
1.0
7
87
M8
8.0
M10
1.25
21
2.1
15
—
25
2.5
18
—
1.0
22
2.2
16
—
26
2.7
20
—
1.5
41
4.2
30
—
48
4.9
35
—
1.25
43
4.4
32
—
51
5.2
38
—
1.75
71
7.2
52
—
84
8.6
62
—
10.0
M12
12.0 1.25
77
7.9
57
—
92
9.4
68
—
M14
14.0
1.5
127
13.0
94
—
147
15.0
108
—
M6
6.0
1.0
12
1.2
9
—
15
1.5
11
—
1.25
29
3.0
22
—
35
3.6
26
—
M8
8.0 1.0
31
3.2
23
—
37
3.8
27
—
M10
M12 M14
1.5
59
6.0
43
—
70
7.1
51
—
1.25
62
6.3
46
—
74
7.5
54
—
1.75
98
10.0
72
—
118
12.0
87
—
1.25
108
11.0
80
—
137
14.0
101
—
1.5
177
18.0
130
—
206
21.0
152
—
10.0
12.0 14.0
1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head. Grade
*: Nominal diameter
Mark
4T
............
4
7T
............
7
9T
............
9
M
6 üüüNominal diameter of bolt threads (Unit: mm)
üüüMetric screw threads
GI-50
ISO 15031-2 TERMINOLOGY LIST ISO 15031-2 Terminology List All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new terms, new acronyms/abbreviations and old terms are listed in the following chart. ***: Not applicable
NEW ACRONYM / ABBREVIATION
NEW TERM
OLD TERM
Absolute pressure sensor
***
***
Air cleaner
ACL
Air cleaner
Barometric pressure
BARO
***
Barometric pressure sensor-BCDD
BAROS-BCDD
BCDD
Camshaft position
CMP
***
Camshaft position sensor
CMPS
Crank angle sensor
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 EEPROM memory
***
Electronic ignition system
EI system
Ignition timing control
Engine control module
ECM
Engine 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 or Canister
EVAP canister or Canister
Canister
Evaporative emission canister purge control solenoid valve
EVAP canister purge control solenoid valve
Canister control solenoid valve
GI-51
ISO 15031-2 TERMINOLOGY LIST ISO 15031-2 Terminology List (Cont’d) ***: Not applicable
NEW ACRONYM / ABBREVIATION
NEW TERM
OLD TERM
Evaporative emission canister purge control valve
EVAP canister purge control valve
Canister purge cut valve
Evaporative emission canister vent control valve
EVAP canister vent control valve
***
Evaporative emission canister purge volume control valve
EVAP canister purge volume control valve
Canister purge control valve
Evaporative emission control system pressure sensor
EVAP control system pressure sensor
***
Evaporative emission shut valve
EVAP shut valve
Shutoff valve
Evaporative emission system
EVAP system
Evaporative emission control system
Exhaust gas recirculation valve
EGR valve
EGR valve
Exhaust gas recirculation control-BPT valve
EGRC-BPT valve
BPT valve
Exhaust gas recirculation control-solenoid valve
EGRC-solenoid valve
EGR control solenoid valve
Exhaust gas recirculation temperature sensor EGR temperature 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
***
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
Idle speed control-FI pot
ISC-FI pot
FI pot
Idle speed control system
ISC system
***
Ignition control module
ICM
***
Indirect fuel injection system
IFI system
***
Intake air temperature sensor
IATS
Air temperature sensor
Knock
***
Detonation
Knock sensor
KS
Detonation sensor
Malfunction indicator
MI
Check engine light
Manifold absolute pressure
MAP
***
Manifold absolute pressure/Barometric pressure switch solenoid valve
MAP/BARO switch solenoid valve
***
Manifold absolute pressure sensor
MAPS
***
Manifold differential pressure
MDP
***
Manifold differential pressure sensor
MDPS
***
GI-52
ISO 15031-2 TERMINOLOGY LIST ISO 15031-2 Terminology List (Cont’d) ***: Not applicable
NEW ACRONYM / ABBREVIATION
NEW TERM
OLD TERM
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
Neutral position switch
***
Neutral switch
Non-volatile 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
Periodic trap oxidizer system
PTOX system
***
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
***
Tank fuel temperature sensor
***
***
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
GI-53
ISO 15031-2 TERMINOLOGY LIST ISO 15031-2 Terminology List (Cont’d) ***: Not applicable
NEW ACRONYM / ABBREVIATION
NEW TERM
OLD TERM
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
Turbocharger
TC
Turbocharger
Vacuum cut valve
***
Vacuum control valve
Vacuum cut valve bypass valve
***
***
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
GI-54
MAINTENANCE SECTION
MA
CONTENTS PRECAUTIONS AND PREPARATION.......................... 3 Special Service Tools ................................................ 3 Commercial Service Tool........................................... 3 PRE-DELIVERY INSPECTION ITEMS.......................... 4 GENERAL MAINTENANCE .......................................... 5 PERIODIC MAINTENANCE .......................................... 6 Maintenance Schedule for Petrol Engines (Annual Mileage < 30,000 km/year) .......................... 6 Chassis and Body Maintenance................................ 7 Maintenance Schedule for Diesel Engines (Annual Mileage < 30,000 km/year) .......................... 8 Chassis and Body Maintenance................................ 9 Maintenance Under Severe Driving Conditions (Annual Driving Distance < 30,000 km/year) .......... 10 Maintenance Schedule for Petrol Engines (Annual Mileage > 30,000 km/year) .........................11 Chassis and Body Maintenance.............................. 12 Maintenance Schedule for Diesel Engines (Annual Mileage > 30,000 km/year) ........................ 13 Chassis and Body Maintenance.............................. 14 Maintenance Under Severe Driving Conditions (Annual Driving Distance > 30,000 km) .................. 15 RECOMMENDED FLUIDS AND LUBRICANTS......... 16 Fluids and Lubricants .............................................. 16 SAE Viscosity Number ............................................ 17
QG ENGINE MAINTENANCE ............................................ 18 Checking Drive Belts ............................................... 18 Changing Engine Coolant........................................ 19 Checking Cooling System ....................................... 21 Checking Radiator Cap ........................................... 21 Checking Fuel Lines ................................................ 22
Changing Fuel Filter ................................................ 23 Changing Air Cleaner Filter ..................................... 23 Changing Engine Oil................................................ 24 Changing Engine Oil Filter ...................................... 24 Checking and Changing Spark Plugs ..................... 25 Checking Positive Crankcase Ventilation (PCV) System ..................................................................... 26 Checking Vacuum Hoses and Connections ............ 26 Checking EVAP Vapour Lines ................................. 26 Checking Front Heated Oxygen Sensor (HO2S) .... 27
SR20DE ENGINE MAINTENANCE ............................................ 28 Checking Drive Belts ............................................... 28 Changing Engine Coolant........................................ 29 Checking Cooling System ....................................... 31 Checking Fuel Lines ................................................ 33 Changing Fuel Filter ................................................ 33 Changing Air Cleaner Filter ..................................... 34 Changing Engine Oil................................................ 34 Changing Engine Oil Filter ...................................... 35 Checking and Changing Spark Plugs ..................... 35 Checking Ignition Leads .......................................... 36 Checking Positive Crankcase Ventilation (PCV) System ..................................................................... 36 Checking Vacuum Hoses and Connections ............ 37 Checking EVAP Vapor Lines ................................... 37 Checking Front Heated Oxygen Sensor (HO2S) .... 38
CD20T ENGINE MAINTENANCE ............................................ 39 Checking Drive Belts ............................................... 39 Changing Engine Coolant........................................ 40
MA
Checking Cooling System ....................................... 42 Checking Fuel Lines ................................................ 43 Checking and Replacing Fuel Filter and Draining Water ....................................................................... 43 Changing Air Cleaner Filter ..................................... 44 Changing Engine Oil................................................ 45 Changing Engine Oil Filter ...................................... 45 Checking Injection Nozzles ..................................... 46 Replacing Timing Belt.............................................. 47
Tire Rotation ............................................................ 53 Checking Steering Gear and Linkage ..................... 53 Checking Power Steering Fluid and Lines .............. 53 Lubricating Hood Latches, Locks and Hinges......... 54 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters............................................. 54 Checking Body Corrosion........................................ 55
QG SERVICE DATA AND SPECIFICATIONS (SDS) ........ 56 Engine Maintenance ................................................ 56
CHASSIS AND BODY MAINTENANCE ..................... 48 Checking Exhaust System....................................... 48 Checking Clutch Fluid Level and Leaks.................. 48 Checking Clutch System ......................................... 48 Checking M/T Oil ..................................................... 48 Changing M/T Oil..................................................... 49 Checking CVT Fluid Level....................................... 49 Changing CVT Fluid ................................................ 50 Checking Brake Fluid Level and Leaks................... 51 Checking Brake System .......................................... 51 Changing Brake Fluid .............................................. 51 Checking Brake Booster, Vacuum Hoses, Connections and Check Valve ................................ 51 Checking Disc Brake ............................................... 51 Balancing Wheels .................................................... 53
SR20DE SERVICE DATA AND SPECIFICATIONS (SDS) ........ 57 Engine Maintenance ................................................ 57
CD20T SERVICE DATA AND SPECIFICATIONS (SDS) ........ 58 Engine Maintenance ................................................ 58
SERVICE DATA AND SPECIFICATIONS (SDS) ........ 59 Chassis and Body Maintenance.............................. 59
MA-2
PRECAUTIONS AND PREPARATION Special Service Tools The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number Tool name
Engine application
Description
KV10115800 Oil filter cap wrench 65 mm (2.56 in) dia.
QG
SR
CD
−
X
−
X
−
−
−
−
X
X
X
X
−
−
X
Removing oil filter
NT346
Removing oil filter
KV10105900 Oil filter cap wrench 15 faces, Inner span: 80 mm (3.15 in) (Face to opposite corner) NT555
99545R2500 (KV101060S0) Oil filter wrench
Removing oil filter 15 faces, Inner span: 92.5 mm (3.642 in) (Face to opposite corner) NT631
EG17650301 Radiator cap tester adapter
a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) NT564
KV119E0030 Nozzle holder socket
Removing and installing injection nozzle assembly
NT648
Commercial Service Tool Tool name
Engine application
Description
QG
SR
CD
X
X
−
Wrench with a magnet to hold spark plug
Spark plug wrench
16 mm (0.63 in) NT047
MA-3
PRE-DELIVERY INSPECTION ITEMS Shown below 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.
UNDER HOOD − engine off
UNDER BODY
Radiator coolant level and coolant hose connections for leaks Battery fluid level, specific gravity and conditions of battery terminals Drive belts tension Fuel filter for water or dust, fuel lines and connections for leaks Engine oil level and oil leaks Clutch and brake reservoir fluid level and fluid lines for leaks Windshield and rear window washer and headlamp cleaner reservoir fluid level Power steering reservoir fluid level and hose connections for leaks
Manual transmission/transaxle, transfer and differential gear oil level Brake and fuel lines and oil/fluid reservoirs for leaks Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST Clutch operation Parking brake operation Service brake operation Automatic transmission/transaxle shift timing and kickdown Steering control and returnability Engine performance Squeaks and rattles
ON INSIDE AND OUTSIDE Remove front spring/strut spacer (If applicable) Operation of all instruments, gauges, lights and accessories Operation of horn(s), wiper and washer Steering lock for operation Check air conditioner for gas leaks Front and rear seats, and seat belts for operation All moldings, trims and fittings for fit and alignment All windows for operation and alignment Hood, trunk lid, door panels for fit and alignment Latches, keys and locks for operation Weatherstrips for adhesion and fit Headlamp aiming Tighten wheel nuts (Inc. inner nuts if applicable) Tire pressure (Inc. spare tire) Check front wheels for toe-in Install clock/voltmeter/room lamp fuse (If applicable) Install deodorizing filter to air purifier (If applicable) Remove wiper blade protectors (If applicable)
ENGINE OPERATING AND HOT Adjust idle mixture and speed (and ignition timing*1) Automatic transmission/transaxle fluid level Engine idling and stop knob operation (Diesel only)
FINAL INSPECTION Install necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps) Inspect for interior and exterior metal and paint damage Check for spare tire, jack, tools (wheel chock), and literature Wash, clean interior and exterior *1: Not required on models with a direct ignition system : Not applicable to this model.
MA-4
GENERAL MAINTENANCE General maintenance includes those items which should be checked during normal day-to-day operation of the vehicle. They are essential if the vehicle is to continue functioning correctly. Owners can perform the checks and inspections themselves, or they can be carried out by a NISSAN dealer. Item
Reference pages
OUTSIDE THE VEHICLE The maintenance items listed here should be checked periodically, unless otherwise specified. Tires Check the pressure with a gauge weekly when at a service station, including the spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessive wear.
−
Windshield wiper blades Check for cracks or wear if not functioning correctly.
−
Doors and engine hood Check that all doors, the engine hood, the trunk lid and back door function correctly. Also ensure that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch prevents the hood from opening when the primary latch is released. When driving in areas using road salt or other corrosive materials, check for lubrication more often.
MA-54
Tire rotation Tires should be rotated every 10,000 km (6,000 miles).
MA-53
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. Lights Make sure that the headlights, stop lights, tail lights, turn signal lights, and other lights are all operating correctly and installed securely. Also check headlight aim.
−
Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes are functioning correctly.
−
Steering wheel Check that it has the specified play. Check for changes in the steering operation, such as excessive free play, hard steering or strange noises. Free play: Less than 35 mm (1.38 in.)
−
Seat belts 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.
MA-54
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. 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.
MA-24 / MA-34 / MA-45
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-51 / MA-48
Battery Check the fluid level in each cell. It should be between the “MAX” and “MIN” lines.
MA-5
−
PERIODIC MAINTENANCE Maintenance Schedule for Petrol Engines (Annual Mileage < 30,000 km/year) QG16DE/QG18DE/SR20DE engines Abbreviations:
R = Replace
I = Inspect: Correct or replace if necessary
[ ] = At the specified mileage only
MAINTENANCE OPERATION
MAINTENANCE INTERVAL
km × 1,000 Perform on a kilometer basis, but on (miles × 1,000) an annual basis when driving less than 15,000 km (9,000 miles) per year Months
15 (9) 12
30
45
60
75
90
105 120
(18) (27) (36) (45) (54) (63) (72) 24
36
48
60
72
84
96
Engine compartment and under vehicle
QG16DE/ QG18DE
SR20DE
Reference pages
Engine oil (Use recommended oil)*
R
R
R
R
R
R
R
R
MA-24
MA-34
Engine oil filter (Use NISSAN genuine part or equivalent)*
R
R
R
R
R
R
R
R
MA-24
MA-35
Drive belts
I
I
I
I
I
I
I
I
MA-18
MA-28
Cooling system
I
I
I
I
I
I
I
I
MA-21
MA-31
MA-19
MA-29
MA-23
MA-34
EM-92
—
Engine anti-freeze coolant (Use genuine NISSAN Anti-Freeze Coolant (L2N) or equivalent)
See NOTE (1)
Air cleaner filter*
R
Intake and exhaust valve clearance (Non HLA models)
See NOTE (2)
Fuel and vapour lines Spark plugs
(Conventional type)
I
I
I
I
MA-22/MA-26
MA-33/ MA-37
R
R
R
R
MA-25
MA-35
I
—
MA-36
R
MA-23
MA-33
MA-27, EC-QG-134/ EC-QG-173
MA-38, EC-SR-146/ EC-SR-182
MA-26
MA-36
Ignition leads
I
Fuel filter* Heated oxygen sensor* PCV system
R
See NOTE (3) I
I
I
I
NOTE: (1) First replace at 90,000 km (54,000 miles)/72 months, then every 60,000 km (36,000 miles)/48 months. (2) Periodic maintenance is not required for QG engine models. However, if valve noise increases, check valve clearance. (3) Perform only according to “Maintenance under severe driving conditions”. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.
MA-6
PERIODIC MAINTENANCE Chassis and Body Maintenance Abbreviations:
R = Replace age only
I = Inspect: Correct or replace if necessary
L = Lubricate
MAINTENANCE OPERATION
T = Tighten
[ ] = At the specified mile-
MAINTENANCE INTERVAL
Perform on a kilometer basis, but on an annual basis when driving less than 15,000 km (9,000 miles) in a year
km × 1,000
15
(miles × 1,000)
(9)
Months
12
30
45
60
75
90
105
120
(18) (27) (36) (45) (54) (63) (72) 24
36
48
60
72
84
96
Underhood and under vehicle
Reference pages
Headlamp aiming
I
I
I
I
I
I
I
I
EL-87
Wheel alignment (if necessary, balance & rotate wheels)
I
I
I
I
I
I
I
I
FA-6/RA-6 MA-53
Brake pads, rotors & other components*
I
I
I
I
I
I
I
I
MA-51
Foot brake, parking brake & clutch (for free play, stroke & operation)
I
I
I
I
I
I
I
I
BR-13/BR-48/CL-5
I
MA-51
I
MA-51/MA-48
R
BR-7
I
MA-53
Brake booster vacuum hoses, connections, check valve Brake & clutch, systems and fluid (for level and leaks)
I I
Brake fluid*
I
R
Power steering fluid and lines (for level and leaks) Air bag system
I
I
I
I
I
I I
R I
I
I
I
R I
I
I
See NOTE (1)
RS-11
Ventilation air filter*
R
R
R
R
HA-117
Manual transmission oil (check for leakage. Use genuine NISSAN XZ gear oil or exact equivalent)
I
I
I
I
I
I
I
I
MA-49
CVT fluid (for level and leaks or replace. Use genuine NISSAN CVT fluid (NS-1) or exact equivalent)*
I
I
I
[R]
I
I
I
[R]
MA-50
Steering gear & linkage, axle & suspension, exhaust system* Body corrosion
I
See NOTE (2)
I
I
I
MA-53/FA-5/ RA-5/MA-48 MA-55
NOTE: (1) Inspect after 10 years, then every 2 years. (2) Inspect once per year. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.
MA-7
PERIODIC MAINTENANCE Maintenance Schedule for Diesel Engines (Annual Mileage < 30,000 km/year) CD20T engine Abbreviations:
R = Replace
I = Inspect: Correct or replace if necessary
C = Clean
MAINTENANCE OPERATION
[ ] = At the specified mileage only
MAINTENANCE INTERVAL
km × 1,000 Perform on a kilometer basis, but on a semi-annual basis when driving less than (miles x 1,000) 20,000 km (12,000 miles) per year. Months
10
20
30
40
50
60
70
80
90 100 110 120
(6) (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) 6
12
18
24
30
36
42
48
54
60
66
72 CD20T Reference pages
Engine compartment and under vehicle Engine oil (Use recommended oil)*
R
R
R
R
R
R
R
R
R
R
R
R
MA-45
Engine oil filter (Use NISSAN genuine part or equivalent)*
R
R
R
R
R
R
R
R
R
R
R
R
MA-45
Drive belts
I
I
I
I
I
I
I
I
I
I
I
I
MA-39
Camshaft
[R]
EM-59
Injection pump
[R]
EM-59
Timing belts Cooling system Engine anti-freeze coolant (Use genuine NISSAN Anti-freeze Coolant (L2N) or equivalent)
I
I
I
I
I
See NOTE (1) R
Fuel lines
I
I
R
MA-44
I
MA-43
See NOTE (2)
Fuel filter
MA-42 MA-40
Air cleaner filter*
Injection nozzles
I
MA-46 R
R
R
MA-43
NOTE: (1) First replace at 80,000 km (48,000 miles)/48 months, then every 60,000 km (36,000 miles)/36 months. (2) If engine power decreases, black exhaust smoke is emitted or engine noise increases, inspect and if necessary, adjust the fuel injection nozzles starting pressure and spray pattern. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.
MA-8
PERIODIC MAINTENANCE Chassis and Body Maintenance Abbreviations:
R = Replace age only
I = Inspect: Correct or replace if necessary
L = Lubricate
MAINTENANCE OPERATION Perform on a kilometer basis, but on a semi-annual basis when driving less than 20,000 km (12,000 miles) per year
T = Tighten
[ ] = At the specified mile-
MAINTENANCE INTERVAL km × 1,000
10
(miles x 1,000)
(6)
Months
6
20
30
40
50
60
70
80
90
100 110 120
(12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) 12
18
24
30
36
42
48
54
60
66
72 Reference pages
Underhood and under vehicle Headlamp aiming
I
I
I
I
I
I
EL-87
Wheel alignment (if necessary, balance & rotate wheels)
I
I
I
I
I
I
FA-6/RA-6/ (MA-53)
Brake pads, rotors & other components*
I
I
I
I
I
I
MA-51
Foot brake, parking brake & clutch (for free play, stroke & operation)
I
I
I
I
I
I
BR-48/ BR-13/CL-5
I
MA-51
I
MA-51/ MA-48
R
BR-7
I
MA-53
Brake booster vacuum hoses, connections, check valve Brake & clutch, systems and fluid (for level and leaks)
I I
I
Brake fluid* I
I
I
I
R I
I
I
See NOTE (1)
RS-11
Ventilation air filter*
R
Manual transmission oil (check for leakage. Use genuine NISSAN XZ gear oil or exact equivalent)
I
Steering gear & linkage, axle & suspension, exhaust system* Body corrosion
I
R
Power steering fluid and lines (for level and leaks) Air bag system
I
R I I
See NOTE (2)
I
R I I
I
R
HA-117
I
MA-49
I
MA-53/FA-5/ RA-5/MA-48 MA-55
NOTE: (1) Inspect after 10 years, then every 2 years. (2) Inspect once per year. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.
MA-9
PERIODIC MAINTENANCE Maintenance Under Severe Driving Conditions (Annual Driving Distance < 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. A B C D E
— — — — —
Driving under dusty conditions Driving repeatedly short distances Towing a trailer or caravan Extensive idling Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high — Driving in high humidity areas or in mountainous areas
F
Driving condition A B C D .
A .
A .
.
.
.
.
.
.
.
.
.
.
.
E .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
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 — Low quality lubricants or fuel
Maintenance item .
.
.
.
.
.
.
.
.
.
.
L
.
.
.
.
.
.
.
.
C .
.
.
.
.
F
.
.
.
.
.
.
.
.
H .
.
.
.
.
.
.
.
.
.
Petrol models
Replace
Every 7,500 km (4,500 miles) or 6 months
Diesel models
Replace
Every 5,000 km (3,000 miles) or 3 months
Petrol models
Replace
Every 30,000 km (18,000 miles) or 24 months
Diesel models
Replace
Every 20,000 km (12,000 miles) or 12 months
Petrol models
Replace
Every 45,000 km (27,000 miles) or 36 months
Diesel models
Replace
Every 20,000 km (12,000 miles) or 12 months
Inspect
Every 30,000 km (18,000 miles) or 24 months
Petrol models
Replace
Every 15,000 km (9,000 miles) or 12 months
Diesel models
Replace
Every 20,000 km (12,000 miles) or 12 months
Petrol models
Replace
Every 15,000 km (9,000 miles) or 12 months
Diesel models
Replace
Every 20,000 km (12,000 miles) or 12 months
Replace
Every 30,000 km (18,000 miles)
Air cleaner filter
Fuel filter
Front/Rear Heated Oxygen Sensor
Ventilation air filter
Brake fluid
CVT fluid Petrol models
A .
.
.
C .
.
.
.
.
.
.
G H I
G H .
.
.
.
.
.
.
Maintenance interval
Engine oil & engine oil filter
Petrol models A .
Maintenance operation
Brake pads, rotors & other brake system components Petrol models
Inspect
Every 7,500 km (4,500 miles) or 6 months
Diesel models
Inspect
Every 10,000 km (6,000 miles) or 6 months
Steering gear & linkage, axle & suspension parts, exhaust system Petrol models
Inspect
Every 15,000 km (9,000 miles) or 12 months
Diesel models
Inspect
Every 20,000 km (12,000 miles) or 12 months
MA-10
PERIODIC MAINTENANCE Maintenance Schedule for Petrol Engines (Annual Mileage > 30,000 km/year) QG16DE/QG18DE/SR20DE engines Abbreviations:
R = Replace
I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATION Perform on a kilometer basis only.
MAINTENANCE INTERVAL km × 1,000
15
(miles x 1,000)
(9)
30
45
60
75
90
105 120
(18) (27) (36) (45) (54) (63) (72)
Engine compartment and under vehicle
QG16DE/ QG18DE
SR20DE
Reference pages
Engine oil (Use recommended oil)*
R
R
R
R
R
R
R
R
MA-24
MA-34
Engine oil filter (Use NISSAN genuine part or equivalent)*
R
R
R
R
R
R
R
R
MA-24
MA-35
Drive belts
I
I
I
I
I
I
I
I
MA-18
MA-28
I
MA-21
MA-31
MA-19
MA-29
MA-23
MA-34
EM-92
—
I
MA-22/ MA-26
MA-33/ MA-37
R
Cooling system
I
Engine anti-freeze coolant (Use genuine NISSAN AntiFreeze Coolant (L2N) or equivalent)
I
See NOTE (1)
Air cleaner filter*
R
Intake & exhaust valve clearance (Non HLA models)
R
See NOTE (2)
Fuel and vapour lines Spark plugs
I
I
MA-25
MA-35
Ignition leads
(Conventional type)
I
—
MA-36
Fuel filter*
R
MA-23
MA-33
Heated oxygen sensor* PCV system
R
R
R
EC-QG-134/ EC-SR-146/ EC-QG-173 EC-SR-182
See NOTE (3) I
PCV filter*
I R
I
I
MA-26
MA-36
R
—
—
NOTE: (1) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles). (2) Periodic maintenance is not required for QG engine models. However, if valve noise increases, check valve clearance. (3) Perform only according to “Maintenance under severe driving conditions”. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.
MA-11
PERIODIC MAINTENANCE Chassis and Body Maintenance Abbreviations:
R = Replace age only
I = Inspect: Correct or replace if necessary
L = Lubricate
MAINTENANCE OPERATION Perform on a kilometer basis only.
T = Tighten
[ ] = At the specified mile-
MAINTENANCE INTERVAL km × 1,000
15
30
45
60
75
90
105
120
(miles x 1,000)
(9)
(18)
(27)
(36)
(45)
(54)
(63)
(72) Reference pages
Underhood and under vehicle Headlamp aiming
I
I
I
I
EL-87
Wheel alignment (if necessary, balance & rotate wheels)
I
I
I
I
FA-6/RA-6/ (MA-53)
Brake pads, rotors & other components*
I
I
I
I
MA-51
I
BR-48/BR-13/ CL-5
I
MA-51
Foot brake, parking brake & clutch (for free play, stroke & operation)
I
Brake booster vacuum hoses, connections, check valve
I
I
Brake & clutch, systems and fluid (for level and leaks)
I
Brake fluid*
I
I
R
Power steering fluid and lines (for level and leaks) Air bag system
I
I
I
I
I
MA-51/MA-48
R
BR-7
I
MA-53
See NOTE (1)
RS-11
Ventilation air filter*
R
R
R
R
HA-117
Manual transmission oil (check for leakage. Use genuine NISSAN XZ gear oil or exact equivalent.)
I
I
I
I
MA-49
CVT fluid (for level and leaks or replace. Use genuine NISSAN CVT fluid (NS-1) or exact equivalent)*
I
[R]
I
[R]
MA-50
Steering gear and linkage, axle & suspension, exhaust system* Body corrosion
See NOTE (2)
I
I
MA-53/FA-5/ RA-5/MA-48 MA-55
NOTE: (1) Inspect after 10 years, then every 2 years. (2) Inspect once per year. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.
MA-12
PERIODIC MAINTENANCE Maintenance Schedule for Diesel Engines (Annual Mileage > 30,000 km/year) CD20T engine Abbreviations:
R = Replace
I = Inspect: Correct or replace if necessary
C = Clean
MAINTENANCE OPERATION Perform on a kilometer basis only.
MAINTENANCE INTERVAL km × 1,000
10
(miles x 1,000)
(6) (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) CD20T
20
30
40
50
60
70
80
90 100 110 120
Reference pages
Engine compartment and under vehicle Engine oil (Use recommended oil)*
R
R
R
R
R
R
R
R
R
R
R
R
MA-45
Engine oil filter (Use NISSAN genuine part or equivalent)*
R
R
R
R
R
R
R
R
R
R
R
R
MA-45
Drive belts
I
I
I
I
I
I
I
I
I
I
I
I
MA-39
Camshaft
R
MA-47
Injection pump
R
MA-47
Timing belts Cooling system Engine anti-freeze coolant (Use genuine NISSAN Anti-Freeze Coolant (L2N) or equivalent)
I
I
I
See NOTE (1)
Air cleaner filter* Fuel lines Injection nozzles
I
MA-40 R
R
I
I
See NOTE (2)
Fuel filter
MA-42
MA-44 MA-43 MA-46
R
R
MA-43
NOTE: (1) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles). (2) If engine power decreases, black exhaust smoke is emitted or engine noise increases, inspect and if necessary, adjust the fuel injection nozzles starting pressure and spray pattern. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.
MA-13
PERIODIC MAINTENANCE Chassis and Body Maintenance Abbreviations:
R = Replace
I = Inspect: Correct or replace if necessary
L = Lubricate
MAINTENANCE OPERATION Perform on a kilometer basis only.
T = Tighten
MAINTENANCE INTERVAL
km × 1,000
10
(miles x 1,000)
(6)
20
30
40
50
60
70
80
90
100 110 120
(12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) Reference pages
Underhood and under vehicle Headlamp aiming
I
I
I
I
EL-87
Wheel alignment (if necessary, balance & rotate wheels)
I
I
I
I
FA-6/RA-6/ (MA-53)
Brake pads, rotors & other components*
I
I
I
I
MA-51
Foot brake, parking brake & clutch (for free play, stroke & operation)
I
I
I
I
BR-13/BR-48/ CL-5
I
MA-51
I
MA-51/MA-48
R
BR-7
I
MA-53
Brake booster vacuum hoses, connections, check valve Brake & clutch, systems and fluid (for level and leaks)
I I
Brake fluid*
I
R
Power steering fluid and lines (for level and leaks) Air bag system
I
I
I
I
See NOTE (1)
RS-11
Ventilation air filter*
R
R
R
R
HA-117
Manual transmission oil (check for leakage. Use genuine NISSAN XZ gear oil or exact equivalent.)
I
I
I
I
MA-49
I
MA-53/FA-5/ RA-5/MA-48
Steering gear & linkage, axle & suspension, exhaust system* Body corrosion
I
See NOTE (2)
MA-55
NOTE: (1) Inspect after 10 years, then every 2 years. (2) Inspect once per year. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.
MA-14
PERIODIC MAINTENANCE Maintenance Under Severe Driving Conditions (Annual Driving Distance > 30,000 km) 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. A B C D E
— — — — —
Driving under dusty conditions Driving repeatedly short distances Towing a trailer or caravan Extensive idling Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high — Driving in high humidity areas or in mountainous areas
F
Driving condition A B C D .
A .
A .
A .
.
.
.
.
.
.
.
.
.
E .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
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 — Low quality lubricants or fuel
Maintenance item .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
L
Petrol models
Replace
Every 7,500 km (4,500 miles)
Diesel models
Replace
Every 5,000 km (3,000 miles)
Petrol models
Replace
Every 30,000 km (18,000 miles)
Diesel models
Replace
Every 30,000 km (18,000 miles)
Petrol models
Replace
Every 45,000 km (27,000 miles)
Diesel models
Replace
Every 30,000 km (18,000 miles)
Replace
Every 30,000 km (18,000 miles)
Inspect
Every 60,000 km (36,000 miles)
Petrol models
Replace
Every 15,000 km (9,000 miles)
Diesel models
Replace
Every 15,000 km (9,000 miles)
Petrol models
Replace
Every 30,000 km (18,000 miles)
Diesel models
Replace
Every 30,000 km (18,000 miles)
Replace
Every 22,500 km (13,500 miles)
Air cleaner filter
Fuel filter
PCV filter
Front/Rear Heated Oxygen Sensor Petrol Models
A .
.
.
.
.
.
.
.
.
.
.
F
.
.
.
.
.
.
.
.
.
.
.
.
Maintenance interval
Engine oil & engine oil filter
QG16DE .
Maintenance operation
Ventilation air filter
Brake fluid
.
C .
.
.
.
H .
.
.
.
CVT fluid
A .
C .
.
.
G H I
.
.
.
Brake pads, rotors & other brake system components
Petrol models
.
.
.
.
.
.
G H .
.
.
.
Petrol models
Inspect
Every 15,000 km (9,000 miles)
Diesel models
Inspect
Every 15,000 km (9,000 miles)
Steering gear & linkage, axle & suspension parts, exhaust system Petrol models
Inspect
Every 30,000 km (18,000 miles)
Diesel models
Inspect
Every 30,000 km (18,000 miles)
MA-15
RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants Capacity (Approximate)
Recommended fluids and lubricants
Liter
Imp measure
QG16DE/QG18DE
2.9
5-1/8 pts
SR20DE
3.7
6-1/2 pts
CD20T
5.0
8-3/4 pts
QG16DE/QG18DE
2.7
4-3/4 pts
SR20DE
3.5
6-1/8 pts
CD20T
4.5
7-7/8 pts
QG16DE/QG18DE
6.1
10-3/4 pts
M/T
6.6
11-5/8 pts
CVT
6.8
12 pts
6.4
11-1/4 pts
0.8
1-3/8 pts
RS5F70A
3.0
5-1/4 pts
RS5F32A
3.6
6-3/8 pts
CVT fluid
8.1
14-1/8 pts
Power steering fluid
1.1
2 pts
Brake fluid
−
−
DOT 4 (US FMVSS No. 116)
Multi-purpose grease
−
−
NLGI No. 2 (Lithium soap base)
Engine oil (Refill)
With oil filter
Without oil filter
Cooling system (With reservoir tank)
SR20DE CD20T
Reservoir Manual transmission gear oil
Air conditioning system refrigerant
Petrol engines: API SH or SJ*/ACEA A2/96 Diesel engines: ACEA B2-96 (CCMC-PD2)*
Genuine NISSAN Anti-freeze Coolant (L2N) or equivalent.
Genuine NISSAN XZ gear oil or exact equivalent. Genuine NISSAN CVT fluid (NS-1) or exact equivalent Type DEXRONTM III or equivalent
R-134a compressor CR-14
NISSAN A/C System Oil Type R or exact equivalent
compressor CSV613
NISSAN A/C System Oil Type S or equivalent
Air conditioning system lubricants
*: For further details, see “SAE Viscosity Number”.
MA-16
RECOMMENDED FLUIDS AND LUBRICANTS SAE Viscosity Number Outside Temperature Range Anticipated Before Next Oil Change
Outside Temperature Range Anticipated Before Next Oil Change PETROL ENGINE OIL
DIESEL ENGINE OIL
* Not recommended for sustained high speed driving
* Not recommended for sustained high speed driving
NTI035
●
●
TI0006
For warm and cold areas: 10W-30 is suitable. The use of 5W-30 can have a positive effect on fuel economy (ACEA A1-98). For hot areas: 20W-40 and 20W-50 are suitable.
●
●
●
MA-17
For cold and warm areas: 10W-30 is preferable for ambient temperatures above −20°C (−4°F). On turbocharger models, 5W-20 is not recommended, and 5W-30 should be used only below 0°C (32°F). For hot areas: 20W-40 and 20W-50 are suitable.
QG
ENGINE MAINTENANCE Checking Drive Belts
Lock bolt
.
Adjusting bolt .
16 - 21 (1.6 - 2.1, 12 - 15)
Alternator
Water pump pulley Power steering pump
Loosen
Idler pulley
Lock nut 6.3 - 8.3 (0.64 - 0.85, 56 - 74)
.
Adjusting bolt
Compressor
Loosen Crankshaft pulley Water pump pulley
With air conditioner
Alternator
Power steering pump .
Without air conditioner
: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) 왔 : Check point
Crankshaft pulley
NMA106
1. Inspect belt for cracks, fraying, wear and oil. If necessary, replace. 2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys. ● Inspect drive belt deflection or tension when engine is cold. ● Adjust if belt deflection exceeds the limit or if belt tension is not within specifications. ● Turn crankshaft two revolutions and recheck drive belt deflection or tension. Deflection adjustment
Unit: mm (in)
Tension adjustment*
Used belt Limit
Unit: N (kg, lb)
Used belt New belt
After adjustment
Limit
After adjustment
New belt
292 (29.8, 65.6)
652 - 740 (66.5 - 75.5, 146.6 - 166.4)
789 - 877 (80.5 - 89.7, 177.4 - 197.6)
196 (20.0, 44.1)
495 - 583 (50.5 - 59.5, 111.3 - 131.1)
603 - 691 (61.5 - 70.5, 135.6 - 155.3)
Alternator Without airconditioner compressor With airconditioner compressor Power steering oil pump Applied pushing force
10.2 (0.402)
6.5 - 7.0 5.5 - 6.1 (0.256 - 0.276) (0.217 - 0.240)
8.1 (0.319)
5.3 - 5.7 4.5 - 5.0 (0.209 - 0.224) (0.177 - 0.197)
10.8 (0.425)
6.6 - 7.5 6.0 - 6.6 (0.260 - 0.295) (0.236 - 0.260) 98 N (10 kg, 22 lb)
—
*: If belt tension gauge cannot be installed at check points shown, check drive belt tension at a different location on the belt.
MA-18
ENGINE MAINTENANCE
QG
Changing Engine Coolant
Turn to HOT
WARNING: To avoid being scalded, never change the coolant when the engine is hot. — DRAINING ENGINE COOLANT — Heater 1. Set heater system as follows to prevent coolant from remaining in the system. ● Move temperature control dial all the way to “HOT”. Temperature control dial
NMA104
Semi-automatic air conditioning 1. Set air conditioning system as follows to prevent coolant from remaining in the system. a. Turn ignition switch “ON” and enter a temperature of 32°C on the heater control. b. Wait 30 seconds before turning ignition switch “OFF”.
Temperature control
NMA103
Front .
Front
.
Lower radiator hose
.
.
Radiator cap
Loosen
2. Disconnect lower radiator hose and remove radiator cap. 3. Remove reservoir tank, drain coolant, then clean reservoir tank. Install it temporarily. ● Be careful not to allow coolant to contact drive belts.
NMA051
4. Remove cylinder block drain plug and air relief plug. 5. Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to “FLUSHING COOLING SYSTEM”, MA-21. Drain plug
Loosen
NMA001
Air relief plug
NMA107
MA-19
ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)
QG
— REFILLING ENGINE COOLANT — 6. Install lower radiator hose, reservoir tank and tighten cylinder block drain plug securely. ● Apply sealant to the thread of the cylinder block drain plug. : 34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-lb) 7. Fill up radiator with coolant at the speed of less than 3 (2-5/8 Imp qt)/min. ● If coolant spills from the air relief hole without bubbles, reinstall the plug. Air relief plug: : 7 - 8 N·m (0,7 - 0,8 kg-m, 5,1 - 5,8 ft-lb) Then pour coolant in again. ● Use genuine NISSAN Anti-Freeze Coolant or equivalent. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Coolant capacity (With reservoir tank): Unit: (Imp qt)
QG16DE/QG18DE
6.1 (5-3/8)
8. Fill radiator and reservoir tank to specified level. 9. Start engine without installing radiator cap and warm it up at 2,000 rpm until radiator lower hose becomes hot. ● If coolant level becomes low, refill coolant until coolant level does not change. ● If coolant overflows radiator filler hole, install filler cap.
Radiator
SMA182B
MAX. MIN.
SMA412B
10. Run engine at 2,500 rpm for 10 seconds and return to idle speed. ● Repeat 2 or 3 times. Watch coolant temperature gauge so as not to overheat the engine. 11. Stop engine and wait until it cools down. ● If necessary, refill radiator up to filler neck. 12. Refill reservoir tank to Max line with coolant. 13. Repeat steps 9 through 12 two or more times with radiator cap installed until coolant level no longer drops. 14. Check cooling system for leaks with engine running. 15. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature control set at several positions between COOL and HOT. ● Sound may be noticeable at heater water cock. 16. If the sound is heard, bleed air from cooling system by repeating steps 9 through 12 until coolant level no longer drops.
MA-20
ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)
QG
— FLUSHING COOLING SYSTEM — 1. Open air relief plug. 2. Fill radiator with water until water spills from the air relief hole. Then reinstall air relief plug. Air relief plug : 7 - 8 N·m (0.7 - 0.8 kg-m, 5.1 - 5.8 ft-lb) Fill radiator and reservoir tank with water and reinstall radiator cap. 3. Run engine and warm it up sufficiently. 4. Rev engine 2 or 3 times under no-load. ● Make sure that blower fan is “OFF”. 5. Stop engine and wait until it cools down. 6. Drain water. 7. Repeat steps 1 through 6 until clear water begins to drain from radiator.
Checking Cooling System CHECKING HOSES Check hoses for proper attachment and for 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. 4. Blow air into the back side of radiator core vertically downward. 2 ● Use compressed air lower than 5 kg/cm and keep distance more than 30 cm (11.8 in). 5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
Checking Radiator Cap
EG17650301
SLC613
Apply pressure to radiator cap with cap tester to see if it is satisfactory. Radiator cap relief pressure: Standard 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
MA-21
ENGINE MAINTENANCE Checking Radiator Cap (Cont’d) ●
QG
When installing radiator cap to the tester, apply water or coolant to the radiator cap seal.
Pull the negative-pressure valve to open it. Check that it closes completely when released.
SMA871B
CHECKING COOLING SYSTEM FOR LEAKS Hose adapter
EG17650301
Apply pressure to the cooling system with cap tester to check for leakage. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher pressure than the specified value may cause damage to radiator.
SMA990A
Checking Fuel Lines Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace faulty parts. Engine
Fuel line
Fuel tank
SMA803A
3 (0.12)
Unit: mm (in)
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.
28 (1.10) Fuel hose clamps 1.0 - 1.5 N·m (0.10 - 0.15 kg-m, 8.7 - 13.0 in-lb) MMA104A
MA-22
ENGINE MAINTENANCE
QG
Changing Fuel Filter WARNING: Before removing fuel filter, release fuel pressure from fuel line.
With Consult II 1. Release fuel pressure using the following procedure. a. Start engine. b. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode to release fuel pressure to zero. c. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. d. Turn ignition switch “OFF”. PEF823K
.
SMA288C
WARNING: Use rubber gloves to prevent fuel from contacting the skin when removing fuel hoses and filter. 2. Loosen fuel hose clamps. 3. Replace fuel filter. ● Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel. ● Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. ● When tightening fuel hose clamps, refer to “Checking Fuel Lines”, MA-22
Changing Air Cleaner Filter Viscous paper type Unfasten clamps to change air cleaner filter. The viscous paper type filter does not need cleaning.
.
NMA006
MA-23
QG
ENGINE MAINTENANCE Oil filler cap
Oil filter Drain plug
SMA672C
Changing Engine Oil 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. 2. Stop engine. 3. Remove drain plug and oil filler cap. 4. Drain oil and refill with new engine oil. Oil grade: API SH or SJ/ACEA A2/96 Viscosity: See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Refill oil capacity (Approximate): Unit: (Imp pts)
Drain and refill With oil filter change
2.9
Without oil filter change
2.7
Dry engine (engine overhaul)
3.0
CAUTION: ● Be sure to clean drain plug and install with new washer. Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) ● The refill oil capacity depends on oil temperature and drain time. Use these specifications as a reference only. Always use the dipstick to determine when the proper amount of oil is in the engine.
5. Start engine and check area around drain plug and oil filter for oil leakage. 6. Run engine for a few minutes, then turn it off. After several minutes, check oil level.
Refill oil to this “H” level. Do not overfill. SMA390C
Changing Engine Oil Filter 1. Remove oil filter with Tool. WARNING: Be careful not to burn yourself, as the engine and the engine oil are hot. 2. Clean the oil filter mounting surface on the cylinder block. Coat the rubber seal of the new oil filter with engine oil.
SMA010
MA-24
QG
ENGINE MAINTENANCE Changing Engine Oil Filter (Cont’d)
3. Screw in the oil filter until a slight resistance is felt, then tighten an additional 2/3 turn. 4. Add engine oil. Refer to “Changing Engine Oil”, MA-24. ● Clean excess oil from engine. 2/3 turn
SMA229B
Checking and Changing Spark Plugs 1. Remove ignition coils.
.
Ignition coils
SEM870F
Wrench with a magnet to hold spark plug
2. Remove spark plugs with spark plug wrench. 3. Check insulator for cracks or chips, gasket for damage or deterioration and electrode for wear and burning. If excessively worn, replace with new spark plugs. Spark plug:
16 mm (0.63 in)
Make
SMA294A
CHAMPION
NGK
Standard type
RC10YCC4, RC10YC4
BKR5E-11
Hot type
RC12YCC4, RC12YC4
BKR4E-11
Cold type
RC7YCC4, RC7YC4
BKR6E-11
Use standard type spark plug for normal condition. The hot type spark plug is suitable when fouling may occur with the standard type spark plug such as: ● frequent engine starts ● low ambient temperatures The cold type spark plug is suitable when spark knock may occur with the standard type spark plug such as: ● extended highway driving ● frequent high engine revolution
Side electrode
Gap
4. Check spark plug gap. Gap: 1.0 - 1.1 mm (0.039 - 0.043 in) 5. Install spark plugs. Reinstall ignition coils. Spark plug: : 20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)
SMA476
MA-25
ENGINE MAINTENANCE
QG
Checking Positive Crankcase Ventilation (PCV) System CHECKING PCV VALVE With engine running at idle, disconnect ventilation hose from PCV valve. If valve is working correctly, a hissing noise will be heard as air passes through it, and a strong vacuum should be felt immediately when a finger is placed over valve inlet. SMA048
CHECKING VENTILATION HOSES 1. Check hoses and hose connections for leaks. 2. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.
Checking Vacuum Hoses and Connections Check vacuum hoses for leaks, cracks, damage, loose connections, chafing and deterioration. Refer to Vacuum Hose Drawing in EMISSION CONTROL OVERALL SYSTEM in EC section.
Checking EVAP Vapour Lines Vapor line
Purge line
1. Visually inspect vapor lines for leaks, cracks, damage, loose connections, chafing and deterioration. 2. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, etc. Refer to EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION in EC section.
SMA275C
MA-26
QG
ENGINE MAINTENANCE Checking Front Heated Oxygen Sensor (HO2S) Checking procedure INSPECTION START 왔
Start engine and warm it up until water temperature indicator points to the middle of gauge. C2DMM06 왔
1. See “M/R F/C MNT” in “Data monitor” mode. 2. Run engine at about 2,000 rpm for about 2 minutes under noload. 3. Maintaining engine at 2,000 rpm under no-load (engine is warmed up sufficiently.), check that the monitor fluctuates between “LEAN” and “RICH” more than 5 times during 10 seconds. 1 time RICH → LEAN → RICH 2 times RICH → LEAN → RICH → LEAN → RICH ...
Fuse box Data link connector
.
NEF125A NEF125A
왔
OK
왔
INSPECTION END
Malfunction indicator lamp SEF051PA
MA-27
NG
Check and adjustment should be made by referring to IDLE SPEED/IGNITION TIMING/ IDLE MIXTURE RATIO INSPECTION (BASIC SERVICE PROCEDURE) in EC section.
SR20DE
ENGINE MAINTENANCE Checking Drive Belts Adjusting bolt
Adjusting bolt
Loosen Loosen
Tighten
Tighten
16 - 22 (1.6 - 2.2,12 - 16)
Loosen
16 - 22 (1.6 - 2.2, 12 - 16) Water pump
Alternator
Water pump Alternator
Power steering oil pump Power steering oil pump Crankshaft pulley Crankshaft pulley
Compressor
: N·m (kg-m, ft-lb)
Without air conditioner
With air conditioner
SMA266C
1. Inspect belt for cracks, fraying, wear and oil. If necessary, replace. 2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys. ● Inspect drive belt deflection or tension when engine is cold. ● Adjust if belt deflection exceeds the limit or if belt tension is not within specifications. ● Turn crankshaft two revolutions and recheck drive belt deflection or tension. Deflection adjustment
Unit: mm (in)
Tension adjustment*
Used belt Limit
After adjustment
New belt
12 - 13 (0.47 - 0.51)
8-9 (0.31 - 0.35)
Air conditioner compressor Power steering oil pump
Alternator
Applied pushing force
Unit: N (kg, lb)
Used belt Limit
After adjustment
7-8 (0.28 - 0.31)
264 (26.9, 59.3)
493 - 583 (50.3 - 59.5, 110.8 - 131.1)
9 (0.35)
5.5 - 6.5 (0.217 - 0.256)
4.5 - 5.5 (0.177 - 0.217)
304 (31.0, 68.3)
534 - 623 (54.5 - 63.5, 120.0 - 140.1)
12 (0.47)
8-9 (0.31 - 0.35)
7-8 (0.28 - 0.31)
264 (26.9, 59.3)
493 - 583 (50.3 - 59.5, 110.8 - 131.1)
98 N (10 kg, 22 lb)
New belt 11720 70J00
11720 70J05
603 - 691 (61.5 - 70.5, 135.6 - 155.3)
652 - 740 (66.5 - 75.5, 146.6 - 166.4)
11920 9F500
11920 9F505
652 - 740 (66.5 - 75.5, 146.6 - 166.4)
838 - 926 (85.5 - 94.5, 188 - 208)
603 - 691 (61.5 - 70.5, 135.6 - 155.3)
603 - 691 (61.5 - 70.5, 135.6 - 155.3)
—
*: If belt tension gauge cannot be installed at check points shown, check drive belt tension at a different location on the belt.
MA-28
ENGINE MAINTENANCE Checking Drive Belts (Cont’d)
SR20DE
Alternator drive belt fitting place (Models without air conditioner) Alternator drive belt Crankshaft pulley
Engine front
Alternator drive belt
Engine front
Set a belt in both crankshaft and alternator pulleys as shown in the figure.
Alternator pulley SMA328C
Changing Engine Coolant
Turn to HOT
WARNING: To avoid being scalded, never change the coolant when the engine is hot. Heater
— DRAINING ENGINE COOLANT — 1. Set heater system as follows to prevent coolant from remaining in the system. ● Move temperature control dial all the way to “HOT”.
Temperature control dial NMA104
Semi-automatic air conditioning 1. Set air conditioner system as follows to prevent coolant from remaining in the system. a. Turn ignition switch “ON” and enter a temperature of 32°C on the heater control. b. Wait 30 seconds before turning ignition switch “OFF”.
Temperature control
NMA103
Lower radiator hose
2. Disconnect lower radiator hose and remove radiator cap. 3. Remove reservoir tank, drain coolant, then clean reservoir tank. Install it temporarily. ● Be careful not to allow coolant to contact drive belts.
Remove .
SMA285C
MA-29
SR20DE
ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)
.
.
4. Remove cylinder block drain plug on water pipe and air relief plug. 5. Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to “FLUSHING COOLING SYSTEM”, MA-31.
Remove
Radiator filler cap
NMA048
Drain plug
Remove Oil level gauge guide .
SMA269c
Loosen
NMA005
— REFILLING ENGINE COOLANT — 6. Install lower radiator hose, reservoir tank and tighten cylinder block drain plug securely. ● Apply sealant to the thread of the cylinder block drain plug. : 34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-lb) 7. Fill up radiator with coolant at the speed of less than 3 (2-5/8 Imp qt)/min. ● If coolant spills from the air relief hole without bubbles, re-install the plug. Air relief plug: : 10 N·m (1.0 kg-m, 7 ft-lb) Then pour coolant in again ● Use genuine NISSAN Anti-Freeze Coolant or equivalent. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Coolant capacity (With reservoir tank): Unit: (Imp qt)
SR20DE
Radiator
SMA182B
MA-30
M/T
6.6 (5-7/8)
CVT
6.8 (6)
ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)
MAX. MIN.
SMA412B
SR20DE
8. Fill radiator and reservoir tank to specified level. 9. Start engine without installing radiator cap and warm it up at 2,000 rpm until radiator lower hose becomes hot. ● If coolant level becomes low, refill coolant until coolant level does not change. ● If coolant overflows radiator filler hole, install filler cap. 10. Run engine at 2,500 prm for 10 seconds and return to idle speed. ● Repeat 2 or 3 times. Watch coolant temperature gauge so as not to overheat the engine. 11. Stop engine and cool it down. ● Cool down using a fan to reduce the time. ● If necessary, refill radiator up to filler neck. 12. Refill reservoir tank to Max line with coolant. 13. Repeat steps 9 through 12 two or more times with radiator cap installed until coolant level no longer drops. 14. Check cooling system for leaks with engine running. 15. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature control set at several positions between COOL and HOT. ● Sound may be noticeable at heater water cock. 16. If the sound is heard, bleed air from cooling system by repeating steps 9 through 12 until coolant level no longer drops.
— FLUSHING COOLING SYSTEM — 1. Open air relief plug. 2. Fill radiator with water until water spills from air relief hole, then reinstall air relief plug. Air relief plug: : 7 - 8 N·m (0.7 - 0.8 kg-m, 5,1 - 5.8 ft-lb) Fill radiator and reservoir tank with water and reinstall radiator cap. 3. Run engine and warm it up sufficiently. 4. Rev engine 2 or 3 times under no-load. ● Make sure that blower fan is “OFF”. 5. Stop engine and wait until it cools down. 6. Drain water. 7. Repeat steps 1 through 6 until clear water begins to drain from radiator.
Checking Cooling System CHECKING HOSES Check hoses for proper attachment and for 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.
MA-31
ENGINE MAINTENANCE Checking Cooling System (Cont’d)
SR20DE
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. 2 ● Use compressed air lower than 5 kg/cm and keep distance more than 30 cm (11.8 in). 5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
CHECKING RADIATOR CAP
EG17650301
SLC613
Apply pressure to radiator cap with cap tester to see if it is satisfactory. Radiator cap relief pressure: Standard 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi) ● When installing radiator cap to the tester, apply water or coolant to the radiator cap seal.
Pull the negative-pressure valve to open it. Check that it closes completely when released.
SMA871B
CHECKING COOLING SYSTEM FOR LEAKS Hose adapter
EG17650301
Apply pressure to the cooling system with cap tester to check for leakage. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher pressure than the specified value may cause damage to radiator.
SMA990A
MA-32
ENGINE MAINTENANCE
SR20DE
Checking Fuel Lines Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace faulty parts. Engine
Fuel line
Fuel tank
SMA803A
3 (0.12)
Unit: mm (in)
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.
28 (1.10) Fuel hose clamps 1.0 - 1.5 N·m (0.10 - 0.15 kg-m, 8.7 - 13.0 in-lb) MMA104A
Changing Fuel Filter WARNING: Before removing fuel filter, release fuel pressure from fuel line.
With Consult II 1. Release fuel pressure using the following procedure. a. Start engine. b. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode to release fuel pressure to zero. c. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. d. Turn ignition switch “OFF”. PEF823K
WARNING: Use rubber gloves to prevent fuel from contacting the skin when removing fuel hoses and filter. 2. Loosen fuel hose clamps. 3. Replace fuel filter. ● Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel. ● Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. .
SMA288C
MA-33
ENGINE MAINTENANCE
SR20DE
Changing Air Cleaner Filter Viscous paper type Unfasten clamps to change air cleaner filter. The viscous paper type filter does not need cleaning.
NMA006
Changing Engine Oil
SR20DE engine model
Oil filter
NMA039
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. 2. Stop engine. 3. Remove drain plug and oil filler cap. 4. Drain oil and refill with new engine oil. Oil grade: API SH or SJ/ACEA A2/96 Viscosity: See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Refill oil capacity (Approximate): Unit: (Imp pts)
Drain and refill With oil filter change
3.7 (6 - 1/2)
Without oil filter change
3.5 (6 - 1/8)
Dry engine (engine overhaul)
3.9 (6 - 7/8)
CAUTION: ● Be sure to clean drain plug and install with new washer. Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) ● The refill oil capacity depends on oil temperature and drain time. Use these specifications as a reference only. Always use the dipstick to determine when the proper amount of oil is in the engine.
5. Start engine and check area around drain plug and oil filter for oil leakage. 6. Run engine for a few minutes, then turn it off. After several minutes, check oil level. Overfill
Add
Normal range NDI021
MA-34
SR20DE
ENGINE MAINTENANCE .
Changing Engine Oil Filter
SR20DE engine model
1. Remove oil filter with Tool. WARNING: Be careful not to burn yourself, as the engine and the engine oil are hot.
Loosen
.
KV10115800
NMA041
2. Clean the oil filter mounting surface on cylinder block. Coat the rubber seal of the new oil filter with engine oil.
SMA010
3. Screw in the oil filter until a slight resistance is felt, then tighten an additional 2/3 turn. 4. Add engine oil. Refer to “Changing Engine Oil”, MA-34. ● Clean excess oil from engine. 2/3 turn
SMA229B
OK
Checking and Changing Spark Plugs
NG
1. Disconnect ignition wires from spark plugs at boot. Do not pull on the wire.
SMA273C
Wrench with a magnet to hold spark plug
2. Remove spark plugs with spark plug wrench. 3. Check insulator for cracks or chips, gasket for damage or deterioration and electrode for wear and burning. If excessively worn, replace with new spark plugs.
Spark plug 16 mm (0.63 in)
Make
NGK
Standard type
BKR6EY-11
Hot type
—
Cold type
—
SMA294A
MA-35
Side electrode
ENGINE MAINTENANCE Checking and Changing Spark Plugs (Cont’d)
SR20DE
4. Check spark plug gap. Gap: 1.0 - 1.1 mm (0.039 - 0.043 in)
Gap
SMA476
5. Install spark plugs. Reconnect ignition wires according to numbers indicated on them. Spark plug: : 20 - 29 N·m (2 - 3 kg-m, 14 - 22 ft-lb)
Checking Ignition Leads 1. Inspect wires for cracks, damage, burned terminals and for improper fit. 2. Measure the resistance of wires and check for intermittent breaks. Resistance: Cylinder No.
Resistance kΩ [at 25°C (77°F)]
1
Approximately 3.8
2
Approximately 3.5
3
Approximately 2.7
4
Approximately 2.4
SMA015A
For U.K. (Made by Bougicord) 4.48 - 6.72 kΩ/m (1.365 - 2.048 kΩ/ft) [at 25°C (77°F)] If it exceeds the limit, replace the ignition wire with a new one.
Checking Positive Crankcase Ventilation (PCV) System CHECKING PCV VALVE With engine running at idle, disconnect ventilation hose from PCV valve. If valve is working correctly, a hissing noise will be heard as air passes through it, and a strong vacuum should be felt immediately when a finger is placed over valve inlet. SMA048
MA-36
SR20DE ENGINE MAINTENANCE Checking Positive Crankcase Ventilation (PCV) System (Cont’d)
CHECKING VENTILATION HOSES 1. Check hoses and hose connections for leaks. 2. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.
Checking Vacuum Hoses and Connections Check vacuum hoses for leaks, cracks, damage, loose connections, chafing and deterioration. Refer to Vacuum Hose Drawing in EMISSION CONTROL OVERALL SYSTEM in EC section.
Checking EVAP Vapor Lines Vapor line
Purge line
1. Visually inspect vapor lines for leaks, cracks, damage, loose connections, chafing and deterioration. 2. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, etc. Refer to EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION in EC section.
SMA275C
MA-37
SR20DE
ENGINE MAINTENANCE
Checking Front Heated Oxygen Sensor (HO2S) Checking procedure INSPECTION START 왔
Start engine and warm up until water temperature indicator points to the middle of gauge. PEF054P 왔
1. See “M/R F/C MNT” in “Data monitor” mode. 2. Run engine at about 2,000 rpm for about 2 minutes under noload. 3. Maintaining engine at 2,000 rpm under no-load (engine is warmed up sufficiently.), check that the monitor fluctuates between “LEAN” and “RICH” more than 5 times during 10 seconds. 1 time RICH → LEAN → RICH 2 times RICH → LEAN → RICH → LEAN → RICH ...
Fuse box Data link connector
.
NEF125A NEF125A
왔
OK
왔
INSPECTION END
Malfunction indicator lamp SEF051PA
MA-38
NG
Check and adjustment should be made by referring to IDLE SPEED/IGNITION TIMING/ IDLE MIXTURE RATIO INSPECTION (BASIC SERVICE PROCEDURE) in EC section.
CD20T
ENGINE MAINTENANCE Checking Drive Belts
SMA880C
1. Inspect belt for cracks, fraying, wear and oil. If necessary, replace. 2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys. ● Inspect drive belt deflection or tension when engine is cold. ● Adjust if belt deflection exceeds the limit or if belt tension is not within specifications. ● Turn crankshaft two revolutions and recheck drive belt deflection or tension.
Deflection adjustment
Unit: mm (in)
Used belt
New belt
Limit
After adjustment
Generator
17 (0.67)
10.5 - 12.5 (0.413 - 0.492)
8.5 - 10.5 (0.335 - 0.413)
Air conditioner compressor
17 (0.67)
11.5 - 13.5 (0.453 - 0.531)
9.5 - 11.5 (0.374 - 0.453)
Power steering oil pump
8 (0.31)
5-7 (0.20 - 0.28)
4-6 (0.16 - 0.24)
Applied pushing force
98 N (10 kg, 22 lb)
MA-39
ENGINE MAINTENANCE
CD20T
Changing Engine Coolant
Turn to HOT
WARNING: To avoid being scalded, never change the coolant when the engine is hot.
— DRAINING ENGINE COOLANT — Heater 1. Set heater system as follows to prevent coolant from remaining in the system. ● Move temperature control dial all the way to “HOT”.
Temperature control dial NMA104
Semi-automatic air conditioning 1. Set air conditioning system as follows to prevent coolant from remaining in the system. a. Turn ignition switch “ON” and enter a temperature of 32°C on the heater control. b. Wait 30 seconds before turning ignition switch “OFF”.
Temperature control
.
NMA103
Radiator lower hose
.
2. Disconnect lower radiator hose and remove radiator cap. 3. Remove reservoir tank, drain coolant, then clean reservoir tank. Install it temporarily. ● Be careful not to allow coolant to contact drive belts.
NLC040
4. Remove cylinder block drain plug and air relief plug. 5. Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to “FLUSHING COOLING SYSTEM”, MA-41.
Drain plug (cylinder block)
NLC041
— REFILLING ENGINE COOLANT — Air bleeder
SMA353C
6. Install lower radiator hose, reservoir tank and tighten cylinder block drain plug securely. ● Apply sealant to the thread of the cylinder block drain plug. : 55 - 75 N·m (5.7 - 7.6 kg-m, 41 - 55 ft-lb) 7. Fill up radiator with coolant at the speed of less than 3 (2-5/8 Imp qt)/min. ● If coolant spills from the air relief hole without bubbles, install the plug and then pour coolant in again.
MA-40
CD20T
ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)
Air relief plug: : 8 - 9 N·m (0.8 - 0.9 kg-m, 5.9 - 6.6 ft-lb) ● Use genuine NISSAN Anti-Freeze Coolant or equivalent. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Coolant capacity (With reservoir tank):
Radiator
Unit: (Imp qt)
CD20T
6.1 (5-3/8)
SMA182B
MAX. MIN.
SMA412B
8. Fill radiator and reservoir tank to specified level. 9. Start engine without installing radiator cap and warm it up at 2,000 rpm until radiator lower hose becomes hot. ● If coolant level becomes low, refill coolant until coolant level does not change. ● If coolant overflows radiator filler hole, install filler cap. 10. Run engine at 2,500 prm for 10 seconds and return to idle speed. ● Repeat 2 or 3 times. Watch coolant temperature gauge so as not to overheat the engine. 11. Stop engine and wait until it cools down. ● If necessary, refill radiator up to filler neck. 12. Refill reservoir tank to Max line with coolant. 13. Repeat steps 9 through 12 two or more times with radiator cap installed until coolant level no longer drops. 14. Check cooling system for leaks with engine running. 15. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature control lever set at several positions between COOL and HOT. ● Sound may be noticeable at heater water cock. 16. If the sound is heard, bleed air from cooling system by repeating steps 9 through 12 until coolant level no longer drops.
— FLUSHING COOLING SYSTEM — 1. Open air relief plug. 2. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Air relief plug : 7 - 8 N·m (0.7 - 0.8 kg-m, 5.1 - 5.8 ft-lb) Fill radiator and reservoir tank with water and reinstall radiator cap. 3. Run engine and warm it up sufficiently. 4. Rev engine 2 or 3 times under no-load. ● Make sure that blower is “OFF”. 5. Stop engine and wait until it cools down. 6. Drain water. 7. Repeat steps 1 through 6 until clear water begins to drain from radiator.
MA-41
ENGINE MAINTENANCE
CD20T
Checking Cooling System CHECKING HOSES Check hoses for proper attachment and for 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. 4. Blow air into the back side of radiator core vertically downward. 2 ● Use compressed air lower than 5 kg/cm and keep distance more than 30 cm (11.8 in). 5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
CHECKING RADIATOR CAP
EG17650301
SLC613
Apply pressure to radiator cap with cap tester to see if it is satisfactory. Radiator cap relief pressure: Standard 98 - 118 kPa (0.98 - 1.18 bar, 1.0 - 1.2 kg/cm2, 14 - 17 psi) Limit 59 - 118 kPa (0.59 - 1.18 bar, 0.6 - 1.2 kg/cm2, 9 - 17 psi) ● When installing radiator cap to the tester, apply water or coolant to the radiator cap seal.
MA-42
ENGINE MAINTENANCE Checking Cooling System (Cont’d)
CD20T
Pull the negative-pressure valve to open it. Check that it closes completely when released.
SMA871B
CHECKING COOLING SYSTEM FOR LEAKS Hose adapter
EG17650301
Apply pressure to the cooling system with cap tester to check for leakage. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher pressure than the specified value may cause damage to radiator.
SMA990A
Checking Fuel Lines Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace faulty parts. Engine
Fuel line
Fuel tank
SMA803A
Checking and Replacing Fuel Filter and Draining Water CHECKING FUEL FILTER Check fuel filter for fuel leakage, damage and other abnormal signs. Loosen Drain valve
SMA794C
REPLACING FUEL FILTER 1. Disconnect fuel filter sensor connector and drain fuel.
MA-43
CD20T ENGINE MAINTENANCE Checking and Replacing Fuel Filter and Draining Water (Cont’d) 2. Remove fuel filter, using a suitable tool.
SMA896A
3. Wipe clean fuel filter mounting surface on fuel filter bracket and smear a little fuel on rubber seal of fuel filter. 4. Screw fuel filter on until O-ring touches mounting surface, then tighten an additional 2/3 turn. Follow instructions on fuel filter. 5. Install fuel filter sensor to new fuel filter. 6. Bleed air from fuel line. 7. Start engine and check for leaks.
SMA010
Up and down
Loosen
Drain valve
DRAINING WATER 1. Set a container under fuel filter. 2. Loosen drain cock and drain water. Loosening drain cock 4 to 5 turns causes water to start draining. Do not remove drain cock by loosening it excessively. If water does not drain properly, move the priming pump up and down. 3. Bleed air.
MMA105A
FUEL SYSTEM AIR BLEEDING 1. Move priming pump up and down until there is suddenly more resistance in the movement. Then stop this action and start the engine. 2. If engine does not operate smoothly after being started, rev it two or three times. When refilling empty fuel tank, bleed air out of fuel system.
Up and down
SMA795C
Changing Air Cleaner Filter Air filter
.
Unfasten clamps to change air cleaner filter. The viscous paper type filter does not need cleaning.
SMA668B
MA-44
CD20T
ENGINE MAINTENANCE Changing Engine Oil
Engine oil drain plug
SMA418C
Oil filter cap
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. 2. Stop engine. 3. Remove drain plug and oil filler cap. 4. Drain oil and refill with new engine oil. Oil specification and viscosity: ● ACEA B2-96 (CCMC-PD2) ● See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Oil capacity (Approximately): Unit: (Imp pts)
Engine oil level gauge
Drain and refill With oil filter change
5.0
Without oil filter change
4.5
Dry engine (engine overhaul)
5.1
.
SMA411C
Refill oil to this “H” level. Do not overfill. SMA822C
CAUTION: ● Be sure to clean drain plug and install with new washer. Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) ● 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. 5. Warm up engine, and check area around drain plug and oil filter for oil leakage. 6. Stop engine. 7. Check oil level.
Changing Engine Oil Filter 1. Remove oil filter with Tool. WARNING: Be careful not to burn yourself, as engine and engine oil are hot.
Engine oil filter
SMA412C
MA-45
ENGINE MAINTENANCE Changing Engine Oil Filter (Cont’d) .
CD20T
99545R2500 (KV101060S0)
NMA037
2. Clean the oil filter mounting surface on cylinder block. Coat the rubber seal of the new oil filter with engine oil.
SMA010
3. Screw in the oil filter until a slight resistance is felt, then tighten an additional 2/3 turn. 4. Add engine oil. Refer to “Changing Engine Oil”, MA-45. ● Clean excess oil from engine. 2/3 turn
SMA229B
Injection nozzle assembly
Checking Injection Nozzles 1. Remove injection delivery tubes and fuel spill tube. 2. Remove nozzle assembly with S.S.T. KV119E0030. No. 1 cylinder nozzle assembly should not be disassembled as it is provided with a needle lift sensor.
SMA419C
WARNING: When using nozzle tester, be careful not to allow diesel fuel sprayed from nozzle to come into contact with your hand or body, and make sure that your eyes are properly protected. 3. Clean and check nozzles. 4. Install nozzle to injection nozzle tester and bleed air from flare nut.
EF791A
MA-46
ENGINE MAINTENANCE Checking Injection Nozzles (Cont’d)
CD20T
5. Check initial injection pressure by pumping tester handle slowly (one time per second). Injection pressure: 12,749 kPa (127.5 bar, 130 kg/cm2, 1,849 psi) ● Always check initial injection pressure before installing new nozzle.
SEF672A
6. Check fuel spray pattern by pumping tester handle quickly (4 or 6 times per second). a. If main spray angle is within 30 degrees as shown, injection nozzle is good. b. It is still normal even if a thin stream of spray deviates from main spray (pattern B).
SEF079S
7. If spray is not correct, clean injection nozzle tip or replace it. Refer to EC section for injection pressure adjustment, cleaning and replacement. 8. Install all injection nozzles with S.S.T. KV119E0030 and securely connect fuel spill hoses and delivery tubes. 9. Bleed air from fuel system and check for fuel leakage with engine running.
Replacing Timing Belt Refer to “TIMING BELT” in EM section.
MA-47
CHASSIS AND BODY MAINTENANCE Checking Exhaust System Check exhaust pipes, silencers and mountings are attached correctly and inspect for leaks, cracks, damage, loose connections, chafing or deterioration.
SMA211A
Checking Clutch Fluid Level and Leaks If fluid level is very low, check clutch system for leaks.
.
SMA449C
Checking Clutch System HYDRAULIC TYPE Check fluid lines, operating cylinder & damper for leaks, cracks, damage, loose connections, chafing & deterioration.
NMA044
MECHANICAL TYPE Check cable and linkage for incorrect attachment, chafing, wear and deterioration.
SMA141A
Checking M/T Oil Check for oil leakage and oil level. Never start engine while checking oil level. Filler plug: : 25 - 34 N·m (2.6 - 3.4 kg-m, 19 - 25 ft-lb)
SMA065C
MA-48
CHASSIS AND BODY MAINTENANCE Checking M/T Oil (Cont’d) 3.7 - 5.0 (0.38 - 0.51, 33 - 44)
Speedometer pinion assembly O-ring
Check that oil is not leaking from transaxle or around it. ● Remove speedometer pinion and check oil level distance “L” as shown. Oil level (“L”): RS5F70A (QG16DE/QG18DE) 75.5 - 80.5 mm (2.97 - 3.17 in) RS5F70A (SR20DE) 56.5 - 61.0 mm (2.22 - 2.60 in) RS5F32A (CD20T) 57 - 62 mm (2.24 - 2.44 in) Use genuine NISSAN XZ gear oil or exact equivalent.
Ruler Transmission case
: N·m (kg-m, in-lb)
NMA045
Changing M/T Oil Oil capacity (reference values only): RS5F70A 3.0 (5-1/4 Imp pts) RS5F32A 3.6 - 3.8 (6-3/8 - 6-3/4 Imp pts) Drain plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb) Use genuine NISSAN XZ gear oil or exact equivalent. Drain plug SMA145A
Checking CVT Fluid Level 1. Check for fluid leakage.
SMA146B
MIN
MAX
MIN MAX
UMA036
2. Check fluid level. Fluid level should be check using “HOT” range on dipstick at fluid temperatures of 50 to 80°C (122 to 176°F) after vehicle has been driven approximately 10 minutes in urban areas after engine is warmed up. But it can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on dipstick for reference after engine is warmed up and before driving. However, fluid level must be rechecked using “HOT” range. a. Park vehicle on level surface and set parking brake. b. Start engine and then move selector lever through reach gear range, ending in “P”.
MA-49
CHASSIS AND BODY MAINTENANCE Checking CVT Fluid Level (Cont’d) c. d. e. f.
Check fluid level with engine idling. Remove dipstick and wipe it clean with lint-free paper. Re-insert dipstick into charging pipe as far as it will go. Remove dipstick and note reading. If level is at low side of either range, add fluid. Use genuine NISSAN CVT fluid (NS-1) or exact equivalent. CAUTION Do not overfill.
CAUTION: Firmly fix the dipstick using a lip attached to the fluid charging pipe. Stopper (when fixing) Stopper (when releasing) A/T fluid level gauge A/T fluid charging pipe
SMA051D
3. Check fluid condition. Check fluid for contamination. If fluid is very dark, smells burned or contains frictional material check operation of CVT. Refer to section AT for checking operation of CVT.
Check fluid for contamination. SMA853B
Changing CVT Fluid
Drain plug SMA294C
1. Warm up CVT fluid by driving the vehicle for 10 minutes. 2. Stop engine. 3. Drain CVT fluid from drain plug and refill with new CVT fluid. Always refill same volume compared with drained fluid. Oil capacity: 8.1 (14 - 1/4 Imp pt) Drain plug: : 23 - 27 N·m (2.4 - 2.8 kg-m, 17 - 20 ft-lb) Use genuine NISSAN CVT fluid (NS-1) or exact equivalent. 4. Run engine at idle speed for five minutes. 5. Jack up the front of the vehicle, and rotate front wheels by selecting “D” and depressing accelerator pedal slowly until 50 km/h (2 or 3 times). 6. Check fluid level and condition. Refer to “Checking CVT Fluid Level”. If fluid is still dirty, repeat step 2. throught 6.
MA-50
CHASSIS AND BODY MAINTENANCE Checking Brake Fluid Level and Leaks If fluid level is extremely low, check brake system for leaks, and brake pads for wear.
SBR991
Checking Brake System Check brake fluid lines and parking brake cables for security, leaks, chafing, abrasion, deterioration, etc.
ABR159
Changing Brake Fluid
SBR992
1. Drain brake fluid from each air bleeder valve. 2. 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 section BR. ● Refill with recommended brake fluid “DOT 4”. ● Never reuse drained brake fluid. ● Be careful not to splash brake fluid on painted areas. ● Avoid skin contamination and ingestion.
Checking Brake Booster, Vacuum Hoses, Connections and Check Valve Check vacuum lines, connections and check valve for security, air tightness, chafing and deterioration.
SMA402A
Checking Disc Brake Check condition of disc brake components.
ROTOR
SMA260A
Check condition and thickness. CL25VBG: Standard thickness 22.0 mm (0.866 in) Minimum thickness 20.0 mm (0.787 in)
MA-51
CHASSIS AND BODY MAINTENANCE Checking Disc Brake (Cont’d) CL25VG: Standard thickness 22.0 mm (0.866 in) Minimum thickness 20.0 mm (0.787 in) CL9HG: Standard thickness 10.0 mm (0.394 in) Minimum thickness 9.0 mm (0.354 in) CL9HDG: Standard thickness 10.0 mm (0.394 in) Minimum thickness 9.0 mm (0.354 in)
CALIPER Check operation and for leakage.
SMA922A
PAD
SMA847B
Check for wear or damage. CL25VBG: Standard thickness 11.0 mm (0.433 in) Minimum thickness 2.0 mm (0.079 in) CL25VG: Standard thickness 11.0 mm (0.433 in) Minimum thickness 2.0 mm (0.079 in) CL9HG: Standard thickness 9.3 mm (0.366 in) Minimum thickness 2.0 mm (0.079 in) CL9HDG: Standard thickness 9.3 mm (0.366 in) Minimum thickness 2.0 mm (0.079 in)
MA-52
CHASSIS AND BODY MAINTENANCE Balancing Wheels Wheel balance (maximum allowable unbalance): 10 g (0.35 oz) at rim flange. Tire balance weight: 5 - 60 g (0.18 - 2.12 oz)
Tire Rotation Right front
●
Right rear Spare tire
Radial tire
Left front
Do not include the T-type or space saver spare tire when rotating the tires. Wheel nuts: : 98 - 118 N·m (10 - 12 kg-m, 72 - 87 ft-lb)
Left rear SMA785C
Checking Steering Gear and Linkage STEERING GEAR ● ●
STEERING LINKAGE
: Check grease leakage. : Check tightening torque.
● SMA316C
Check ball joint, dust cover and other component parts for security, wear, damage or grease leakage.
Checking Power Steering Fluid and Lines
OPEN .
HOT MAX
COLD MAX COLD MIN .
Front
Check gear housing and boots for security, damage or grease leakage. Check connection with steering column for security. : Refer to ST section.
HOT MIN
Check fluid level in reservoir with engine off. Use “HOT” range at fluid temperatures of 50 to 80°C (122 to 196°F). Use “COLD” range at fluid temperatures of 0 to 30°C (32 to 86°F). CAUTION: ● Do not overfill. ● Recommended fluid is Automatic Transmission Fluid “DEXRONTM III” type.
NMA052
CHECKING LINES ● ●
Check lines for leaks, cracks, damage, loose connections, chafing and deterioration. Check rack boots for accumulation of power steering fluid.
SST575B
MA-53
CHASSIS AND BODY MAINTENANCE Lubricating Hood Latches, Locks and Hinges
: Greasing point
MMA106A
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters CAUTION: ● After any collision, inspect all seat belt assemblies, including retractors and other attached hardwares (i.e. 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 improperly operating. ● 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 seat belt assembly.
Check anchors for loose mounting.
Check belts for damage. Check retractor for smooth operation.
For seat belt pre-tensioner, refer to section RS.
Check functioning of buckles and tongues when buckled and released.
Anchor bolt 43 - 55 N·m (4.4 - 5.6 kg-m, 32 - 41 ft-lb)
MMA098A
MA-54
CHASSIS AND BODY MAINTENANCE Checking Body Corrosion Visually check body panels for corrosion, paint damage (scratches, chipping, rubbing, etc.) or damage to the anti-corrosion materials. In particular, check the following locations.
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-55
QG
SERVICE DATA AND SPECIFICATIONS (SDS) Engine Maintenance INSPECTION AND ADJUSTMENT Drive belt deflection and tension Deflection adjustment
Unit: mm (in)
Tension adjustment*
Used belt
Used belt New belt
After adjustment
Limit
Unit: N (kg, lb)
Limit
After adjustment
New belt
292 (29.8, 65.6)
652 - 740 (66.5 - 75.5, 146.6 - 166.4)
789 - 877 (80.5 - 89.7, 177.4 - 197.6)
196 (20.0, 44.1)
495 - 583 (50.5 - 59.5, 111.3 - 131.1)
603 - 691 (61.5 - 70.5, 135.6 - 155.3)
Alternator Without airconditioner compressor With airconditioner compressor Power steering oil pump
10.2 (0.402)
6.5 - 7.0 5.5 - 6.1 (0.256 - 0.276) (0.217 - 0.240)
8.1 (0.319)
5.3 - 5.7 4.5 - 5.0 (0.209 - 0.224) (0.177 - 0.197)
10.8 (0.425)
6.6 - 7.5 6.0 - 6.6 (0.260 - 0.295) (0.236 - 0.260)
Applied pushing force
98 N (10 kg, 22 lb)
—
*: If belt tension gauge cannot be installed at check points shown, check drive belt tension at a different location on the belt.
Oil capacity (Refill capacity)
Unit: (Imp pts)
Spark plug
With oil filter change
2.9 (5 - 1/8)
Make
Without oil filter change
2.7 (4 - 3/4)
Standard type
RC10YCC4 RC10YC4
BKR5E-11
Hot type
RC12YCC4 RC12YC4
BKR4E-11
Cold type
RC7YCC4 RC7YC4
BKR6E-11
Coolant capacity
CHAMPION
Unit: (Imp pts)
With reservoir tank
6.1 (10 - 3/4)
Reservoir tank
0.8 (1 - 3/8)
Plug gap
MA-56
mm (in)
NGK
1.0 - 1.1 (0.039 - 0.043)
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS) Engine Maintenance INSPECTION AND ADJUSTMENT Drive belt deflection and tension Deflection adjustment
Unit: mm (in)
Tension adjustment*
Used belt
Alternator
Used belt
Limit
After adjustment
New belt
12 - 13 (0.47 - 0.51)
8-9 (0.31 - 0.35)
Air conditioner compressor Power steering oil pump
Unit: N (kg, lb) New belt
Limit
After adjustment
7-8 (0.28 - 0.31)
264 (26.9, 59.3)
493 - 583 (50.3 - 59.5, 110.8 - 131.1)
9 (0.35)
5.5 - 6.5 (0.217 0.256)
4.5 - 5.5 (0.177 0.217)
304 (31.0, 68.3)
534 - 623 (54.5 - 63.5, 120.0 - 140.1)
12 (0.47)
8-9 (0.31 - 0.35)
7-8 (0.28 - 0.31)
264 (26.9, 59.3)
603 - 691 603 - 691 493 - 583 (61.5 - 70.5, (61.5 - 70.5, (50.3 - 59.5, 110.8 - 131.1) 135.6 - 155.3) 135.6 - 155.3)
Applied pushing force
98 N (10 kg, 22 lb)
11720 70J00
11720 70J05
652 - 740 603 - 691 (66.5 - 75.5, (61.5 - 70.5, 135.6 - 155.3) 146.6 - 166.4) 11920 9F500
11920 9F505
652 - 740 (66.5 - 75.5, 146.6 - 166.4)
838 - 926 (85.5 - 94.5, 188 - 208)
—
*: If belt tension gauge cannot be installed at check points shown, check drive belt tension at a different location on the belt.
Oil capacity (Refill capacity)
Unit: (Imp pts)
Spark plug Make
With oil filter change
3.7 (6 - 1/2)
Without oil filter change
3.5 (6 - 1/8)
Type Standard
Coolant capacity (Refill capacity) Unit: (Imp pts) Engine
BKR6EY-11
Hot
—
Cold
—
Plug gap
mm (in)
1.0 - 1.1 (0.039 - 0.043)
SR20DE M/T
6.6 (11 - 5/8)
CVT
6.8 (12)
With reservoir tank Reservoir tank
NGK
Ignition lead Ignition lead
0.8 (1 - 3/8)
Unit: kΩ/m Resistance [at 25°C (77°F)]
No. 1 cylinder
Approx 3.8
No. 2 cylinder
Approx 3.5
No. 3 cylinder
Approx 2.7
No. 4 cylinder
Approx 2.4
For U.K. (Made by Bougicord) 4.48 - 6.72 kΩ (1.365 - 2.048 kΩ/ft) [at 25°C (77°F)]
MA-57
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS) Engine Maintenance INSPECTION AND ADJUSTMENT Drive belt deflection Deflection adjustment
Unit: mm (in)
Used belt
New belt
Limit
After adjustment
Alternator
17 (0.67)
10.5 - 12.5 (0.413 - 0.492)
8.5 - 10.5 (0.335 - 0.413)
Air conditioner compressor
17 (0.67)
11.5 - 13.5 (0.453 - 0.531)
9.5 - 11.5 (0.374 - 0.453)
Power steering oil pump
8 (0.31)
5-7 (0.20 - 0.28)
4-6 (0.16 - 0.24)
Applied pushing force
98 N (10 kg, 22 lb)
Coolant capacity (Refill capacity)
Injection nozzle Unit: kPa (bar, kg/cm2, psi)
Unit: (Imp pts) With reservoir tank
6.4 (11 - 1/4)
Reservoir tank
0.8 (1 - 3/8)
Injection pressure
Engine oil capacity (Refill capacity) Unit: (Imp pts) With oil filter
5.0 (8 - 3/4)
Without oil filter
4.5 (7 - 7/8)
MA-58
12,749 (127.5, 130, 1,849)
SERVICE DATA AND SPECIFICATIONS (SDS) Chassis and Body Maintenance Wheel balance Wheel balance (Maximum allowable unbalance at rim flange) g (oz) Tire balance weight
g (oz)
10 (0.35) 5 - 60 (0.18 - 2.12) Spacing 5 (0.18)
MA-59
SERVICE DATA AND SPECIFICATIONS (SDS) NOTE
MA-60
ENGINE MECHANICAL SECTION
EM
CONTENTS PRECAUTIONS ...............................................................5 Parts Requiring Angular Tightening.............................5 Liquid Gasket Application Procedure ..........................5 PREPARATION................................................................6 Special Service Tools ..................................................6 Commercial Service Tools .........................................10 QG NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................11 NVH Troubleshooting - Engine Noise .......................11 OUTER COMPONENT PARTS .....................................13 Removal and Installation ...........................................13 MEASUREMENT OF COMPRESSION PRESSURE ....16 OIL PAN .........................................................................17 Components...............................................................17 Removal.....................................................................17 Installation..................................................................18 TIMING CHAIN ..............................................................19 Components...............................................................19 Removal.....................................................................20 Inspection...................................................................24 Installation..................................................................24 OIL SEAL.......................................................................29 Replacement..............................................................29 VALVE OIL SEAL .....................................................29 FRONT OIL SEAL ....................................................29 REAR OIL SEAL ......................................................30 CYLINDER HEAD..........................................................31 Components...............................................................31 Removal.....................................................................32 Disassembly...............................................................34 Inspection...................................................................34 CYLINDER HEAD DISTORTION ...............................34 CAMSHAFT VISUAL CHECK ....................................34 CAMSHAFT RUNOUT ..............................................35
CAMSHAFT CAM HEIGHT .......................................35 CAMSHAFT JOURNAL CLEARANCE ........................35 CAMSHAFT END PLAY ............................................36 CAMSHAFT SPROCKET RUNOUT ...........................36 VALVE GUIDE CLEARANCE ....................................36 VALVE GUIDE REPLACEMENT ................................37 VALVE SEATS .........................................................38 REPLACING VALVE SEAT FOR SERVICE PARTS .....38 VALVE DIMENSIONS ...............................................39 VALVE SPRING .......................................................39 VALVE LIFTER AND VALVE SHIM.............................40
Valve Clearance.........................................................40 CHECKING .............................................................40 ADJUSTING ............................................................41 Assembly ...................................................................43 Installation..................................................................43 ENGINE REMOVAL.......................................................48 Removal and Installation ...........................................48 REMOVAL ...............................................................49 INSTALLATION ........................................................51 CYLINDER BLOCK .......................................................52 Components...............................................................52 Removal and Installation ...........................................53 Disassembly...............................................................53 PISTON AND CRANKSHAFT ....................................53 Inspection...................................................................54 PISTON AND PISTON PIN CLEARANCE...................54 PISTON RING SIDE CLEARANCE ............................54 PISTON RING END GAP ..........................................54 CONNECTING ROD BEND AND TORSION ...............55 CYLINDER BLOCK DISTORTION AND WEAR ...........55 PISTON-TO-BORE CLEARANCE ..............................56 CRANKSHAFT.........................................................57 BEARING CLEARANCE ...........................................57 CONNECTING ROD BUSHING CLEARANCE (Small end) ..............................................................59 REPLACEMENT OF CONNECTING ROD BUSHING (Small end) ..............................................60 FLYWHEEL/DRIVE PLATE RUNOUT .........................60
EM
CONTENTS Assembly ...................................................................60 PISTON ..................................................................60 CRANKSHAFT.........................................................61
Inspection.................................................................110 PISTON AND PISTON PIN CLEARANCE.................110 PISTON RING SIDE CLEARANCE .......................... 111 PISTON RING END GAP ........................................ 111 CONNECTING ROD BEND AND TORSION ............. 111 CYLINDER BLOCK DISTORTION AND WEAR .........112 PISTON-TO-BORE CLEARANCE ............................112 CRANKSHAFT.......................................................113 BEARING CLEARANCE .........................................114
SR20DE NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ........................................64 NVH Troubleshooting - Engine Noise .......................65 OUTER COMPONENT PARTS .....................................66 COMPRESSION PRESSURE........................................69 Measurement of Compression Pressure...................69 OIL PAN .........................................................................70 Removal.....................................................................70 Installation..................................................................73 TIMING CHAIN ..............................................................75 Components...............................................................75 Removal.....................................................................76 Inspection...................................................................79 Installation..................................................................79 OIL SEAL REPLACEMENT ..........................................84 VALVE OIL SEAL .....................................................84 FRONT OIL SEAL ....................................................84 REAR OIL SEAL ......................................................85 CYLINDER HEAD..........................................................86 Components...............................................................86 Removal.....................................................................87 Disassembly...............................................................89 Inspection...................................................................91 CYLINDER HEAD DISTORTION ...............................91 CAMSHAFT VISUAL CHECK ....................................91 CAMSHAFT RUNOUT ..............................................92 CAMSHAFT CAM HEIGHT .......................................92 CAMSHAFT JOURNAL CLEARANCE ........................92 CAMSHAFT END PLAY ............................................93 CAMSHAFT SPROCKET RUNOUT ...........................93 VALVE GUIDE CLEARANCE ....................................93 VALVE GUIDE REPLACEMENT ................................94 VALVE SEATS .........................................................95 REPLACING VALVE SEAT FOR SERVICE PARTS .....95 VALVE DIMENSIONS ...............................................95 VALVE SPRING .......................................................96 HYDRAULIC LASH ADJUSTER ................................96 ROCKER ARM, SHIM AND ROCKER ARM GUIDE .....97 Assembly ...................................................................97 Installation..................................................................99 ENGINE REMOVAL.....................................................106 Components.............................................................106 Removal...................................................................107 Installation................................................................108 CYLINDER BLOCK .....................................................109 Components.............................................................109 Disassembly.............................................................110 PISTON AND CRANKSHAFT ..................................110
(Cont’d)
CONNECTING ROD BUSHING CLEARANCE (Small end) ............................................................116 REPLACEMENT OF CONNECTING ROD BUSHING (Small end) ............................................117 REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (CVT) ....................................117 FLYWHEEL/DRIVE PLATE RUNOUT .......................117
Assembly .................................................................117 PISTON ................................................................117 CRANKSHAFT.......................................................118 CD20T NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................121 NVH Troubleshooting Chart - Engine Noise ...........122 OUTER COMPONENT PARTS ...................................123 COMPRESSION PRESSURE......................................126 OIL PAN .......................................................................129 Removal...................................................................129 Installation................................................................129 TIMING BELT...............................................................131 Camshaft Timing Belt ..............................................131 REMOVAL .............................................................131 Inspection.................................................................133 Installation................................................................134 Injection Pump Timing Belt......................................135 REMOVAL .............................................................135 INSTALLATION ......................................................136 OIL SEAL REPLACEMENT ........................................138 VALVE OIL SEAL ...................................................138 CAMSHAFT AND CRANKSHAFT OIL SEAL INSTALLING DIRECTION AND MANNER ................138 CAMSHAFT OIL SEALS .........................................138 CRANKSHAFT FRONT OIL SEAL ...........................139 CRANKSHAFT REAR OIL SEAL .............................139
CYLINDER HEAD........................................................140 Components.............................................................140 Removal...................................................................141 Disassembly.............................................................141 Inspection.................................................................142 CYLINDER HEAD DISTORTION .............................142 VALVE GUIDE CLEARANCE ..................................142 VALVE GUIDE REPLACEMENT ..............................142 VALVE SEATS .......................................................143 VALVE SEAT REPLACEMENT ................................143
EM-2
CONTENTS VALVE DIMENSIONS .............................................144 VALVE SPRING SQUARENESS ..............................145 VALVE SPRING PRESSURE LOAD ........................145 VALVE LIFTER ......................................................145 COMBUSTION CHAMBER REPLACEMENT ............146 CAMSHAFT VISUAL CHECK ..................................147 CAMSHAFT END PLAY ..........................................147 CAMSHAFT RUNOUT ............................................147 CAMSHAFT CAM HEIGHT .....................................147 CAMSHAFT JOURNAL CLEARANCE ......................147
Valve clearance .......................................................148 Checking ..................................................................148 Adjusting ..................................................................149 Assembly .................................................................151 Installation................................................................151 TURBOCHARGER.......................................................156 Removal...................................................................156 Disassembly.............................................................157 Inspection.................................................................158 OIL AND WATER TUBES........................................158 ROTOR SHAFT .....................................................158 TURBINE WHEEL ..................................................159 COMPRESSOR WHEEL .........................................159 WASTEGATE VALVE..............................................160 WASTEGATE VALVE ACTUATOR ...........................160 Assembly .................................................................160 Installation................................................................160 ENGINE REMOVAL.....................................................162 CYLINDER BLOCK .....................................................166 Components.............................................................166 Preparation ..............................................................167 Disassembly.............................................................167 PISTON AND CRANKSHAFT ..................................167 Inspection.................................................................168 PISTON AND PISTON PIN CLEARANCE.................168 PISTON RING SIDE CLEARANCE ..........................168 PISTON RING END GAP ........................................169 MAIN BEARING CLEARANCE ................................169 CONNECTING ROD BEARING CLEARANCE (Big end) ......................................................................170 CONNECTING ROD AND PISTON PIN CLEARANCE (Small end) .......................................171 CONNECTING ROD BEND AND TORSION .............172 CRANKSHAFT.......................................................172 CYLINDER BLOCK DISTORTION ...........................173 CYLINDER BORE ..................................................173 PISTON-TO-BORE CLEARANCE ............................174
Assembly .................................................................175 PISTON ................................................................175 CRANKSHAFT.......................................................175 PISTON WITH CONNECTING ROD ........................176 FLYWHEEL RUNOUT.............................................177
(Cont’d) QG
SERVICE DATA AND SPECIFICATIONS (SDS) ........178 General Specifications.............................................178 Compression Pressure ............................................178 Cylinder Head ..........................................................178 Valve ........................................................................179 VALVE...................................................................179 VALVE SPRING .....................................................179 VALVE LIFTER ......................................................179 VALVE CLEARANCE ..............................................179 VALVE GUIDE .......................................................180 AVAILABLE SHIMS ................................................180 VALVE SEAT .........................................................182 VALVE SEAT RESURFACE LIMIT ...........................183 Camshaft and Camshaft Bearing ............................183 Cylinder Block..........................................................184 Piston, Piston Ring and Piston Pin .........................185 PISTON ................................................................185 PISTON RING .......................................................185 PISTON PIN ..........................................................185 Connecting Rod .......................................................186 Crankshaft................................................................186 Main Bearing............................................................186 STANDARD ...........................................................186 UNDERSIZE ..........................................................186 Connecting Rod Bearing .........................................187 STANDARD SIZE ...................................................187 UNDERSIZE ..........................................................187 Bearing Clearance ...................................................187 Miscellaneous Components.....................................187 SR20DE SERVICE DATA AND SPECIFICATIONS (SDS) ........188 General Specifications.............................................188 Inspection and Adjustment ......................................188 COMPRESSION PRESSURE .................................188 CYLINDER HEAD ..................................................188 VALVE...................................................................189 CAMSHAFT AND CAMSHAFT BEARING .................192 CYLINDER BLOCK ................................................192 PISTON, PISTON RING AND PISTON PIN ..............193 CONNECTING ROD...............................................193 CRANKSHAFT.......................................................194 AVAILABLE MAIN BEARING ...................................194 AVAILABLE CONNECTING ROD BEARING .............195 MISCELLANEOUS COMPONENTS .........................195 CD20T SERVICE DATA AND SPECIFICATIONS (SDS) ........196 General Specifications.............................................196 Inspection and Adjustment ......................................196 COMPRESSION PRESSURE .................................196 CYLINDER HEAD ..................................................196
EM-3
CONTENTS CAMSHAFT AND CAMSHAFT BEARING .................196 VALVE...................................................................197 VALVE LIFTER ......................................................198 AVAILABLE SHIMS ................................................198 VALVE CLEARANCE..............................................198 CYLINDER BLOCK ................................................199
EM-4
(Cont’d) PISTON, PISTON RING AND PISTON PIN ..............199 CONNECTING ROD...............................................200 CRANKSHAFT.......................................................200 AVAILABLE MAIN BEARINGS .................................200 TURBOCHARGER .................................................201 MISCELLANEOUS COMPONENTS .........................201
PRECAUTIONS Parts Requiring Angular Tightening
Parts Requiring Angular Tightening I I
I
I I I
Some important engine parts are tightened using an angulartightening method rather than a torque setting method. If these parts are tightened using a torque setting method, dispersal of the tightening force (axial bolt force) will be two or three times that of the dispersal produced by using the correct angular-tightening method. Although the torque setting values (described in this manual) are equivalent to those used when bolts and nuts are tightened with an angular-tightening method, they should be used for reference only. To assure the satisfactory maintenance of the engine, bolts and nuts must be tightened using an angular-tightening method. Before tightening the bolts and nuts, ensure that the thread and seating surfaces are clean and then coated with engine oil. The bolts and nuts which require the angular-tightening method are as follows: (1) Cylinder head bolts ..... SR, CD, QG (2) Main bearing cap bolts ..... SR (3) Connecting rod cap nuts ..... SR, QG
Liquid Gasket Application Procedure a. Inner side
b. Groove
Bolt hole
SEM164F
c.
d.
Groove
Before applying liquid gasket, use a scraper to remove all traces of old liquid gasket from mating surface and groove, and then completely clean any oil stains from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.) I Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) wide for SR engine and 3.5 to 4.5 mm (0.138 to 0.177 in) wide for QG and CD engine (for oil pan). I Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oil pan). Apply liquid gasket to inner surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) Wait at least 30 minutes before refilling with engine oil and engine coolant.
Inner side AEM080
EM-5
PREPARATION Special Service Tools
Special Service Tools Tool number Tool name
Engine application
Description
ST0501S000 Engine stand assembly 1 ST05011000 p Engine stand 2 ST05012000 p Base
SR
CD
QG
X
X
X
X
—
X
X
—
—
—
—
X
—
X
—
X
—
X
When overhauling engine
NT042
KV10106500 Engine stand shaft
When overhauling engine
NT028
KV10115300 Engine sub-attachment
When overhauling engine
NT008
Engine attachment assembly 1 KV10106500 p Engine attachment 2 KV10113300 p Sub-attachment
When overhauling engine
NT029 1 KV10108101 p
2 p
When overhauling engine
Engine attachment KV10102500 Engine stand shaft
NT366
ST10120000 Cylinder head bolt wrench
Loosening and tightening cylinder head bolt
a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39)
Unit: mm (in)
NT583
EM-6
PREPARATION Special Service Tools (Cont’d)
Tool number Tool name
Engine application
Description
KV10116200 Valve spring compressor 1 KV10115900 p Attachment
SR
CD
QG
X
—
X
—
X
—
Disassembling and assembling valve mechanism
NT022
KV101092S0 Valve spring compressor 1 KV10109210 p Compressor 2 KV10109220 p Adapter
Disassembling and assembling valve mechanism
NT021
KV10115600 Valve oil seal drift
Installing valve oil seal
Side A
Side B
Side A a: 20 (0.79) b: 13 (0.51) c: 10.3 (0.406) d: 8 (0.31) e: 10.7 (0.421) f: 5 (0.20)
Side B 20 (0.79) 14.2 (0.559) 11 (0.43) 8 (0.31) 10.7 (0.421) 5 (0.20)
X (Side B)
X — (Side A)
Unit: mm (in)
NT603
KV10107902 Valve oil seal puller 1 KV10116100 p Valve oil seal puller adapter
Removing valve oil seal
X
X
X
—
—
X
—
X
X
X
X
X
NT605
KV10115700 Dial gauge stand
Adjusting shims
NT012
KV101151S0 Lifter stopper set 1 KV10115110 p Camshaft pliers 2 KV10115120 p Lifter stopper
Changing shims
NT041
EM03470000 Piston ring compressor
Installing piston assembly into cylinder bore
NT044
EM-7
PREPARATION Special Service Tools (Cont’d)
Tool number Tool name KV10107400 Piston pin press stand 1 KV10107310 p Center shaft 2 ST13040020 p Stand 3 ST13040030 p Spring 4 KV10107320 p Cap 5 ST13040050 p Drift
Engine application
Description
SR
CD
QG
X
—
X
—
X
—
—
X
—
—
X
—
—
X
—
X
X
X
Disassembling and assembling piston pin
NT013
KV10109300* Pulley holder
Removing and installing camshaft sprocket
a: 68 mm (2.68 in) b: 8 mm (0.31 in) dia.
NT628
ED19600000* Compression gauge set
Measuring compression pressure
NT626
KV11100300 Nozzle holder socket No. 2-4 injection nozzle holder socket
Loosening and tightening injector nozzle
NT563
KV119E0030 No. 1 injection nozzle holder socket
Loosening and tightening injector nozzle
NT648
KV10111100 Seal cutter
Removing oil pan
NT046
*: Special tool or commercial equivalent
EM-8
PREPARATION Special Service Tools (Cont’d)
Tool number Tool name
Engine application
Description
WS39930000 Tube presser
SR
CD
QG
X
X
X
X
X
X
X
X
—
—
X
—
—
X
X
Pressing the tube of liquid gasket
NT052
KV10112100 Angle wrench
Tightening bolts for bearing cap, cylinder head, etc.
NT014
ST16610001* Pilot bushing puller
Removing pilot bushing
NT045
KV11102900* Pulley puller
Removing injection pump pulley
NT647
KV101056S0* Ring gear stopper 1 KV10105630 p Adapter 2 KV10105620 p Adapter 3 KV10105610 p Plate assembly
Preventing crankshaft from rotating
a: 3 (0.12) b: 6.4 (0.252) c: 2.8 (0.110) d: 6.6 (0.260) e: 107 (4.21) f: 14 (0.55) g: 20 (0.79) h: 14 (0.55) dia.
Unit: mm (in)
NT617
*: Special tool or commercial equivalent
EM-9
PREPARATION Commercial Service Tools
Commercial Service Tools Tool name
Engine application
Description
Spark plug wrench
SR
CD
QG
X
—
X
X
X
X
X
X
X
X
—
X
X
—
X
X
—
X
X
—
X
Removing and installing spark plug
16 mm (0.63 in) NT047
Valve seat cutter set
Finishing valve seat dimensions
NT048
Piston ring expander
Removing and installing piston ring
NT030
Valve guide drift
Removing and installing valve guide SR Intake & Exhaust a = 9.5 mm (0.374 in) dia. b = 5.0 mm (0.197 in) dia. QG Intake & Exhaust a = 9.5 mm (0.374 in) dia. b = 5.5 mm (0.217 in) dia.
NT015
Reaming valve guide p 1 or hole for oversize valve guide
Valve guide reamer
2 p
SR d1 = d2 = QG d1 = d2 =
Front oil seal drift
Intake & Exhaust 6.0 mm (0.236 in) dia. 10.175 mm (0.4006 in) dia. Intake & Exhaust 5.5 mm (0.217 in) dia. 9.685 mm (0.3813 in) dia.
Installing front oil seal
NT016
a = 75 mm (2.95 in) dia. b = 45 mm (1.77 in) dia.
NT049
Rear oil seal drift
Installing rear oil seal
a = 110 mm (4.33 in) dia. b = 80 mm (3.15 in) dia.
NT049
EM-10
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
QG
NVH Troubleshooting — Engine Noise
NVH Troubleshooting — Engine Noise
NCEM0005S01
Use the chart below to help you find the cause of the symptom. 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
Top of Engine Rocker Cover Cylinder Head Crankshaft Pulley Cylinder block (Side of Engine) Oil pan
Source of noise
Reference page
Before After warm- warmup up
When starting
When idling
When While racing driving
Ticking or click
C
A
—
A
B
—
Tappet noise
Valve clearance
EM-40
Rattle
C
A
—
A
B
C
Camshaft bearing noise
Camshaft journal clearance Camshaft runout
EM-35
Slap or knock
—
A
—
B
B
—
Piston pin noise
Piston and piston pin clearance Connecting rod bushing clearance
EM-54, 59
Slap or rap
A
—
—
B
B
A
Piston slap noise
Piston-to-bore clearance EM-54, 55, Piston ring side clearance 56 Piston ring end gap Connecting rod bend and torsion
Knock
A
B
C
B
B
B
Connecting rod-bearing noise
Connecting rod bearing clearance (Big end) Connecting rod bushing clearance (Small end)
EM-58, 59
Knock
A
B
—
A
B
C
Main bearing noise
Main bearing oil clearance Crankshaft runout
EM-57
Front of Tapping or A Engine Tim- ticking ing Chain Cover
A
—
B
B
B
Timing chain and chain tensioner noise
Timing chain cracks and wear Timing chain tensioner operation
EM-24
Front of Engine
Squeak or A fizzing
B
—
B
—
C
Other drive belts (sticking or slipping)
Drive belts deflection
Creaking
A
B
A
B
A
B
Other drive belts (slipping)
Idler pulley bearing operation
MA Section (“Checking Drive Belts”, “Engine Maintenance”)
Squall or creak
A
B
—
B
A
B
Water pump Water pump operation noise
A: Closely related
B: Related
C: Sometimes related
—: Not related
EM-11
Check item
LC Section (“Water Pump Inspection”, “Engine Cooling System”)
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
QG
NVH Troubleshooting — Engine Noise (Cont’d)
Camshaft bearing noise
Tappet noise
Timing chain and chain tensioner noise
VALVE MECHANISM
Valve TIMING CHAIN
Water pump noise
Piston pin noise
ROTATION MECHANISM
DRIVE BELT
Connecting rod bearing noise Piston slap noise
Main bearing noise SEM937F
EM-12
QG
OUTER COMPONENT PARTS
Removal and Installation
Removal and Installation
NCEM0006
YEM026
1. 2. 3. 4.
Oil pressure switch EGR valve* EGR guide tube* Air relief plug
5. 6. 7. 8.
Intake manifold Intake manifold upper support Intake manifold rear supports Oil filter
*: If so equipped
EM-13
9. Thermostat 10. Water pump 11. Water pump pulley
QG
OUTER COMPONENT PARTS Removal and Installation (Cont’d)
6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) .
1st 12 - 14 (1.2 - 1.4, 9 - 10) 6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)
2nd 17 - 24 (1.7 - 2.4, 12 - 17)
6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) 2.0 - 2.5 (0.20 - 0.26, 17.4 - 22.6)
Gasket Clip .
2.9 - 3.8 (0.30 - 0.39, 26.0 - 33.9)
O-ring O-ring
Gasket
6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)
Gasket
3.0 - 4.0 (0.31 - 0.41, 26.9 - 35.6) 3.0 - 4.0 (0.31 - 0.41, 26.9 - 35.6)
17 - 24 (1.7 - 2.4, 12 - 17)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)
17 - 24 (1.7 - 2.4, 12 - 17)
: Do not re-use. Intake manifold bolts and nuts tightening order
Throttle body bolts tightening procedure 1) Tighten all bolts to 9 to 11 N·m (0.9 to 1.1 kg-m, 6.5 to 8.0 ft-lb) 2) Tighten all bolts to 18 to 22 N·m (1.8 to 2.2 kg-m, 13 to 16 ft-lb)
Engine front Tighten in numerical order.
Tighten in numerical order. SEM865F
1. 2. 3.
Throttle position sensor IACV-AAC valve Throttle body
4. 5. 6.
Injector Injector tube Pressure regulator
EM-14
7. 8.
Intake manifold Canister purge control valve
QG
OUTER COMPONENT PARTS
Removal and Installation (Cont’d)
5.10 - 6.37 (0.52 - 0.66, 45.1 - 57.3)
13 p
20 - 26 (2.0 - 2.7, 14 - 20)
20 - 29 (2.0 - 3.0, 14 - 22)
Washer 20 - 29 (2.0 - 3.0, 14 - 22) 30 - 40 (3.1 - 4.0, 23 - 29) 40 - 60 (4.1 - 6.1, 30 - 44)
58.8 - 78.4 (6.0 - 8.0, 43 - 58)
29 - 34 (3.0 - 3.5, 22 - 25) 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8) 34.3 - 44.1 (3.50 - 4.50, 25.3 - 32.5)
Washer
132 - 152 (13.5 - 15.5, 98 - 112) ★
26 - 29 (2.7 - 3.0, 20 - 22)
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
29 - 34 (3.0 - 3.5, 22 - 25) Exhaust manifold nuts tightening order
6.3 - 8.3 (0.64 - 0.83, 55.6 - 72.0)
33 - 46 (3.4 - 4.7, 25 - 34) 16 - 21 (1.6 - 2.1, 12 - 15)
: N·m (kg-m, in-lb)
33 - 46 (3.4 - 4.7, 25 - 34)
: N·m (kg-m, ft-lb)
Engine front
6.3 - 8.3 (0.64 - 0.83, 55.6 - 72.0)
: Use Genuine Liquid Gasket or equivalent.
16 - 21 (1.6 - 2.1, 12 - 15)
: Do not re-use.
Tighten in numerical order.
: Lubricate with new engine oil. SEM866F
1. 2. 3. 4. 5.
Crankshaft pulley Engine coolant temperature Gasket Exhaust manifold Exhaust manifold cover
6. 7. 8. 9.
Thermal transmitter Water drain plug Heated oxygen sensor Three way catalyst
EM-15
10. 11. 12. 13.
Converter cap Converter cover Ignition coil Spark plug
MEASUREMENT OF COMPRESSION PRESSURE 1. 2. 3. 4. 5. I
Warm up engine. Turn ignition switch OFF. Release fuel pressure. Refer to “Releasing Fuel Pressure” in EC section. Remove ignition coils. Remove spark plugs. Clean area around plug with compressed air before removing the spark plug.
6. 7.
SEM973E
20 mm (0.79 in) dia. Use compression tester whose end (rubber portion) is less than 20 mm (0.79 in) dia. Otherwise, it may be caught by cylinder head during removal.
AEM308
QG
Attach a compression tester to No. 1 cylinder. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. I Always use a fully-charged battery to obtain specified engine speed. Compression pressure: kPa (bar, kg/cm2, psi)/rpm Standard 1,324 (13.24, 13.5, 192)/350 Minimum 1,128 (11.28, 11.5, 164)/350 Maximum allowable difference between cylinders 98 (0.98, 1.0, 14)/300 10. If cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and retest compression. I If adding oil improves cylinder compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. I If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. Refer to SDS, EM-178. If valve or valve seat is damaged excessively, replace them. I If compression in any two adjacent cylinders is low and if adding oil does not improve compression, there is leakage past the gasket surface. If so, replace cylinder head gasket. 11. Reinstall spark plugs, ignition coils and fuel pump fuse. 12. Perform “Self-diagnosis Procedure” referring to EC section. Erase DTC if any DTC appears.
EM-16
QG
OIL PAN
Components
Components
NCEM0008
Gasket Oil pan Oil pan side
Oil strainer
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
Washer
Drain plug 29.4 - 39.2 (3.00 - 4.00, 21.69 - 28.91) 6.28 - 8.34 (0.641 - 0.851, 55.6 - 73.8) 6.28 - 8.34 (0.641 - 0.851, 55.6 - 73.8)
: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb)
6.28 - 8.34 (0.641 - 0.851, 55.6 - 73.8)
: Use Genuine Liquid Gasket or equivalent
SEM867F
Removal 1. 2. 3. Centre member
NCEM0009
5.
Remove engine RH side cover and under covers. Drain engine oil. Remove front exhaust tube. Refer to FE section (“EXHAUST SYSTEM”). Set a suitable transmission jack under transaxle and lift engine with engine slinger. Remove center member.
6.
Remove rear engine gussets.
4.
SEM067F
Drain plug Lower rear engine plate
Gusset .
SEM071FA
EM-17
OIL PAN
QG
Removal (Cont’d)
7. a. 1)
b.
Remove oil pan. Insert Tool between cylinder block and oil pan. Be careful not to damage aluminum mating face. Do not insert screwdriver, or oil pan flange will be damaged. Slide Tool by tapping on the side of the Tool with a hammer.
SEM365EB
Installation 1. I
NCEM0010
Use a scraper to remove old liquid gasket from mating surface of oil pan. Also remove old liquid gasket from mating surface of cylinder block.
Scraper SEM295C
2.
Cut here. 7 mm (0.28 in)
I I I
Liquid gasket
Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Liquid Gasket or equivalent. Apply to groove on mating surface. Allow 7 mm (0.28 in) clearance around bolt holes.
Inner side
Groove
Bolt hole SEM015E
I
Tube presser
I
Be sure liquid gasket diameter is 3.5 to 4.5 mm (0.138 to 0.177 in). Attaching should be done within 5 minutes after coating.
3. I I 4.
Install oil pan. Tighten oil pan nuts and bolts in the numerical order. Wait at least 30 minutes before refilling engine oil. Install parts in reverse order of removal.
SEM296CB
Engine front
SEM072F
EM-18
QG
TIMING CHAIN
Components
Components
NCEM0011
108 - 118 (11.0 - 12.0, 80 - 87)
7.2 - 10.8 (0.73 - 1.10, 63.4 - 95.5) 6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)
O-ring
98 - 128 (10.0 - 13.1, 72 - 95)
6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) 17 - 24 (1.7 - 2.4, 12 - 17)
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
17 - 24 (1.7 - 2.4, 12 - 17)
6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)
6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) 16 - 21 (1.6 - 2.1, 12 - 15) : N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) 6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) 132 - 152 (13.5 - 15.5, 98 - 112)
: Use Genuine Liquid Gasket or equivalent : Lubricate with new engine oil. : Do not re-use. SEM868F
1. 2. 3. 4. 5. 6.
Chain tensioner Camshaft sprocket (Intake) Camshaft sprocket (Exhaust) O-ring Slack side timing chain guide Timing chain tension guide
7. 8. 9. 10. 11. 12.
Timing chain Crankshaft sprocket Oil pump drive spacer Front cover O-ring Oil seal
EM-19
13. Crankshaft pulley 14. Cylinder head front cover 15. Camshaft position sensor (PHASE) 16. Cylinder block dowels
TIMING CHAIN
QG
Components (Cont’d)
CAUTION: I After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. I When installing chain tensioner, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. I Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprocket and crankshaft pulley. I When removing oil pump assembly, remove camshaft position sensor (PHASE), then remove timing chain from engine. I Be careful not to damage sensor edges.
Removal
Drain plug
1. 2.
SEM869F
3. I I 4. 5. 6. 7. 8.
NCEM0012
Drain engine coolant from radiator and cylinder block. Be careful not to spill coolant on drive belts. Release fuel pressure. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”). Remove the following belts. Power steering pump drive belt Alternator drive belt Remove power steering pulley and pump with bracket. Remove front right-side wheel. Remove front right-side splash cover. Remove front undercovers. Remove front exhaust tube.
9. Remove vacuum hoses, fuel hoses, and so on. 10. Remove ignition coils. 11. Remove cylinder head front mounting bracket.
Ignition coil Engine front SEM870F
12. Remove rocker cover bolts in numerical order as shown in the figure. 13. Remove spark plugs.
Remove in numerical order. SEM871F
EM-20
QG
TIMING CHAIN
Removal (Cont’d)
14. Set No. 1 piston at TDC on its compression stroke.
SEM872F
I
Mating mark
(INT) RH camshaft sprocket
Mating mark
Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure at left.
(EXH) LH camshaft sprocket SEM873F
15. Remove camshaft position sensor (PHASE). I Do not allow any magnetic materials to contact the camshaft position sensor (PHASE). I Be careful not to damage sensor. 16. Remove cylinder head front cover.
Cylinder head front cover
O-ring
Camshaft position sensor (PHASE)
SEM874F
17. Remove timing chain guide from camshaft bracket. 18. Attach a suitable stopper pin to chain tensioner. 19. Remove chain tensioner.
Chain guide
Stopper pin Chain tensioner
SEM875F
Mating mark
20. Remove camshaft sprocket bolts. I Apply paint to timing chain and cam sprockets for alignment during installation. 21. Remove camshaft sprockets.
SEM876F
EM-21
TIMING CHAIN
QG
Removal (Cont’d)
22. Remove cylinder head bolts at engine front side.
Engine front
Loosen in numerical order.
SEM008G
23. 24. 25. 26.
Remove center member. Support engine with a suitable hoist or jack. Remove oil pan. Refer to “Removal” in “OIL PAN” (EM-17). Remove oil strainer.
Oil strainer SEM879F
27. Remove starter motor, and set ring gear stopper using mounting bolt holes.
SEM880F
28. Loosen crankshaft pulley bolt. 29. Remove crankshaft pulley with a suitable puller. Suitable puller
Crankshaft pulley SEM881F
30. Remove engine front mounting.
Engine front mounting
SEM079FA
EM-22
QG
TIMING CHAIN
Removal (Cont’d)
31. Remove engine front mounting bracket. Engine front mounting bracket
SEM882F
32. Remove water pump pulley and water pump. 33. Remove front cover bolts and front cover as shown. ★1: Located on water pump ★2: Located on power steering pump adjusting bar I Inspect for oil leakage at front oil seal. Replace seal if oil leak is present.
SEM883F
Timing chain Chain guides
O-rings
34. 35. 36. 37. 38.
Remove Remove Remove Remove Remove
timing chain. oil pump drive spacer. chain guides. crankshaft sprocket. O-rings from cylinder block and front cover.
Crankshaft sprocket Oil pump drive spacer SEM884F
O-rings
SEM897F
39. Remove cylinder block dowels by using locking pliers for easyto-install front cover. I Do not hit dowels because cylinder block may be cracked.
Locking pliers
Cylinder block dowels
SEM944F
EM-23
TIMING CHAIN
QG
Inspection
Inspection
NCEM0013
Check for cracks and excessive wear at roller links. Replace if necessary.
Crack
Wear
SEM885F
Crankshaft sprocket
Crankshaft side
Installation
NCEM0014
1. I
Install crankshaft sprocket on crankshaft. Make sure mating marks on crankshaft sprocket face front of engine.
2.
Position crankshaft so that No. 1 piston is at TDC and key way is at 12 o’clock.
3.
Install slack side timing chain guide and timing chain tension guide.
4. I
Install timing chain on crankshaft sprocket. Set timing chain by aligning its mating mark with that on the crankshaft sprocket. Make sure sprocket’s mating mark faces engine front.
Engine front Mating mark
SEM886F
Crankshaft key
No. 1 piston at TDC
SEM890F
Slack side timing chain guide Timing chain tension guide
SEM891F
Crankshaft sprocket Timing chain
I
Mating mark (different colour) SEM892F
EM-24
QG
TIMING CHAIN
Installation (Cont’d)
5.
Install O-rings to cylinder block.
6.
Before installing front cover, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block.
O-rings
SEM893F
Scraper
I
SEM894F
7. I I I
Liquid gasket
Front cover
2.0 - 3.0 mm (0.079 0.118 in) dia.
Apply a continuous bead of liquid gasket to mating surface of front cover. Check alignment of mating marks on chain and crankshaft sprocket. Align oil drive spacer with oil pump. Place timing chain to the side of chain guide. This prevents the chain from making contact with water seal area of front cover.
SEM895F
8.
Install front cover. Bolt No.
Tightening torque
N⋅m (kg-m, in-lb)
“”
mm (in)
a.
6.9 - 9.5 (0.70 - 0.97, 61 - 84)
20 (0.79)
b.
6.9 - 9.5 (0.70 - 0.97, 61 - 84)
40 (1.57)
c.
17 - 24 (1.7 - 2.4, 148 - 208*)
70 (2.76)
d.
6.9 - 9.5 (0.70 - 0.97, 61 - 84)
72.8 (2.866)
e.
6.9 - 9.5 (0.70 - 0.97, 61 - 84)
12 (0.47)
SEM896F
*: 12 - 17 ft-lb
I I
O-rings
Make sure two O-rings are present. Be careful not to damage oil seal when installing front cover.
SEM897F
EM-25
TIMING CHAIN
QG
Installation (Cont’d)
9. I
Engine front
Tighten in numerical order
Install cylinder head bolts at engine front side. Tightening procedure Tightening bolts (1 - 4) to 6.3 to 8.3 N⋅m (0.64 to 0.85 kg-m, 55.8 to 73.5 in-lb).
SEM009G
10. Install oil pump drive spacer. Oil pump drive spacer
Point mark
SEM945F
11. Install cylinder block dowels. I When installing cylinder block dowels, use new ones.
Cylinder block dowels
SEM946F
Engine front mounting bracket
SEM898F
12. Install water pump and water pump pulley. Refer to LC section (“Water Pump”, “ENGINE COOLING SYSTEM”). 13. Install engine front mounting bracket. 14. Install oil strainer. 15. Install oil pan. Refer to “Installation” in “OIL PAN” EM-18. 16. Install crankshaft pulley. 17. Install center member. 18. Remove ring gear stopper. 19. Install starter motor. 20. Install camshaft sprocket. I Set timing chain by aligning mating marks with those of camshaft sprockets.
Mating mark Mating mark Camshaft sprocket (INT)
Camshaft sprocket (EXH)
SEM905F
EM-26
QG
TIMING CHAIN
Installation (Cont’d)
21. Install camshaft sprocket bolts to correct torque. I Apply new engine oil to bolt threads and seat surface.
SEM906F
22. Install chain tensioner. I Before installing chain tensioner, insert a suitable pin into pin hole of chain tensioner. I After installing chain tensioner, remove the pin. 23. Install timing chain guide.
Chain guide
Chain tensioner Stopper pin SEM907F
24. Install cylinder head front cover. I Apply liquid gasket to cylinder head front cover. I Use Genuine Liquid Gasket or equivalent.
Cylinder head front cover
2.0 - 3.0 mm (0.079 0.118 in) dia.
SEM887F
Camshaft position sensor (PHASE)
25. Install camshaft position sensor (PHASE). O-ring
SEM889F
26. Before installing rocker cover, apply a continuous bead of liquid gasket to mating surface of cylinder head. Liquid gasket
3 mm (0.12 in) dia.
Cylinder head Cylinder head front cover
SEM888F
EM-27
TIMING CHAIN
QG
Installation (Cont’d)
Tighten in numerical order SEM908F
27. Install rocker cover and tighten bolts in numerical order as shown in the figure. 28. Install spark plugs. 29. Install ignition coils. 30. Install engine front mounting. 31. Install front exhaust tube. 32. Install front undercover. 33. Install front right splash cover. 34. Install front right wheel. 35. Install power steering pulley and pump with bracket. To check power steering fluid, refer to MA section (“Checking Power Steering Fluid and Lines”, “CHASSIS AND BODY MAINTENANCE”). 36. Drive belts. For adjusting drive belt deflection, refer to MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”). 37. Reinstall parts in reverse order of removal.
EM-28
OIL SEAL
QG Replacement
Replacement VALVE OIL SEAL
NCEM0015 NCEM0015S01
1. Remove rocker cover. 2. Remove camshaft. 3. Remove valve spring. Refer to EM-34. 4. Remove valve oil seal with Tool. Piston concerned should be set at TDC to prevent valve from falling.
KV10107902
SEM909F
5. 13.5± 0.3 mm (0.531± 0.012 in)
Apply new engine oil to new valve oil seal and install it with Tool.
KV10115600 SEM910F
FRONT OIL SEAL Front oil seal
NCEM0015S02
1. I I I I 2. I
Remove the following parts: Engine under cover RH engine side cover Generator and power steering drive belts Crankshaft pulley Remove front oil seal from front cover. Be careful not to scratch front cover.
3.
Apply new engine oil to new oil seal and install it using a suitable tool. Install new oil seal in the direction shown.
SEM911F
I Engine inside
Oil seal lip
Engine outside
Dust seal lip
SEM715A
Suitable tool
SEM912F
EM-29
OIL SEAL
QG
Replacement (Cont’d)
REAR OIL SEAL
NCEM0015S03
1. 2. I
Remove flywheel or drive plate. Remove rear oil seal. Be careful not to scratch rear oil seal retainer.
3.
Apply new engine oil to new oil seal and install it using a suitable tool. Install new oil seal in the direction shown.
SEM096F
I Engine inside
Oil seal lip
Engine outside
Dust seal lip
SEM715A
Suitable tool SEM097F
EM-30
QG
CYLINDER HEAD
Components
Components
NCEM0016
To intake manifold
2.0 - 3.9 (0.20 - 0.40, 17.4 - 34.7) 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
Refer to “Installation” in “TIMING CHAIN”.
9 p
4 p
Refer to “Installation” in “TIMING CHAIN”.
24.5 - 34.3 (2.5 - 3.5, 18 - 25) O-ring
: N·m (kg-m, in-lb)
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
: N·m (kg-m, ft-lb) : Use Genuine Liquid Gasket or equivalent. : Lubricate with new engine oil. : Do not re-use. SEM913F
1. 2. 3. 4. 5. 6. 7.
Oil filler cap Rocker cover Rocker cover gasket VTC solenoid Camshaft bracket Intake camshaft Exhaust camshaft
8. 9. 10. 11. 12. 13. 14.
Timing chain guide Cylinder head bolt Shim Valve lifter Valve cotter Valve spring retainer Valve spring
EM-31
15. 16. 17. 18. 19. 20. 21.
Valve spring seat Valve oil seal Valve guide Cylinder head Cylinder head gasket Valve seat Valve
CYLINDER HEAD
QG
Components (Cont’d)
CAUTION: I When installing camshaft and oil seal, lubricate contacting surfaces with new engine oil. I When tightening cylinder head bolts, camshaft sprocket bolts and camshaft bracket bolts, lubricate bolt threads and seat surfaces with new engine oil. I Attach tags to valve lifters so as not to mix them up.
Removal
Drain plug
1. 2.
3. 4. 5.
NCEM0017
Drain engine coolant from radiator and cylinder block. Be careful not to spill coolant on drive belts. Release fuel pressure. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”). Remove air duct to intake manifold collector. Remove front undercovers. Remove front exhaust tube.
SEM869F
6. 7.
Remove vacuum hoses, fuel hoses, water hoses, wires, harness, connectors and so on. Remove ignition coils.
Ignition coil Engine front SEM870F
8.
Remove rocker cover bolts in numerical order as shown in the figure. 9. Remove spark plugs. 10. Remove intake manifold rear supports.
Remove in numerical order. SEM871F
11. Set No. 1 piston at TDC on its compression stroke.
SEM872F
EM-32
QG
CYLINDER HEAD
Removal (Cont’d)
I
Mating mark
(INT) RH camshaft sprocket
Mating mark
Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure at left.
(EXH) LH camshaft sprocket SEM873F
12. Remove camshaft position sensor (PHASE). I Do not allow any magnetic materials to contact the camshaft position sensor (PHASE). I Be careful not to damage sensor. 13. Remove cylinder head front cover.
Cylinder head front cover
O-ring
Camshaft position sensor (PHASE)
SEM874F
14. Remove timing chain guide from camshaft bracket. 15. Attach a suitable stopper pin to chain tensioner. 16. Remove chain tensioner.
Chain guide
Stopper pin Chain tensioner
SEM875F
17. Remove camshaft sprocket bolts. I Apply paint to timing chain and cam sprockets for alignment during installation. 18. Remove camshaft sprockets.
Mating mark
SEM876F
19. Remove camshaft brackets and camshafts. I Apply I.D. marks to brackets to ensure correct reassembly. I Bolts should be loosened in two or three steps.
Engine front
Loosen in numerical order.
877F
EM-33
CYLINDER HEAD
QG
Removal (Cont’d)
20. Remove cylinder head bolts. 21. Remove cylinder head with manifolds. I Head warpage or cracking could result from removing in incorrect order. I Cylinder head bolts should be loosened in two or three steps.
Engine front
Loosen in numerical order.
SEM878F
Disassembly 1. 2.
KV10109220
NCEM0018
Remove valve components with Tool. Remove valve oil seal with a suitable tool.
KV10116200
SEM914F
Inspection Straightedge
CYLINDER HEAD DISTORTION I I
Feeler gauge
SEM915F
NCEM0019 NCEM0019S01
Clean surface of cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of cylinder head mating surface. I Check along six positions shown in figure. Head surface flatness: Standard: Less than 0.03 mm (0.0012 in) Limit: 0.1 mm (0.004 in) If beyond the specified limit, replace or resurface it. Resurfacing limit: The limit for cylinder head resurfacing is determined by the amount of cylinder block resurfacing. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, replace cylinder head. Nominal cylinder head height: 117.8 - 118.0 mm (4.638 - 4.646 in)
CAMSHAFT VISUAL CHECK Check camshaft for scratches, seizure and wear.
EM-34
NCEM0019S02
QG
CYLINDER HEAD
Inspection (Cont’d)
CAMSHAFT RUNOUT 1.
2.
NCEM0019S03
Measure camshaft runout at the center journal. Runout (Total indicator reading): Standard Less than 0.02 mm (0.0008 in) Limit 0.1 mm (0.004 in) If it exceeds the limit, replace camshaft.
SEM154D
CAMSHAFT CAM HEIGHT 1.
Micrometer
SEM916F
2.
CAMSHAFT JOURNAL CLEARANCE
Inside micrometer
1. 2.
NCEM0019S04
Measure camshaft cam height. Standard cam height: Intake QG16DE 40.220 - 40.410 mm (1.5835 - 1.5909 in) QG18DE 40.610 - 40.800 mm (1.5988 - 1.6063 in) Exhaust 40.056 - 40.245 mm (1.5770 - 1.5844 in) Cam wear limit: 0.20 mm (0.0079 in) If wear is beyond the limit, replace camshaft.
NCEM0019S05
Install camshaft bracket and tighten bolts to the specified torque. Measure inner diameter of camshaft bearing. Standard inner diameter: No. 1 bearing 28.000 - 28.021 mm (1.1024 - 1.1032 in) No. 2 to No. 5 bearings 24.000 - 24.021 mm (0.9449 - 0.9457 in)
SEM917F
3.
4.
SEM156D
Measure outer diameter of camshaft journal. Standard outer diameter: No. 1 journal 27.935 - 27.955 mm (1.0998 - 1.1006 in) No. 2 to No. 5 journals 23.935 - 23.955 mm (0.9423 - 0.9431 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance: Standard
EM-35
CYLINDER HEAD
QG
Inspection (Cont’d)
0.045 - 0.086 mm (0.0018 - 0.0034 in) Limit 0.15 mm (0.0059 in)
CAMSHAFT END PLAY
Dial guage
1. 2.
SEM918F
3. I
CAMSHAFT SPROCKET RUNOUT 1. 2.
3.
NCEM0019S06
Install camshaft in cylinder head. Refer to EM-24. Measure camshaft end play. Camshaft end play: Standard 0.115 - 0.188 mm (0.0045 - 0.0074 in) Limit 0.20 mm (0.0079 in) If limit is exceeded, replace camshaft and remeasure end play. If limit is still exceeded after replacing camshaft, replace cylinder head.
NCEM0019S07
Install sprocket on camshaft. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.15 mm (0.0059 in) If it exceeds the limit, replace camshaft sprocket.
SEM919F
VALVE GUIDE CLEARANCE 1.
Approx. 25 mm (0.98 in)
NCEM0019S08
Measure valve deflection as shown in figure. (Valve and valve guide wear the most in this direction.) Valve deflection limit (Dial gauge reading): Intake & Exhaust 0.2 mm (0.008 in)
SEM345D
EM-36
QG
CYLINDER HEAD
Inspection (Cont’d)
Micrometer
2. a. b.
c.
If it exceeds the limit, check valve to valve guide clearance. Measure valve stem diameter and valve guide inner diameter. Calculate valve to valve guide clearance. Valve to valve guide clearance = Valve guide inner diameter − Valve stem diameter. Check that clearance is within specification. Unit: mm (in)
SEM938C
Standard
Limit
Intake
0.020 - 0.050 (0.0008 - 0.0020)
0.1 (0.004)
Exhaust
0.040 - 0.070 (0.0016 - 0.0028)
0.1 (0.004)
I I
Oil
If it exceeds the limit, replace valve and remeasure clearance. If limit is still exceeded after replacing valve, replace valve guide.
VALVE GUIDE REPLACEMENT
NCEM0019S09
1.
To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F).
2.
Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.
SEM008A
SEM931C
EM-37
CYLINDER HEAD
QG
Inspection (Cont’d)
3.
Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake & Exhaust 9.685 - 9.696 mm (0.3813 - 0.3817 in)
4.
Heat cylinder head to 110 to 130°C (230 to 266°F) and press service valve guide into cylinder head. Projection “L”: 11.5 - 11.7 mm (0.453 - 0.461 in)
5.
Ream valve guide. Finished size: Intake & Exhaust 5.500 - 5.515 mm (0.2165 - 0.2171 in)
Suitable reamer
SEM932C
MEM096A
Suitable reamer
SEM932C
VALVE SEATS
NCEM0019S10
Check valve seats for pitting at contact surface. Resurface or replace if excessively worn. I Before repairing valve seats, check valve and valve guide for wear. If they have worn, replace them. Then correct valve seat. I Use both hands to cut uniformly.
SEM934C
REPLACING VALVE SEAT FOR SERVICE PARTS .
1. Recess diameter
SEM795A
NCEM0019S11
Bore out old seat until it collapses. Set machine depth stop so that boring cannot contact the bottom face of seat recess in cylinder head. 2. Ream cylinder head recess. Reaming bore for service valve seat Oversize [0.5 mm (0.020 in)]: Refer to SDS, EM-182. Use the valve guide center for reaming to ensure valve seat will have the correct fit.
EM-38
QG
CYLINDER HEAD
Inspection (Cont’d) Oil
3. 4.
Heat cylinder head to 110 to 130°C (230 to 266°F). Press fit valve seat until it seats on the bottom.
5.
Cut or grind valve seat using suitable tool to the specified dimensions as shown in SDS, EM-179. After cutting, lap valve seat with abrasive compound. Check valve seating condition. Seat face angle “α”: 45°15′ - 45°45′ Contacting width “W”: Intake 1.06 - 1.34 mm (0.0417 - 0.0528 in) Exhaust 1.20 - 1.68 mm (0.0472 - 0.0661 in) Use a depth gauge to measure the distance “L” between the mounting surface of the cylinder head spring seat and the valve stem end. If the distance is shorter than specified, repeat step 5 above to correct it. If the distance is longer, replace the valve seat. Valve seat resurface limit: Intake 35.95 - 36.55 mm (1.4154 - 1.4390 in) Exhaust 35.92 - 36.52 mm (1.4142 - 1.4378 in)
SEM008A
6. 7.
SEM892B
8.
AEM343
VALVE DIMENSIONS
T (Margin thickness)
NCEM0019S12
Check dimensions of each valve. Refer to SDS, EM-182 for dimensions. When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less.
SEM188A
S (Out-of-square)
VALVE SPRING Squareness 1.
2.
Measure dimension “S”. Out-of-square “S”: Less than 1.75 mm (0.0689 in) If it exceeds the limit, replace spring.
SEM288A
EM-39
NCEM0019S13 NCEM0019S1301
QG
CYLINDER HEAD Inspection (Cont’d)
Pressure
EM113
NCEM0019S1302
Check valve spring pressure at specified spring height. Pressure: Standard 370.0 N (37.73 kg, 83.19 lb) at 23.64 mm (0.9307 in) Limit More than 347.8 N (35.46 kg, 78.19 lb) at 23.64 mm (0.9307 in) If it exceeds the limit, replace spring.
VALVE LIFTER AND VALVE SHIM
NCEM0019S16
1.
Check contact and sliding surfaces for wear or scratches.
2.
Check diameter of valve lifter and valve lifter guide bore. Valve lifter outside diameter: 29.960 - 29.975 mm (1.1795 - 1.1801 in)
SEM160D
SEM161D
Lifter guide inside diameter: 30.000 - 30.021 mm (1.1811 - 1.1819 in) Clearance between valve lifter and valve lifter guide: 0.025 - 0.065 mm (0.0010 - 0.0024 in) If it exceeds the limit, replace valve lifter or cylinder head which exceeds the standard diameter tolerance.
SEM920F
Valve Clearance CHECKING
Pointer
NCEM0041 NCEM0041S01
Check valve clearance while engine is warm and not running. 1. Remove rocker cover. 2. Remove all spark plugs. 3. Set No. 1 cylinder at TDC on its compression stroke. I Align pointer with TDC mark on crankshaft pulley. I Check that valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight.
Timing mark
Crankshaft pulley SEM921F
EM-40
QG
CYLINDER HEAD
Valve Clearance (Cont’d)
INT
No. 1
No. 2
No. 3
I
If not, turn crankshaft one revolution (360°) and align as described above.
4.
Check only those valves shown in the figure.
I
Using a feeler gauge, measure clearance between valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement adjusting shim. Valve clearance for checking (Hot): Intake 0.21 - 0.49 mm (0.008 - 0.019 in) Exhaust 0.30 - 0.58 mm (0.012 - 0.023 in)
No. 4
EXH Engine front SEM922F
I
.
SEM139D
5.
INT
No. 1
No. 2
No. 3
No. 4
6. I 7. I I
EXH
Turn crankshaft one revolution (360°) and align mark on crankshaft pulley with pointer. Check only those valves shown in the figure. Use the same procedure as mentioned in step 4. If all valve clearances are within specification, install the following parts: Rocker cover All spark plugs
Engine front SEM923F
ADJUSTING
Tool (A) KV10115110
NCEM0041S02
Adjust valve clearance while engine is cold. 1. Turn crankshaft. Position cam lobe upward on camshaft for valve that must be adjusted. 2. Place Tool (A) around camshaft as shown in figure. Before placing Tool (A), rotate notch toward center of cylinder head. (See figure.) This will simplify shim removal later. CAUTION: Be careful not to damage cam surface with Tool (A).
Notch
SEM941F
EM-41
CYLINDER HEAD
QG
Valve Clearance (Cont’d)
3.
Tool (A) KV10115110
Rotate Tool (A) so that valve lifter is pushed down.
SEM924F
4. Tool (B) KV10115120
Tool (A)
Place Tool (B) between camshaft and valve lifter to retain valve lifter. CAUTION: I Tool (B) must be placed as close to camshaft bracket as possible. I Be careful not to damage cam surface with Tool (B). 5. Remove Tool (A).
SEM925F
.
Magnetic finger
6. Tool (B)
SEM144D
Remove adjusting shim using a small screwdriver and a magnetic finger. 7. Determine replacement adjusting shim size using the following formula. I Use a micrometer to determine thickness of removed shim. I Calculate thickness of new adjusting shim so valve clearance comes within specified values. R = Thickness of removed shim N = Thickness of new shim M = Measured valve clearance Intake: N = R + [M − 0.37 mm (0.0146 in)] Exhaust: N = R + [M − 0.40 mm (0.0157 in)] Shims are available in 50 sizes from 2.00 mm (0.0787 in) to 2.98 mm (0.1173 in), in steps of 0.02 mm (0.0008 in).
SEM145D
I
Shim
Select the closest size shim to the calculated thickness. Refer to chart in SDS, EM-180.
Indicate T1 = 2.800 mm (0.1102 in) AEM236
EM-42
QG
CYLINDER HEAD
Valve Clearance (Cont’d)
8. I
Tool (B)
Install new shim using a suitable tool. Install with the surface on which the thickness is stamped facing down.
Suitable tool
SEM146D
9. Place Tool (A) as explained in steps 2 and 3. 10. Remove Tool (B). 11. Remove Tool (A). 12. Recheck valve clearance. Valve clearance:
Tool (B)
Tool (A)
Unit: mm (in) For adjusting
For checking
Hot
Cold* (reference data)
Hot
Intake
0.32 - 0.40 (0.013 - 0.016)
0.25 - 0.33 (0.010 - 0.013)
0.21 - 0.49 (0.008 - 0.019)
Exhaust
0.37 - 0.45 (0.015 - 0.018)
0.32 - 0.40 (0.013 - 0.016)
0.30 - 0.58 (0.012 - 0.023)
SEM147D
*: At a temperature of approximately 20°C (68°F) Whenever valve clearances are adjusted to cold specifications, check that the clearances satisfy hot specifications and adjust again if necessary.
Assembly 1. I I I
Narrow pitch
Wide pitch
I
Narrow pitch
NCEM0020
Install valve component parts. Always use new valve oil seal. Refer to EM-29. Before installing valve oil seal, install valve spring seat. After installing valve components, tap valve stem tip with a plastic hammer to assure a proper fit. Install valve spring (narrow pitch at both ends of spring) with either end toward cylinder head.
AEM293
Installation Liquid gasket
1.
2.0 - 3.0 mm (0.079 - 0.118 in) dia.
2. I
Engine front
NCEM0021
Before installing cylinder head gasket, apply a continuous bead of liquid gasket to mating surface of cylinder block. Install cylinder head gasket. When installing cylinder head with manifolds, use new cylinder head gasket.
SEM899F
EM-43
QG
CYLINDER HEAD Installation (Cont’d)
3. I Cylinder head bolt washer
I I
Install cylinder head with manifolds. Be sure to install washers between bolts and cylinder head. Do not rotate crankshaft and camshaft separately, or valves will strike piston heads. Apply new engine oil to cylinder head bolt threads and seat surfaces.
Cylinder head side
SEM877A
I
Engine front
Tightening procedure Tighten bolts to 29 N⋅m (3 kg-m, 22 ft-lb). Tighten bolts to 59 N⋅m (6 kg-m, 43 ft-lb). Loosen bolts completely. Tighten bolts to 29 N⋅m (3 kg-m, 22 ft-lb). Turn bolts 50 to 55 degrees clockwise or if angle wrench is not available, tighten bolts to 59±4.9 N⋅m (6±0.5 kg-m, 43±3.6 ft-lb). f Tightening bolts (11 - 14) to 6.3 to 8.3 N⋅m (0.64 to 0.85 p kg-m, 55.8 to 73.5 in-lb). a p b p c p d p e p
Tighten in numerical order. SEM900F
Tightening torque N⋅m (kg-m, ft-lb)
Tightening torque N·m (kg-m, ft-lb)
a
59 (6, 43)
Bolts (1 - 10)
29 (3, 22)
b
59 (6, 43)
c
0 (0, 0)
d
e, f
29 (3, 22)
50 - 55 degrees or 59±4.9 (6±0.5, 43±3.6 ft-lb)
—
6.3 - 8.3 (0.64 0.85, 55.8 73.5 in-lb)
29 (3, 22)
Bolts (11 - 14)
—
SEM614EC
Intake
—
—
4.
Install camshaft.
I
Make sure camshafts are aligned as shown in figure.
Exhaust SEM901F
Intake Knock pin
Exhaust Knock pin
SEM902F
EM-44
CYLINDER HEAD
QG Installation (Cont’d)
No.
Front mark
Intake side
5. I
Install camshaft brackets. Make sure camshaft brackets are aligned as marked during disassembly.
I I
Apply new engine oil to bolt threads and seat surface. Tighten camshaft bracket bolts in the following steps. a Tighten bolts 9 - 12, then 1 - 8. 2.0 N⋅m (0.204 kg-m, 17.7 in-lb) b Tighten bolts 1 - 12. 5.9 N⋅m (0.60 kg-m, 52.2 in-lb) c Tighten bolts 1 - 12. 9.8 - 11.8 N⋅m (1.00 - 1.20 kg-m, 86.7 - 104.4 in-lb) If any part of valve assembly or camshaft is replaced, check valve clearance according to reference data. After completing assembly check valve clearance. Refer to “Checking” and “Adjusting” in “VALVE CLEARANCE” (EM-40). Reference data valve clearance (Cold): Intake 0.25 - 0.33 mm (0.010 - 0.013 in) Exhaust 0.32 - 0.40 mm (0.013 - 0.016 in)
Intake mark
No.
Engine front Exhaust side
Front mark
Exhaust mark SEM903F
Engine front
I Tighten in numerical order.
Mating mark
Camshaft sprocket (INT)
SEM904F
6. I
Install camshaft sprocket. Set timing chain by aligning mating marks with those of camshaft sprockets.
7. I
Install camshaft sprocket bolts to correct torque. Apply new engine oil to bolt threads and seat surface.
Mating mark
Camshaft sprocket (EXH)
SEM905F
SEM906F
EM-45
CYLINDER HEAD
QG
Installation (Cont’d)
8. I
Chain guide
I 9.
Install chain tensioner. Before installing chain tensioner, insert a suitable pin into pin hole of chain tensioner. After installing chain tensioner, remove the pin. Install timing chain guide.
Chain tensioner Stopper pin SEM907F
10. Install cylinder head front cover. I Apply liquid gasket to cylinder head front cover. I Use Genuine Liquid Gasket or equivalent.
Cylinder head front cover
2.0 3.0 mm (0.079 0.118 in) dia.
SEM887F
Camshaft position sensor (PHASE)
11. Install camshaft position sensor (PHASE). O-ring
SEM889F
12. Before installing rocker cover, apply a continuous bead of liquid gasket to mating surface of cylinder head. Liquid gasket
3 mm (0.12 in) dia.
Cylinder head Cylinder head front cover
SEM888F
Tighten in numerical order. SEM908F
13. Install rocker cover and tighten bolts in numerical order as shown in the figure. 14. Install spark plugs. 15. Install ignition coils. 16. Install intake manifold rear supports. 17. Install front exhaust tube. 18. Install front undercover. 19. Install air duct to intake manifold collector. 20. Install power steering pulley and pump with bracket. To check power steering fluid, refer to MA section (“Checking
EM-46
CYLINDER HEAD
QG Installation (Cont’d)
Power Steering Fluid and Lines”, “CHASSIS AND BODY MAINTENANCE”). 21. Drive belts. For adjusting drive belt deflection, refer to MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”). 22. Reinstall parts in reverse order of removal.
EM-47
QG
ENGINE REMOVAL Removal and Installation
Removal and Installation SEC. 112
NCEM0022
49 - 59 (5.0 - 6.0, 37 - 43) 16 - 21 (1.7 - 2.1, 12 - 15)
43 - 55 (4.4 - 5.6, 32 - 41)
1 p
43 - 55 (4.4 - 5.6, 32 - 41) 43 - 55 (4.4 - 5.6, 32 - 40)
2 p
30 - 40 (3.1 - 4.0, 23 - 29)
p 5
64 - 74 (6.6 - 7.5, 48 - 54)
62 - 78 (6.4 - 7.9, 46 - 57) .
22 - 28 (2.3 - 2.8, 17 - 20) 60 - 70 (6.2 - 7.1, 45 - 51)
64 - 74 (6.6 - 7.5, 48 - 54)
.
3 p
43 - 55 (4.4 - 5.6, 32 - 41)
43 - 55 (4.4 - 5.6, 32 - 40)
64 - 74 (6.6 - 7.5, 48 - 54)
43 - 55 (4.4 - 5.6, 32 - 40)
6 p
4 p
7 p
43 - 55 (4.4 - 5.6, 32 - 40)
8 p
62 - 78 (6.4 - 7.9, 46 - 57) 60 - 70 (6.2 - 7.1, 45 - 51) 9 p
77 - 98 (7.9 - 9.9, 57 - 72)
77 - 98 (7.9 - 9.9, 57 - 72)
: N·m (kg-m, ft-lb) NEM372
1. 2. 3.
Engine front mounting Cylinder head front mouting bracket Engine front mouting bracket
4. 5. 6.
LH engine mounting Engine rear mounting bracket Engine rear mounting
EM-48
7. 8. 9.
Center member Front mounting bracket Front mounting
ENGINE REMOVAL
QG Removal and Installation (Cont’d)
WARNING: I Position vehicle on a flat and solid surface. I Place chocks at front and back of rear wheels. I Do not remove engine until exhaust system has completely cooled off, otherwise, you may burn yourself and/or fire may break out in fuel line. I Before disconnecting fuel hose, release pressure. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”). I Be sure to lift engine and transaxle in a safe manner. I For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG. CAUTION: I When lifting engine, be sure to clear surrounding parts. Use special care near accelerator wire casing, brake lines and brake master cylinder. I When lifting the engine, always use engine slingers in a safe manner. I When removing drive shaft, be careful not to damage grease seal of transaxle. I Before separating engine and transaxle, remove crankshaft position sensor (POS) from the cylinder block assembly. I Always be extra careful not to damage edge of crankshaft position sensor (POS), or signal plate teeth. Engine cannot be removed separately from transaxle. Remove engine with transaxle as an assembly.
REMOVAL 1.
NCEM0022S01
Drain coolant from radiator and cylinder block. Refer to (LC) section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). 2. Drain engine oil. 3. Remove battery. 4. Remove coolant reservoir tank and bracket. 5. Remove drive belts. 6. Remove generator and air conditioner compressor from engine. 7. Remove power steering oil pump from engine and position aside. Power steering oil pump does not need to be disconnected from power steering tubes.
EM-49
ENGINE REMOVAL
QG
Removal and Installation (Cont’d)
8. I I I I
I SEM174D
Remove the following parts: RH and LH front tires Undercovers Splash covers RH and LH brake caliper assemblies : 54 - 64 N⋅m (5.5 - 6.5 kg-m, 40 - 47 ft-lb) Brake hose does not need to be disconnected from brake caliper assembly. Never depress brake pedal. RH & LH drive shaft. Refer to FA section (“Drive Shaft”, “FRONT AXLE”). When removing drive shaft, be careful not to damage transaxle side grease seal.
I
Disconnect control rod and support rod from transaxle. Control rod: : 14 - 18 N⋅m (1.4 - 1.8 kg-m, 10 - 13 ft-lb) Support rod: : 35 - 47 N⋅m (3.6 - 4.8 kg-m, 26 - 35 ft-lb)
I I I I I
Center member Front exhaust tube Stabilizer bar Cooling fan Radiator
NEM330
.
SEM875DA
I I
Cylinder head front mounting bracket Remove air duct and disconnect wires, harness, pipes, hoses and so on. 9. Lift up engine slightly and disconnect or remove all engine mountings. When lifting engine, be sure to clear surrounding parts. Use special care near brake tubes and brake master cylinder. 10. Remove engine with transaxle as shown. SEM419D
EM-50
QG
ENGINE REMOVAL
Removal and Installation (Cont’d)
Wooden block Jack SEM420D
INSTALLATION I
Install in reverse order of removal.
EM-51
NCEM0022S02
QG
CYLINDER BLOCK Components
Components 83.4 - 93.2 (8.5 - 9.5, 61 - 69)
7.2 - 10.8 (0.73 - 1.10, 63.4 - 95.5) 20.6 - 26.5 (2.1 - 2.7, 15 - 20) O-ring
6.28 - 8.34 (0.64 - 0.85, 55.6 - 73.8)
34.3 - 44.1 (3.50 - 4.50, 25.3 - 32.5)
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
7.64 - 9.22 (0.78 - 0.94, 67.7 - 81.6)
: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) : Use Genuine Liquid Gasket or equivalent. : Lubricate with new engine oil. : Do not re-use.
46.1 - 52.0 (4.70 - 5.30, 34.0 - 38.3)
For installation of connecting rod cap, refer to “Assembly”. NEM331
1. 2. 3. 4. 5. 6. 7. 8. 9.
Oil level gauge guide Cylinder block Rear oil seal retainer Rear oil seal Rear plate Flywheel Drain plug Buffle plate Top ring
10. 11. 12. 13. 14. 15. 16. 17.
2nd ring Oil ring Piston Snap ring Piston pin Connecting rod Connecting rod bearing Connecting rod cap
EM-52
18. 19. 20. 21. 22. 23. 24. 25.
Key Main bearing Thrust bearing Crankshaft Main bearing cap Knock sensor Crankshaft position sensor (POS) Signal plate
CYLINDER BLOCK
QG Removal and Installation
Removal and Installation
NCEM0024
CAUTION: I When installing sliding parts such as bearings and pistons, apply engine oil on the sliding surfaces. I Place removed parts, such as bearings and bearing caps, in their proper order and direction. I When installing connecting rod nuts and main bearing cap bolts, apply new engine oil to threads and seating surfaces. I Do not allow any magnetic materials to contact the signal plate teeth of flywheel or drive plate, and rear plate. I Remove the crankshaft position sensor (POS). I Be careful not to damage sensor edges and single plate teeth.
Disassembly KV10106500
PISTON AND CRANKSHAFT 1. 2. 3.
KV10113300
NCEM0025 NCEM0025S01
Place engine on a work stand. Drain coolant and oil. Remove timing chain. Refer to EM-20.
ST0501S000 SEM927F
Piston heater
Oil
4. I
Remove pistons with connecting rod. When disassembling piston and connecting rod, remove snap ring first. Then heat piston to 60 to 70°C (140 to 158°F) or use piston pin press stand at room temperature. CAUTION: I When piston rings are not replaced, make sure that piston rings are mounted in their original positions. I When replacing piston rings, if there is no punch mark, install with either side up.
SEM877B
5.
Front
6. I I
Loosen main bearing caps in numerical order as shown in figure. Remove bearing caps, main bearings and crankshaft. Before removing bearing caps, measure crankshaft end play. Refer to EM-61. Bolts should be loosened in two or three steps.
SEM165DB
EM-53
CYLINDER BLOCK
QG
Disassembly (Cont’d)
7.
Remove signal plate from crankshaft.
Crankshaft
Signal plate
SEM928F
Inspection PISTON AND PISTON PIN CLEARANCE
NCEM0026 NCEM0026S01
1.
Measure inner diameter of piston pin hole “dp”. Standard diameter “dp”: QG16DE 18.987 - 18.999 mm (0.7474 - 0.7480 in) QG18DE 18.993 - 19.005 mm (0.7478 - 0.7482 in)
2.
Measure outer diameter of piston pin “Dp”. Standard diameter “Dp”: 18.989 - 19.001 mm (0.7476 - 0.7481 in) Calculate piston pin clearance. QG16DE Dp - dp: -0.004 - 0 (-0.0002 - 0 in) QG18DE Dp − dp: 0.002 - 0.006 (0.0001 - 0.0002 in) If it exceeds the above value, replace piston assembly with pin.
AEM023
3.
Micrometer AEM024
PISTON RING SIDE CLEARANCE NG
NCEM0026S02
Side clearance: Refer to SDS, EM-185 Max. limit of side clearance: Refer to SDS, EM-185 If out of specification, replace piston and/or piston ring assembly.
Feeler gauge OK
Feeler gauge Ring
SEM024AA
PISTON RING END GAP
Piston Press-fit
Feeler gauge Ring
End gap: Refer to SDS, EM-185 Max. limit of ring gap: Refer to SDS, EM-185
Ring
AEM096
EM-54
NCEM0026S03
QG
CYLINDER BLOCK
Inspection (Cont’d)
If out of specification, replace piston ring. If gap exceeds maximum limit with a new ring, rebore cylinder and use oversized piston and piston rings. Refer to SDS, EM-185. I When replacing the piston, check the cylinder block surface for scratches or seizure. If scratches or seizure is found, hone or replace the cylinder block.
CONNECTING ROD BEND AND TORSION
Feeler gauge
NCEM0026S04
Bend: Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit 0.3 mm (0.012 in) per 100 mm (3.94 in) length If it exceeds the limit, replace connecting rod assembly. SEM150B
Torsion
Feeler gauge
SEM003F
CYLINDER BLOCK DISTORTION AND WEAR
Straightedge Feeler gauge
213.95 - 214.05 mm (8.4232 - 8.4271 in)
SEM486C
NCEM0026S05
Clean upper surface of cylinder block. Use a reliable straightedge and feeler gauge to check the flatness of cylinder block surface. Check along six positions shown in figure. Block surface flatness: Standard Less than 0.03 mm (0.0012 in) Limit 0.10 mm (0.004 in) If out of specification, resurface it. The limit for cylinder block resurfacing is determined by the amount of cylinder head resurfacing. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) Nominal cylinder block height from crankshaft center: 213.95 - 214.05 mm (8.4232 - 8.4271 in) If necessary, replace cylinder block.
SEM102F
EM-55
CYLINDER BLOCK
QG
Inspection (Cont’d)
20 (0.79) 60 (2.36) 100 (3.94)
PISTON-TO-BORE CLEARANCE 1.
Unit: mm (in) SEM166D
Front Cylinder bore grade number (1, 2, 3)
2. I
No.2 No.4 No.1 No.3
Cylinder block
NCEM0026S06
Using a bore gauge, measure cylinder bore for wear, out-ofround and taper. Standard inner diameter: Refer to SDS, EM-184 Wear limit: 0.2 mm (0.008 in) Out-of-round (X − Y) standard: Less than 0.015 mm (0.0006 in) Taper (A − B) standard: Less than 0.01 mm (0.0004 in) If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Check for score and seizure. If seizure is found, hone it. If cylinder block or piston is replaced, match piston grade with grade number on cylinder block lower surface.
SEM929F
3.
SEM258C
Measure piston skirt diameter. Piston diameter “A”: Refer to SDS, EM-185. Measuring point “a” (Distance from the top): Refer to SDS, EM-185 4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance = Cylinder bore measurement “B” − Piston diameter “A”: Refer to SDS, EM-185 5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to SDS EM-185. 6. Cylinder bore size is determined by adding piston-to-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-bore clearance C: Honing allowance 0.02 mm (0.0008 in) 7. Install main bearing caps and tighten bolts to the specified torque. This will prevent distortion of cylinder bores. 8. Cut cylinder bores. I When any cylinder needs boring, all other cylinders must also be bored. I Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time. 9. Hone cylinders to obtain specified piston-to-bore clearance. 10. Measure finished cylinder bore for out-of-round and taper. I Measurement should be done after cylinder bore cools down.
EM-56
CYLINDER BLOCK
QG Inspection (Cont’d)
CRANKSHAFT 1. 2.
Taper: Out-of-round:
NCEM0026S07
Check crankshaft main and pin journals for score, wear or cracks. With a micrometer, measure journals for taper and out-ofround. Out-of-round (X − Y): Less than 0.003 mm (0.0001 in) Taper (A − B): Less than 0.004 mm (0.0002 in)
SEM316A
3.
Measure crankshaft runout. Runout (Total indicator reading): Less than 0.04 mm (0.0016 in)
SEM346D
BEARING CLEARANCE I
NCEM0026S08
Use Method A or Method B. Method A is preferred because it is more accurate. Method A (Using bore gauge and micrometer)
Oil hole
Main bearing 1.
NCEM0026S0801
Set main bearings in their proper positions on cylinder block and main bearing cap.
Oil groove Front
SEM366E
2. Install main bearing cap to cylinder block. Tighten all bolts in correct order in two or three stages. Refer to EM-52. 3. Measure inner diameter “A” of each main bearing.
Bore gauge
AEM153
4. 5.
.
Measure outer diameter “Dm” of each main journal in crankshaft. Calculate main bearing clearance. Main bearing clearance = A − Dm Standard: 0.020 - 0.044 mm (0.0008 - 0.0017 in) Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted within standard of any bearing, grind crankshaft journal and use undersized bearing.
AEM026
EM-57
QG
CYLINDER BLOCK Inspection (Cont’d) Main journal and pin journal
I I
When grinding crank pin and crank journal: Grind until clearance is within specified standard bearing clearance. Fillets should be finished as shown in the figure. R: 2.3 2.5 mm (0.091 - 0.098 in) Refer to SDS, EM-187 for standard bearing clearance and available spare parts.
SEM588A
6. Front
a. Main journal grade number (0, 1, 2)
If the crankshaft is replaced, select thickness of main bearings as follows: Grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Roman numerals.
No.1 No.3 No.5 No.2 No.4
Cylinder block
SEM930F
b.
Crankshaft journal grade number No. 1
No. 5
Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Roman numerals. c. Select main bearing with suitable thickness according to the following table. Main bearing grade color: Crankshaft main journal grade number
AEM172
Oil hole
0
1
2
0
Black
Red
Green
1
Red
Green
Yellow
2
Green
Yellow
Blue
For example: Cylinder block main journal grade number: 1 Crankshaft main journal grade number: 2 Main bearing grade number = 1 + 2 = Yellow
Oil groove Front
Identification colour
Cylinder block main journal grade number
SEM194C
Connecting rod bearing (Big end)
NCEM0026S0802
1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. 3. Measure inner diameter “C” of each bearing.
Inside micrometer
AEM027
EM-58
QG
CYLINDER BLOCK
Inspection (Cont’d)
4. 5.
Measure outer diameter “Dp” of each crankshaft pin journal. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C − Dp Standard: 0.014 - 0.039 mm (0.0006 - 0.0015 in) Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted using any standard bearing grade, grind crankshaft journal and use undersized bearing. Refer to step 5, EM-57.
AEM028
I Crankshaft pin journal grade number No. 1
No. 4
If a new bearing, crankshaft or connecting rod is replaced, select connecting rod bearing according to the following table. Connecting rod bearing grade number: These numbers are punched in either Arabic or Roman numerals. Crankshaft pin journal grade number
Connecting rod bearing grade color
0
—
1
Brown
2
Green
SEM437CA
Method B (Using Plastigage) CAUTION: I Do not turn crankshaft or connecting rod while Plastigage is being inserted. I If incorrect bearing clearance exists, use a thicker or undersized main bearing to ensure specified clearance.
EM142
CONNECTING ROD BUSHING CLEARANCE (SmallNCEM0026S09 end) 1.
Measure inner diameter “C” of bushing.
AEM029
2. 3.
Measure outer diameter “Dp” of piston pin. Calculate connecting rod bushing clearance. Connecting rod bushing clearance = C − Dp Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in) Limit: 0.023 mm (0.0009 in) If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston pin.
Micrometer AEM030
EM-59
CYLINDER BLOCK
QG
Inspection (Cont’d)
REPLACEMENT OF CONNECTING ROD BUSHING (Small end) NCEM0026S10 1.
Align. SEM062A
Drive in small end bushing until it is flush with end surface of rod. Be sure to align the oil holes. 2. Ream the bushing so that clearance with piston pin is within specification. Clearance between connecting rod bushing and piston pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
FLYWHEEL/DRIVE PLATE RUNOUT Dial gauge
NCEM0026S12
Runout (Total indicator reading): Flywheel Less than 0.15 mm (0.0059 in) CAUTION: I Do not allow any magnetic materials to contact the ring gear teeth and rear plate. I Do not resurface flywheel. Replace as necessary. SEM931F
Assembly PISTON
NCEM0027 NCEM0027S01
1.
Install new snap ring on one side of piston pin hole.
2.
Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, piston pin, connecting rod and new snap ring. Align the direction of piston and connecting rod. Numbers stamped on connecting rod and cap correspond to each cylinder. After assembly, make sure connecting rod swings smoothly.
SEM166B
Piston pin grade number
Piston grade number
Oil hole Cylinder number
Front mark
I I I
Front
SEM932F
Punchmark side up (if mark is present.)
3.
Set piston rings as shown.
CAUTION: I When piston rings are not replaced, make sure that piston rings are mounted in their original position. I Install new piston rings either side up if there is no punch mark.
SEM965E
EM-60
CYLINDER BLOCK
QG Assembly (Cont’d)
Oil ring expander
Top ring Oil ring upper rail
I
Align piston rings so that end gaps are positioned as shown.
Engine front
Oil ring lower rail
2nd ring
SEM160B
CRANKSHAFT 1. 2.
Signal plate
Duel pin
I I
NCEM0027S02
Install signal plate to crankshaft. Set main bearings in their proper positions on cylinder block and main bearing cap. Confirm that correct main bearings are selected by using Method A or Method B. Refer to EM-57. Apply new engine oil to bearing surfaces.
Crankshaft
SEM934F
Oil hole
Oil groove Front
SEM366E
Identification No. Cap
Engine front
SEM420C
3.
Engine front
I I I I Tighten in numerical order.
Install crankshaft and main bearing caps and tighten bolts to the specified torque. Apply new engine oil to the bolt thread and seat surface. Prior to tightening bearing cap bolts, shift crankshaft back and forth to properly seat the bearing caps. Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward as shown in figure. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
SEM933F
EM-61
CYLINDER BLOCK
QG
Assembly (Cont’d)
4.
Measure crankshaft end play. Crankshaft end play: Standard 0.060 - 0.260 mm (0.0024 - 0.0102 in) Limit 0.3 mm (0.012 in) If beyond the limit, replace thrust bearing with new ones.
SEM116F
5.
Align oil hole.
I I I
Install connecting rod bearings in connecting rods and connecting rod caps. Confirm that correct bearings are used. Refer to EM-58. Install bearings so that oil hole in connecting rod aligns with oil hole of bearing. Apply new engine oil to bolt threads and bearing surfaces.
SEM168D
6. a. I I
Piston ring compressor EM03470000
I I
Install pistons with connecting rods. Install them into corresponding cylinders with Tool. Make sure connecting rod does not scratch cylinder wall. Make sure connecting rod bolts do not scratch crankshaft pin journals. Arrange so that front mark on piston head faces engine. Apply new engine oil to piston rings and sliding surface of piston.
SEM942F
b. KV10112100
I I
Install connecting rod caps. Apply new engine oil to bolt threads and nut seating surfaces. Tighten connecting rod cap nuts in the following procedure: Tighten to 13.72 to 15.68 N⋅m (1.399 to 1.599 kg-m, 10.120 - 11.566 ft-lb). Turn nuts to 35° to 40° degrees clockwise with an angle wrench. If an angle wrench is not available, tighten nuts to 23 to 28 N⋅m (2.3 to 2.9 kg-m, 17 to 21 ft-lb).
SEM943F
7.
Feeler gauge
Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.200 - 0.470 mm (0.0079 - 0.0185 in) Limit 0.5 mm (0.0205 in) If beyond the limit, replace connecting rod and/or crankshaft.
SEM935F
EM-62
CYLINDER BLOCK
QG Assembly (Cont’d)
Apply liquid gasket.
8. a. b.
.
Rear oil seal retainer
2.0 - 3.0 mm (0.079 - 0.118 in) dia.
I I 9.
Install rear oil seal retainer. Before installing rear oil seal retainer, remove old liquid gasket from cylinder block and retainer. Apply a continuous bead of liquid gasket to rear oil seal retainer. Use Genuine Liquid Gasket or equivalent. Apply around inner side of bolt holes. Install crankshaft positon sensor (POS).
AEM248
Engine front
10. Install knock sensor.
SEM936F
EM-63
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING SR20DE
Camshaft bearing noise
Rocker noise
Timing chain and chain tensioner noise
VALVE MECHANISM TIMING CHAIN Valve
Water pump noise
Piston pin noise ROTATION MECHANISM DRIVE BELT Drive belt noise (stick/slipping)
Piston slap noise
Connecting rod bearing noise
Drive belt noise (stick/slipping) Main bearing noise NEM335
EM-64
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING SR20DE NVH Troubleshooting — Engine Noise
NVH Troubleshooting — Engine Noise Use the chart below to help you find the cause of the symptom. 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
Top of Engine rocker cover Cylinder head
Type of noise
When starting
When idling
When While racing driving
Source of noise
Front of engine Timing chain cover
Front of Engine
Reference page
C
A
—
A
B
—
Rocker noise
Hydraulic lash adjuster
EM-96
Rattle
C
A
—
A
B
C
Camshaft bearing noise
Camshaft journal clearance Camshaft runout
EM-92
—
Piston pin noise
Piston and piston pin clearance Connecting rod bushing clearance
EM-110, 116
A
Piston slap noise
Piston-to-bore clearance Piston ring side clearance EM-111, 112 Piston ring end gap Connecting rod bend and torsion Connecting rod bearing clearance (Big end) Connecting rod bushing clearance (Small end)
EM-115, 116
Main bearing oil clearance Crankshaft runout
EM-113, 114
—
Slap or rap
A
A
—
—
—
B
B
B
B
Cylinder block (Side of Engine) Oil pan
Check item
Ticking or clicking
Slap or knock
Crankshaft Pulley
Before After warm- warmup up
Knock
A
B
C
B
B
B
Connecting rod-bearing noise
Knock
A
B
—
A
B
C
Main bearing noise
B
Timing chain and Timing chain cracks and chain tenwear sioner noise
Drive belt deflection
Idler pulley bearing operation
Tapping or ticking
A
A
—
B
B
Squeak or fizzing
A
B
—
B
—
C
Other drive belts (sticking or slipping)
Creaking
A
B
A
B
A
B
Other drive belts (slipping)
Squall or creak
A: Closely related
B: Related
A
B
—
C: Sometimes related
B
A
—: Not related
EM-65
B
Water pump Water pump operation noise
EM-132
MA Section (“Checking Drive Belts”, “ENGINE MAINTENANCE”) LC Section (“Water Pump Inspection”, “ENGINE COOLING SYSTEM”)
SR20DE
OUTER COMPONENT PARTS SEC. 130⋅140⋅150⋅210⋅211⋅221 13 - 16 (1.3 - 1.6, 9 - 12)
Refer to “Installation” in “TIMING CHAIN”. Washer 16 - 21 (1.6 - 2.1, 12 - 15)
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
Insulator Gasket
Gasket Gasket 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
16 - 22 (1.6 - 2.2, 12 - 16) .
41 - 52 (4.2 - 5.3, 30 - 38)
18 - 21 (1.8 - 2.1, 13 - 15)
21 - 26 (2.1 - 2.7, 15 - 20)
.
16 - 21 (1.6 - 2.1, 12 - 15)
45 - 60 (4.6 - 6.1, 33 - 44)
16 - 21 (1.6 - 2.1, 12 - 15)
16 - 21 (1.6 - 2.1, 12 - 15)
16 - 22 (1.6 - 2.2, 12 - 16)
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8) ★
16 - 19 (1.6 - 1.9, 12 - 14) ★
15 - 21 (1.5 - 2.1, 11 - 15)
16 - 19 (1.6 - 1.9, 12 - 14)
Oil seal 3.7 - 5.0 (0.38 - 0.51, 33.0 - 44.3)
16 - 21 (1.6 - 2.1, 12 - 15) : Do not re-use.
N·m (kg-m, ft-lb)
: Lubricate with new engine oil.
N·m (kg-m, in-lb) ★
Apply liquid gasket.
1 p 2 p 3 p 4 p 5 p
Oil filler cap Rocker cover PCV valve Camshaft position sensor, ignition coil and power transistor built into distributor Intake manifold supports
6 p 7 p 8 p 9 p 10 p 11 p
: Refer to LC section. (“Thermostat”, “ENGINE COOLING SYSTEM”).
Knock sensor Oil filter bracket Oil catcher Oil filter Water pipe assembly Thermostat housing
EM-66
12 p 13 p 14 p 15 p 16 p 17 p
NEM373
Air relief plug Thermostat Water inlet Starter motor Power steering oil pump adjusting bar Power steering oil pump bracket
SR20DE
OUTER COMPONENT PARTS SEC. 140⋅147⋅163⋅164
2.9 - 3.8 (0.30 - 0.39, 26.0 - 33.9)
O-ring
6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) 6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)
1st 9 - 11 (1.0 - 1.1, . 7.0 - 8.0) 2nd 21 - 26 (2.2 - 2.6, 16.0 - 19.0)
✩
O-ring
Clip 6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)
Gasket
6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) Gasket
Gasket 2.0 - 2.5 (0.20 - 0.26, 17.4 - 22.6)
Gasket
18 - 21 (1.9 - 2.2, 13.3 - 15.4)
3.0 - 4.0 (0.31 - 0.41, 26.9 - 35.6)
✩ Throttle body bolts tightening procedure 1) Tighten all bolts to 9 to 11 N·m (0.9 - 1.1 kg-m, 6.5 - 8.0 ft-lb) 2) Tighten all bolts to 18 to 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
18 - 21 (1.9 - 2.2, 13.3 - 15.4)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) ü : Do not re-use
Tighten in numerical order.
NEM337
1 p 2 p 3 p
Injector Pressure regulator IACV-AAC valve
4 p 5 p 6 p
Canister purge control valve Injector tube Throttle body
EM-67
7 p 8 p
Throttle position sensor Intake manifold
SR20DE
OUTER COMPONENT PARTS SEC. 118⋅140⋅230⋅275
Gasket
5.1 - 6.5 (0.52 - 0.66, 45.1 - 57.3)
8 - 12 (0.8 - 1.2, 64 - 104)
40 - 50 (4.1 - 5.1, 30.0 - 36.8) 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8) 45 - 60 (4.6 - 6.1, 33 - 44) 37 - 48 (7.8 - 4.9, 27.3 - 35.4)
45 - 60 (4.6 - 6.1, 33 - 44)
44 - 52 (4.5 - 5.3, 32.5 - 38.3)
16 - 22 (1.6 - 2.2, 12 - 16)
16 - 22 (1.6 - 2.2, 12 - 16)
39 - 46 (4.0 - 4.7, 28.8 - 33.9)
16 - 22 (1.6 - 2.2, 12 - 16)
45 - 60 (4.6 - 6.1, 33 - 44)
: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) : Apply liquid gasket.
16 - 22 (1.6 - 2.2, 12 - 16)
: Do not re-use
1 p 2 p 3 p 4 p
Oil level gauge Alternator adjusting bar Compressor bracket Alternator bracket
NEM339 5 p 6 p 7 p 8 p
Water outlet Drain plug Exhaust manifold Heated oxygen sensor
EM-68
9 p 10 p 11 p
Exhaust manifold cover Blow-by hose Catalytic convertor
SR20DE
COMPRESSION PRESSURE
Measurement of Compression Pressure
Measurement of Compression Pressure 1. 2. 3. 4. 5.
6. 7. 8. 9. I
Warm up engine. Turn ignition switch off. Release fuel pressure. Refer to “Releasing Fuel Pressure” in EC-section. Remove all spark plugs. Disconnect distributor center cable.
Attach a compression tester to No. 1 cylinder. Depress accelerator pedal fully to keep throttle valve wide open. Crank engine and record highest gauge indication. Repeat the measurement for each cylinder. Always use a fully-charged battery to obtain specified engine revolution.
Compression pressure: kPa (bar, kg/cm2, psi)/300 rpm
SEM968C
Standard
1,275 (12.75, 13.0, 185)
Minimum
1,079 (10.79, 11.0, 156)
Difference limit between cylinders 20 mm (0.79 in) dia
Compression tester rubber adaptor diameter should be less than 20 mm (0.79 in) to prevent fouling with cylinder head.
NEM118
98 (0.98, 1.0, 14)
10. If cylinder compression in one or more cylinders is low: A: pour a small amount of engine oil into cylinders through spark plug holes. B: retest compression. I If adding oil helps compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston condition. I If pressure stays low, a valve may be sticking or seating badly. Inspect and repair valve and valve seat. (Refer to SDS). If valve or valve seat is damaged excessively, replace them. I If compression stays low in two cylinders that are next to each other: A. The cylinder head gasket may be leaking, or B. Both cylinders may have valve component damage. Inspect and repair as necessary.
EM-69
SR20DE
OIL PAN Removal
SEC. 110 Refer to “Installation”. 1 p
Refer to “Installation”.
p 2
6.4 - 7.5 (0.65 - 0.76, 56.6 - 66.0)
5 p
3 p
29 - 39 (3.0 - 4.0, 22 - 29)
1 Aluminum oil pan p 2 Rear cover plate p 3 Drain plug p 4 Steel oil pan p 5 p Baffle plate
: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) : Apply liquid gasket.
Washer üü
üü: Do not re-use
6.4 - 7.5 (0.65 - 0.76, 56.6 - 66.0) Refer to “Installation”.
4 p
6.4 - 7.5 (0.65 - 0.76, 56.4 - 66.0)
NEM217
Removal
9 p
11 p
Remove engine under cover. Drain engine oil.
3.
Remove steel oil pan bolts.
4. a. I I
Remove steel oil pan. Insert Tool between aluminum oil pan and steel oil pan. Be careful not to damage aluminum mating surface. Do not insert screwdriver, or oil pan flange will be deformed.
7 p
4 p
Engine front
1. 2.
3 p
2 p
1 p 8 6 p p
Loosen in numerical order.
10 p
5 p
NEM218
SEM602E
EM-70
OIL PAN
SR20DE Removal (Cont’d)
b. c.
Slide Tool by tapping on the side of the Tool with a hammer. Remove steel oil pan.
d.
Remove baffle plate.
5. 6. 7.
Remove front exhaust tube. Set a suitable transmission jack under transaxle and hoist engine with engine slinger. Remove center member.
8.
Remove compressor gussets.
9.
Remove rear cover plate.
SEM603E
.
Engine front
.
Baffle plate NEM219
Center member Transmission jack SEM045D
Front compressor gusset
Compressor bracket Rear compressor . SEM048D gusset
Rear cover plate
SEM043D
EM-71
OIL PAN
SR20DE
Removal (Cont’d)
10. Remove aluminum oil pan bolts.
Engine front
Loosen in numercal order.
SEM044D
11. Remove the two engine-to-transaxle bolts and install them into open bolt holes shown. Tighten the bolts to release aluminum oil pan from cylinder block.
SEM783E
12. a. I I
Remove aluminum oil pan. Insert Tool between cylinder block and aluminum oil pan. Be careful not to damage aluminum mating surface. Do not insert screwdriver, or oil pan flange will be damaged.
b.
Slide Tool by tapping on the side of the Tool with a hammer.
SEM046D
SEM047D
13. Remove the two engine-to-transaxle bolts previously installed in aluminum oil pan.
SEM223D
EM-72
OIL PAN
SR20DE Installation
Installation 1. a. I
Install aluminum oil pan. Before installation use a scraper to remove all traces of liquid gasket from mating surfaces. Also remove traces of liquid gasket from mating surface of cylinder block and front cover.
SEM050D
b. Cut here.
I I
7 mm (0.28 in)
Liquid gasket
I
Groove
Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan. Use Genuine Liquid Gasket or equivalent. Be sure liquid gasket diameter is 4.0 to 5.0 mm (0.157 to 0.197 in). Attaching should be done within 5 minutes after coating.
Bolt hole SEM357E
I
For areas marked with “★”, apply liquid gasket to the outer side of the bolt hole.
c. I
Install aluminum oil pan. Install bolts in the reverse order of removal. 1 - p 16 bolts: p : 16 - 19 N·m (1.6 - 1.9 kg-m, 12 - 14 ft-lb) 17 , p 18 bolts: p : 8.14 - 9.51 N·m (0.830 - 0.970 kg-m, 72.05 84.77 in-lb)
2.
Install the two engine to transaxle bolts. : 30 - 40 N·m (3.1 - 4.1 kg-m, 22 - 30 ft-lb) Install rear cover plate.
4.0 - 5.0 mm (0.157 - 0.197 in)
Tube presser
Liquid gasket
.
SEM065D
Engine front
Tighten in numerical order. SEM052D
3.
Install
Install
SEM224D
EM-73
OIL PAN
SR20DE
Installation (Cont’d)
Front compressor gusset
4. 5. 6. 7.
Install Install Install Install
compressor gussets. center member. front exhaust tube. baffle plate.
8. a.
Install steel oil pan. Before installation, use a scraper to remove all traces of liquid gasket from mating surfaces. Also remove traces of liquid gasket from mating surface of aluminum oil pan.
Compressor bracket
Rear compressor gusset SEM363D Tighten in numerical order.
I
NEM220
b.
Cut here. 7 mm (0.28 in)
I I
Liquid gasket Inner side
Groove
I
Apply a continuous bead of liquid gasket to mating surface of steel oil pan. Use Genuine Liquid Gasket or equivalent. Be sure liquid gasket diameter is 4.0 to 5.0 mm (0.157 to 0.197 in). Attaching should be done within 5 minutes after coating.
Bolt hole SEM015E
Liquid gasket
4.0 - 5.0 mm (0.157 0.197 in)
NEM221
5 p
8 p
Engine front
c. I
1 p
3 p
I
Install steel oil pan. Tighten bolts in numerical order as shown together with heated oxygen sensor harness bracket. Wait at least 30 minutes before refilling engine oil.
9 p 10 p
11 p 6 p
4 p
2 p
7 p
NEM222
EM-74
SR20DE
TIMING CHAIN
Components
Components
SEM718EC 1 p 2 p 3 p 4 p
Cylinder block Upper chain guide Intake camshaft sprocket Chain tensioner
5 p 6 p 7 p 8 p
Chain guide Front cover Crank pulley Oil pump spacer
EM-75
9 p 10 p 11 p 12 p
Crankshaft sprocket Chain guide Timing chain Exhaust camshaft sprocket
TIMING CHAIN
SR20DE
Components (Cont’d)
CAUTION: I After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. I When installing chain tensioner, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. I Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprocket and crankshaft pulley.
Removal 1. 2. 3.
Rocker cover
4. 5. I I I I
6. 7.
Remove rocker cover bolts in numerical order. Remove rocker cover.
8.
Remove cylinder head outside bolts.
Engine front
Loosen in numerical order.
NLEM0126
Remove engine under cover. Remove front RH wheel and engine side cover. Drain coolant by removing cylinder block drain plug and lower radiator hose. Refer to MA-29, “Changing Engine Coolant”. Remove drive belts and water pump pulley. Disconnect the following parts: Vacuum hoses Wires Harness Connectors
SEM029G
Front cover
SEM287G
EM-76
SR20DE
TIMING CHAIN
Removal (Cont’d)
9.
Set No. 1 piston at TDC of its compression stroke.
I
Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure.
SEM983C
SEM695DA
10. Remove oil pans. Refer to EM-70, “Oil Pan”.
11. Remove oil strainer. 12. Temporarily install center member to support engine.
SEM038G
13. 14. 15. 16. 17.
Suitable puller
Remove crankshaft pulley. Remove generator. Remove A/C compressor and position it to the side. Remove A/C bracket. Remove generator bracket.
SEM980C
EM-77
TIMING CHAIN
SR20DE
Removal (Cont’d)
18. Set a suitable transmission jack under main bearing beam.
Engine front
Transmission jack SEM039G
19. Remove RH engine mounting.
RH engine mounting SEM040G
RH engine mounting bracket
20. Remove RH engine mounting bracket.
Water pump
SEM041G
21. Remove oil pump drive spacer. CAUTION: Be careful not to damage oil pump drive spacer and front oil seal. 22. Remove front cover. CAUTION: I Be careful not to tear or damage the cylinder gasket. I Inspect for oil leakage at front oil seal. Replace seal if oil leak is present. SEM721E
23. Remove chain tensioner.
Chain tensioner
.
SEM032G
EM-78
TIMING CHAIN
SR20DE Removal (Cont’d)
24. Remove timing chain guides.
SEM982CA
25. Remove camshaft sprockets. I For retiming, apply paint mark to timing chain matched with mating marks of camshaft sprockets. 26. Remove timing chain and crankshaft sprocket.
SEM034G
Inspection
NLEM0127
Check for cracks and excessive wear at roller links. Replace chain if necessary.
SEM984C
Installation
Engine front
NLEM0128
1. I
Install crankshaft sprocket on crankshaft. Make sure mating marks on crankshaft sprocket face front of engine.
2.
Position crankshaft so that No. 1 piston is set at TDC and key way is at 12 oclock. Fit timing chain on crankshaft sprocket, aligning the mating marks.
Crankshaft side
Crankshaft sprocket SEM470E
SEM985C
EM-79
TIMING CHAIN
SR20DE
Installation (Cont’d) 20 rollers
I
Mating mark color on timing chain. 1: Golden 2, 3: White
3.
Install timing chain and timing chain guides.
4.
Install camshaft sprockets and timing chain on them. Line up mating marks on timing chain with mating marks on camshaft sprockets.
Mating mark
Mating mark
56 rollers
48 rollers
Mating mark SEM500E
SEM982CA
Mating mark
Mating mark
Mating mark
.
Mating mark
.
RH camshaft sprocket
LH camshaft sprocket SEM048G
I
Lock camshafts as shown in figure and tighten to specified torque. : 137 - 157 N⋅m (14.0 - 16.0 kg-m, 101 - 116 ft-lb) Apply new engine oil to threads and seating surfaces of camshaft sprocket bolts before installing them.
SEM049G
EM-80
TIMING CHAIN
SR20DE Installation (Cont’d)
5. Install chain tensioner. Make sure the camshaft sprockets are tightened completely. Press cam stopper down and press-in sleeve until hook can be engaged on pin. When tensioner is bolted in position the hook will release automatically. Make sure arrow A points toward engine front.
SEM990C
SEM991C
6. I
Use a scraper to remove old liquid gasket from mating surface of front cover. Also remove old liquid gasket from mating surface of cylinder block.
SCL491A
7. 2.0 - 3.0 mm
I
Apply a continuous bead of liquid gasket to front cover. Also apply liquid gasket to matching surface to cylinder head gasket. Use Genuine RTV silicone sealant part No. 999MP-A7007 or equivalent. Be sure to install new front oil seal in the right direction. Refer to EM-84, “FRONT OIL SEAL”.
8. 9.
Install oil pump drive spacer. Install front cover.
Never apply liquid gasket to this groove.
BEM010
SEM721E
EM-81
TIMING CHAIN Installation (Cont’d)
I
Wipe off excessive liquid gasket.
Wipe off liquid gasket SEM042G
10. Install cylinder head outside bolts.
Front cover
SEM287G
11. Install RH engine mounting and bracket. 12. Install generator bracket and generator. 13. Install A/C compressor bracket and compressor.
RH engine mounting SEM040G
14. Install crankshaft pulley. 15. Set No. 1 piston at TDC of its compression stroke.
Crankshaft pulley
.
SEM073D
16. Install oil strainer. 17. Install oil pans. Refer to EM-70, “Oil Pan”.
SEM038G
EM-82
SR20DE
TIMING CHAIN
SR20DE Installation (Cont’d)
(0.39)
Engine front Unit: mm (in)
18. Remove old liquid gasket from mating surfaces of rocker cover and cylinder head. 19. Apply a continuous bead of liquid gasket to rocker cover gasket and cylinder head as shown in the illustrations. I Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent.
(0.39) 3 (0.12) BEM006
3 mm (0.12 in) dia.
SEM051G
Rocker cover
Engine front
Tighten in numerical order.
SEM052G
20. Install rocker cover and oil separator. I Be sure to install washers between bolts and rocker cover. I Tightening procedure STEP 1: Tighten bolts 1 - 10 - 11 - 13 - 8 in that order. STEP 2: Tighten bolts 1 - 13 in that order. : 8 - 10 N⋅m (0.8 - 1.0 kg-m, 69 - 87 in-lb) 21. Install the following parts: I Spark plugs and leads I Water pump pulley and drive belts. For adjusting drive belt deflection, refer to MA-28, “Checking Drive Belts”. I Refit lower radiator hose and cylinder block drain plug. I Refill with engine coolant. Refer to MA-29, “Changing Engine Coolant”. I Front RH wheel I Engine under cover 22. Connect the following: I Vacuum hoses I Wire harnesses and connectors
EM-83
OIL SEAL REPLACEMENT
SR20DE
VALVE OIL SEAL 1. 2. 3. 4. 5.
SEM077D
6.
Remove accelerator cable. Remove rocker cover and oil separator. Remove camshafts and sprockets. Refer to “Removal” in “CYLINDER HEAD” (EM-87). Remove spark plugs. Install air hose adapter into spark plug hole and apply air pressure to hold valves in place. Apply a pressure of 490 kPa (4.9 bar, 5 kg/cm2, 71 psi). Remove rocker arm, rocker arm guide and shim.
7. Remove valve spring with Tool. Piston concerned should be set at TDC to prevent valve from falling.
Attachment Compressor assembly SEM604E
8.
Remove valve oil seal.
9.
Apply engine oil to new valve oil seal and install it with Tool.
10.7 mm (0.421 in)
SEM994C
KV10115600
SEM358E
FRONT OIL SEAL 1. I I I I 2. Be
Remove the following parts: Engine undercover Front RH wheel and engine side cover Drive belts Crankshaft pulley Remove front oil seal. careful not to scratch front cover.
SEM997C
EM-84
OIL SEAL REPLACEMENT
Engine inside
Oil seal lip
SR20DE
I
Install new oil seal in the direction shown.
3.
Apply engine oil to new oil seal and install it using a suitable tool.
Engine outside
Dust seal lip
SEM715A
SEM998C
REAR OIL SEAL 1. 2. 3. I
Remove transaxle. (Refer to MT or AT section.) Remove flywheel or drive plate. Remove rear oil seal. Be careful not to scratch rear oil seal retainer.
I
Install new oil seal in the direction shown.
4.
Apply engine oil to new oil seal and install it using a suitable tool.
SEM999C
Engine inside
Oil seal lip
Engine outside
Dust seal lip
SEM715A
Suitable tool SEM001D
EM-85
SR20DE
CYLINDER HEAD Components
Components .
NLEM0130
SEC. 111⋅130
Refer to “Installation” in “CYLINDER HEAD”. Washer Intake side Rocker cover gasket
Refer to “Installation” in “CYLINDER HEAD”. Exhaust side
Gasket
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
Valve oil seal
O-ring Refer to LC section (“Water Outlet”, “ENGINE COOLING SYSTEM”).
Gasket
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8) 9.0 - 11.8 (0.92 - 1.2, 79.9 - 104.2)
Refer to “Installation” in “CYLINDER HEAD”. Refer to “Installation” in “CYLINDER HEAD”.
N·m (kg-m, in-lb) N·m (kg-m, ft-lb) Apply Genuine RTV Silicone SEALANT Part No. 999 MP-A7007 or equivalent.
137 - 157 (14 - 16, 101 - 116)
1. 2. 3. 4. 5. 6. 7.
Oil filler cap Rocker cover Rocker arm guide Rocker arm Shim Hydraulic lash adjuster Chain tensioner
8. 9. 10. 11. 12. 13.
Lubricate with new engine oil.
Camshaft sprocket Camshaft Camshaft bracket Water outlet Cylinder head Valve
EM-86
14. 15. 16. 17. 18. 19.
Valve spring seat Valve spring Valve spring retainer Valve collet Spark plug Cylinder head bolt
NEM355
CYLINDER HEAD
SR20DE Removal
Removal 1. 2. 3. 4. 5. 6. 7. I I I I I I 8.
Rocker cover
9. Remove rocker cover bolts in numerical order. 10. Remove rocker cover.
Engine front
Loosen in numerical order.
SEM029G
11. Remove intake manifold supports. Intake manifold supports
SEM030G Intake manifold
NLEM0131
Release fuel pressure. Refer to EC-SR-31, “Fuel Pressure Release”. Remove engine under covers. Remove front RH wheel and engine side cover. Drain coolant by removing cylinder block drain plug and radiator drain cock. Refer to MA-29, “Changing Engine Coolant”. Remove radiator. Remove air duct to intake manifold. Disconnect the following parts: Vacuum hoses Fuel hoses Wires Harness Connectors Front exhaust tube Remove all spark plugs.
12. Remove water pipe assembly.
SEM065G
EM-87
CYLINDER HEAD
SR20DE
Removal (Cont’d)
13. Set No. 1 piston at TDC of its compression stroke.
SEM983C
Mating mark
Mating mark
I
Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure.
LH camshaft sprocket RH camshaft sprocket SEM031G
14. Remove chain tensioner.
Chain tensioner
.
SEM032G Rotor head position (No. 1 cylinder at TDC)
15. Remove distributor. Do not turn rotor with distributor removed.
SEM033G
16. Remove camshaft sprockets. I For retiming in cylinder head removal, apply paint mark to timing chain matched with mating marks of camshaft sprockets.
SEM034G
EM-88
CYLINDER HEAD
SR20DE Removal (Cont’d)
RH camshaft
Camshaft bracket
17. Remove camshaft brackets and camshafts. I Mark these parts’ original positions for reassembly.
Engine front
LH camshaft Loosen in numerical order.
SEM035G
18. 19. I I
Remove starter motor. Remove the following water hoses: Water hose for cylinder block. Water hoses for heater.
SEM036G
20. Remove cylinder head outside bolts. Water inlet
Water outlet
SEM037G
21. Remove cylinder head bolts in numerical order. I Removing bolts in incorrect order could result in a warped or cracked cylinder head. I Loosen cylinder head bolts in two or three steps. 22. Remove cylinder head completely with intake and exhaust manifolds.
SEM978C
Disassembly OK
NG
SEM878CA
CAUTION: I When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting surfaces with new engine oil. I When tightening cylinder head bolts, camshaft sprocket bolts, cramshaft pulley bolt and seat surfaces, lubricate with new engine oil. I If a hydraulic lash adjuster is kept on its side, there is a risk of air entering it. After removal, always set hydraulic
EM-89
CYLINDER HEAD
SR20DE
Disassembly (Cont’d)
lash adjuster straight up, or keep it soaked in new engine oil. I Do not disassemble hydraulic lash adjusters. I Attach tags to lash adjusters so as not to mix them up. 1. Remove rocker arms, shims, rocker arm guides and hydraulic lash adjusters from cylinder head. CAUTION: Keep parts in order so that they can be installed in their original positions during assembly.
Rocker arm guide Rocker arm Shim Hydraulic lash adjuster
SEM202D
2. 3.
Remove exhaust manifold cover. Remove exhaust manifold.
4.
Remove water outlet.
5.
Remove intake manifold.
6.
Remove thermostat housing with water pipe.
Loosen in numerical order. SEM059G
Water outlet
.
SEM082D
Loosen in numerical order.
SEM061G
Thermostat housing
Water pipe NEM215
EM-90
CYLINDER HEAD
SR20DE Inspection
7.
Remove valve components with Tool.
8.
Remove valve oil seal with a suitable tool.
Attachment Compressor assembly SEM604E
SEM994C
Inspection CYLINDER HEAD DISTORTION
SEM925C
Head surface flatness: Standard Less than 0.03 mm (0.0012 in) Limit 0.1 mm (0.004 in) If beyond the specified limit, replace or resurface. Resurfacing limit: The limit of cylinder head is determined by the cylinder block resurfacing in an engine. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced. Nominal cylinder head height: 136.9 - 137.1 mm (5.390 - 5.398 in)
CAMSHAFT VISUAL CHECK Check camshaft for scratches, seizure and wear.
EM-91
CYLINDER HEAD
SR20DE
Inspection (Cont’d)
CAMSHAFT RUNOUT 1.
2.
Measure camshaft runout at the center journal. Runout (Total indicator reading): Standard Less than 0.02 mm (0.0008 in) Limit 0.1 mm (0.004 in) If it exceeds the limit, replace camshaft.
SEM926C
CAMSHAFT CAM HEIGHT 1.
SEM549A
2.
Measure camshaft cam height. Standard cam height: Intake 37.775 mm (1.4872 in) Exhaust 37.404 mm (1.4726 in) Cam wear limit: Intake & Exhaust 0.2 mm (0.008 in) If wear is beyond the limit, replace camshaft.
CAMSHAFT JOURNAL CLEARANCE 1. 2.
Install camshaft bracket and tighten bolts to the specified torque. Measure inner diameter of camshaft bearing. Standard inner diameter: 28.000 - 28.021 mm (1.1024 - 1.1032 in)
SEM927C
3.
4.
.
SEM012A
Measure outer diameter of camshaft journal. Standard outer diameter: 27.950 - 27.970 mm (1.1004 - 1.1012 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance: Standard 0.030 - 0.071 mm (0.0012 - 0.0028 in) Limit 0.15 mm (0.0059 in)
EM-92
SR20DE
CYLINDER HEAD
Inspection (Cont’d)
CAMSHAFT END PLAY 1. 2.
Install camshaft in cylinder head. Measure camshaft end play. Camshaft end play: Standard 0.055 - 0.139 mm (0.0022 - 0.0055 in) Limit 0.20 mm (0.0079 in)
SEM002D
CAMSHAFT SPROCKET RUNOUT 1. 2.
3.
Install sprocket on camshaft. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.25 mm (0.0098 in) If it exceeds the limit, replace camshaft sprocket.
SEM929C
VALVE GUIDE CLEARANCE 1.
Measure valve deflection in a parallel direction with rocker arm. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (Dial gauge reading): Intake & Exhaust 0.2 mm (0.008 in)
2. a. b.
If it exceeds the limit, check valve to valve guide clearance. Measure valve stem diameter and valve guide inner diameter. Check that clearance is within specification. Valve to valve guide clearance: Standard Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust 0.040 - 0.073 mm (0.0016 - 0.0029 in) Limit Intake 0.08 mm (0.0031 in) Exhaust 0.1 mm (0.004 in) If it exceeds the limit, replace valve or valve guide.
Approx. 15 mm (0.59 in)
SEM003D
Micrometer
SEM938C
c.
EM-93
CYLINDER HEAD
SR20DE
Inspection (Cont’d) Oil
VALVE GUIDE REPLACEMENT 1.
To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F).
2.
Press out valve guide or use a hammer and suitable tool.
3.
Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake: 10.175 - 10.196 mm (0.4006 - 0.4014 in) Exhaust: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
4.
Heat cylinder head to 110 to 130°C (230 to 266°F) and press service valve guide onto cylinder head. Projection “L”: 14.0 - 14.2 mm (0.551 - 0.559 in)
5.
Ream valve guide. Valve guide inner diameter: Intake: 6.000 - 6.018 mm (0.2362 - 0.2369 in) Exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM008A
SEM931C
Suitable reamer
.
SEM932C
SEM083D
Suitable reamer
.
SEM932C
EM-94
CYLINDER HEAD
SR20DE Inspection (Cont’d)
VALVE SEATS Check valve seats for any evidence of pitting at valve contact surface. Reset or replace if it has worn out excessively. I Before repairing valve seats, check valve and valve guide for wear. If they have worn, replace them. Then correct valve seat. I Use both hands to cut uniformly.
SEM934C
REPLACING VALVE SEAT FOR SERVICE PARTS .
1. Recess diameter
SEM795A
Oil
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. 2. Ream cylinder head recess. Reaming bore for service valve seat Oversize [0.5 mm (0.020 in)]: Intake 35.500 - 35.516 mm (1.3976 - 1.3983 in) Exhaust 31.500 - 31.516 mm (1.2402 - 1.2408 in) Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly. 3. Heat cylinder head to 110 to 130°C (230 to 266°F). 4. Press fit valve seat until it seats on the bottom.
SEM008A
5. 6. 7.
SEM892B
Cut or grind valve seat using a suitable tool at the specified dimensions as shown in SDS (EM-190). After cutting, lap valve seat with abrasive compound. Check valve seating condition. Seat face angle “α”: 44°53′ - 45°07′ Contacting width “W”: Intake 1.385 - 1.401 mm (0.0545 - 0.0552 in) Exhaust 1.385 - 1.401 mm (0.0545 - 0.0552 in)
VALVE DIMENSIONS
T (Margin thickness)
Check dimensions in each valve. For dimensions, refer to SDS (EM-189). When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less.
.
SEM188A
EM-95
CYLINDER HEAD
SR20DE
Inspection (Cont’d) S (Out-of-square)
VALVE SPRING Squareness 1.
2.
Measure “S” dimension. Out-of-square: Less than 2.2 mm (0.087 in) If it exceeds the limit, replace spring. Free height Check free height: 49.36 mm (1.9433 in)
SEM288A
Pressure Check valve spring pressure. Pressure: N (kg, lb) at height mm (in) Standard 519 - 571 (52.9 - 58.2, 116.6 - 128.3) at 27 (1.063) Limit Replace if load is less than 501 (51.1 - 112.7) at 27 (1.063) EM113
HYDRAULIC LASH ADJUSTER 1.
Check contact and sliding surfaces for wear or scratches.
2.
Check diameter of lash adjuster. Outer diameter: 16.980 - 16.993 mm (0.6685 - 0.6690 in)
3.
Check lash adjuster guide inner diameter. Inner diameter: 17.000 - 17.020 mm (0.6693 - 0.6701 in) Standard clearance between lash adjuster and adjuster guide: 0.007 - 0.040 mm (0.0003 - 0.0016 in)
SEM935C
SEM936C
.
SEM084D
EM-96
CYLINDER HEAD
SR20DE Assembly
ROCKER ARM, SHIM AND ROCKER ARM GUIDE Bearing surface
Rocker arm
Check contact and sliding surfaces of rocker arms, shims and rocker arm guides for wear or scratches.
Shim
Rocker arm guide
NEM144
Assembly
Tighten in numerical order.
1.
Install intake manifold.
2. I 1) 2) 3) 4)
Install thermostat housing with water pipe. Tightening procedure: A to 2 - 5 N·m (0.2 - 0.5 kg-m, 1.4 - 3.6 ft-lb). Tighten bolt p Tighten bolt p C to 16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb). A to 16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb). Tighten bolt p B to 16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb). Tighten bolt p
3. 4.
Install exhaust manifold. Install exhaust manifold cover.
5. a.
Install water outlet. Before installing water outlet, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder head. Apply a continuous bead of liquid gasket to mating surface of water outlet. Use Genuine Liquid Gasket or equivalent. Install valve component parts. Install valves with larger diameter head on the intake side.
SEM064G
Thermostat housing
Water pipe NEM216
Tighten in numerical order. SEM059GA
I 2.0 - 3.0 mm (0.079 - 0.118 in)
Liquid gasket SEM086D
b. I 6. I
EM-97
CYLINDER HEAD
SR20DE
Assembly (Cont’d)
I I I
Wide pitch
I Narrow pitch
Always use new valve oil seal. Refer to OIL SEAL REPLACEMENT. Before installing valve oil seal, install valve spring seat. Install valve spring (uneven pitch type) with its narrow pitched side toward cylinder head side (paint mark). After installing valve component parts, tap valve stem tip with plastic hammer to assure a proper fit.
Paint mark SEM085D
Cylinder head side
7. a. Push
Check hydraulic lash adjusters. Push rocker arm at hydraulic lash adjuster location, and see if rocker arm moves. If it moves at least 1 mm (0.04 in), it indicates that there is air in the high pressure chamber. Noise will be emitted from hydraulic lash adjuster if engine is started without bleeding air.
NEM146
b.
Rod
Engine oil
Remove hydraulic lash adjuster and dip in a container filled with engine oil. While pushing plunger as shown in figure, lightly push check ball using a thin rod. Air is completely bled when plunger no longer moves. Air cannot be bled from this type of lash adjuster by running the engine.
NEM147
8.
Install rocker arms, shims, rocker arm guides and hydraulic lash adjusters. CAUTION: Install all parts in their original positions.
Rocker arm guide Rocker arm Shim Hydraulic lash adjuster
SEM202D
9. Shim Rocker arm guide Valve collet
a. I
Valve spring retainer Valve spring
Select a suitable shim when replacing any of the following parts with a new one: Cylinder head, shim, rocker arm guide and valve seat. Proceed as follows to select the shim of correct thickness. Install valve component parts to cylinder head (Except shim). Always replace rocker arm guide with a new one.
Valve spring seat Valve oil seal Valve SEM364D
EM-98
CYLINDER HEAD
SR20DE Assembly (Cont’d)
Dial gauge
b. c.
Remove hydraulic lash adjuster. Install Tool* into hydraulic lash adjuster fixing hole. * Tool (KV10115700) is screwed into magnetic stand rod used with dial gauge.
Rod
SEM365DA
SEM899D
d.
Make sure that the following parts are installed to the cylinder head: Valve, valve spring, collet, retainer and rocker arm guide (except shim). Measure difference (T1) between sliding surface of rocker arm guide and valve stem end on shim side. When measuring, lightly pull dial indicator rod toward you to eliminate play in Tool (KV10115700).
e.
I
Shim
Select correct shim. Shim thickness (T): T1 ± 0.025 mm (0.0010 in) Shims are available in different thicknesses from 2.800 mm (0.1102 in) to 3.200 mm (0.1260 in) in increments of 0.025 mm (0.0010 in).
Indicate T = 2.800 mm (0.1102 in) SEM096D
Installation 1.
2.0 - 3.0 mm (0.079 - 0.118 in) dia.
NLEM0136
Before installing cylinder head gasket, apply liquid gasket as shown in the illustration.
Liquid gasket AEM250
EM-99
CYLINDER HEAD
SR20DE
Installation (Cont’d)
2.
SEM390G
Install cylinder head completely with intake and exhaust manifolds. 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 ones. Limit (d1 − d2): 0.15 mm (0.0059 in) CAUTION: If reduction of outer diameter appears in a position other than d2, use it as d2 point.
Cylinder head bolt washer
Cylinder head side
SEM877A
3. a. b. c. d.
Tighten cylinder head bolts using the following procedure. Tighten all bolts to 39 N⋅m (4.0 kg-m, 29 ft-lb). Tighten all bolts to 78 N⋅m (8.0 kg-m, 58 ft-lb). Loosen all bolts completely. Tighten all bolts to 39 N⋅m (4.0 kg-m, 29 ft-lb).
SEM986C
e.
Method A degrees degrees
SEM043G
Method B
Method A: Turn all bolts 90 to 95 degrees clockwise with Tool or suitable angle wrench. Method B: If an angle wrench is not available, mark all cylinder head bolts on the side facing engine front. Then, turn each cylinder head bolt 90 to 95 degrees clockwise. f. Turn all bolts another 90 to 95 degrees clockwise. g. Ensure that paint mark on each bolt faces the rear of the engine. (Method B only) Do not turn any bolt 180 to 190 degrees clockwise all at once.
degrees
degrees
Engine front Paint mark
SEM044G
EM-100
SR20DE
CYLINDER HEAD
Installation (Cont’d)
N·m (kg-m, ft-lb)
Tightening torque N⋅m (kg-m, ft-lb)
118 (12, 87)
Plastic zone
78 (8, 58) Elastic zone 39 (4, 29)
AEM113
Water inlet
Water outlet
a.
39 (4.0, 29)
b.
78 (8.0, 58)
c.
0 (0, 0)
d.
39 (4.0, 29)
e.
90 - 95 degrees (90 degrees preferred)
f.
90 - 95 degrees (90 degrees preferred)
4. 5. I I
Install Install Water Water
cylinder head outside bolts. the following water hoses: hose for cylinder block. hoses for heater.
6.
Install starter motor.
7.
Remove old liquid gasket from mating surface of LH camshaft end bracket. Also remove old liquid gasket from mating surface of cylinder head. Apply liquid gasket to mating surface of LH camshaft end bracket as shown in illustration. Use Genuine RTV silicone sealant part No. 999MP-A7007 or equivalent.
SEM037G
SEM036G
Apply liquid gasket to the shaded area.
I 8. I
LH camshaft end bracket BEM004
9. I I I
RH camshaft key
LH camshaft key
Install camshafts, camshaft brackets. Position camshaft. LH camshaft key at about 12 o’clock. RH camshaft key at about 10 o’clock. Apply new engine oil to bearing and cam surfaces of camshafts before installing them.
SEM045G
EM-101
CYLINDER HEAD
SR20DE
Installation (Cont’d)
I
Position camshaft brackets as shown in the illustration. Apply new engine oil to threads and seating surfaces of camshaft bracket bolts before installing them.
I
Arrange bolts (Size and length). A: M6 x 53.8 mm (2.12 in) B: M6 x 37 mm (1.46 in) C: M8 x 35 mm (1.38 in)
I
Tightening procedure STEP 1: RH camshaft Tighten bolts 9 - 10 in that order then tighten bolts 1 - 8 in numerical order. : 2 N⋅m (0.2 kg-m, 17 in-lb) LH camshaft Tighten bolts 11 - 12 in that order then tighten bolts 1 - 10 in numerical order. : 2 N⋅m (0.2 kg-m, 17 in-lb) STEP 2: Tighten bolts in numerical order. : 6 N⋅m (0.6 kg-m, 52 in-lb) STEP 3: Tighten bolts in numerical order. Bolt type A B : 9.8 - 11.8 N⋅m (1.0 - 1.2 kg-m, 7.2 - 8.7 ft-lb) Bolt type C : 18 - 25 N⋅m (1.8 - 2.6 kg-m, 13 - 19 ft-lb)
End bracket
RH camshaft bracket
End bracket
Engine front No. 1 to 4 brackets No. 1 to 4 brackets
LH camshaft bracket SEM098DA
Engine front
Bolt type SEM046G
RH camshaft
Engine front
LH camshaft Tighten in numerical order.
SEM047G
Engine front
Bolt type SEM046G
Mating mark
Mating mark
Mating mark
.
Mating mark
.
RH camshaft sprocket
10. Install camshaft sprockets and timing chain on them. Line up mating marks on timing chain with mating marks on camshaft sprockets.
LH camshaft sprocket SEM048G
EM-102
CYLINDER HEAD
SR20DE Installation (Cont’d)
I
Lock camshafts as shown in figure and tighten to specified torque. : 137 - 157 N⋅m (14.0 - 16.0 kg-m, 101 - 116 ft-lb) Apply new engine oil to threads and seating surfaces of camshaft sprocket bolts before installing them.
SEM049G
11. Install distributor. I Make sure that position of camshaft is as shown in figure.
SEM050G Rotor head position (No. 1 cylinder at TDC)
I
Make sure that No. 1 piston is set at TDC and that distributor rotor is set at No. 1 cylinder spark position.
SEM033G
12. Install chain tensioner. Make sure the camshaft sprockets are tightened completely. Press cam stopper down and “press-in” sleeve until hook can be engaged on pin. When tensioner is bolted in position the hook will release automatically. Make sure arrow “A” points toward engine front.
SEM990C
SEM991C
EM-103
CYLINDER HEAD
SR20DE
Installation (Cont’d)
13. Install thermostat housing with water pipe. 16 - 20 (1.6 - 2.1, 12 - 15) 16 - 20 (1.6 - 2.1, 12 - 15)
6.3 - 8.3 (0.64 - 0.85, 56 - 73)
16 - 20 (1.6 - 2.1, 12 - 15)
6.3 - 8.3 (0.64 - 0.85, 56 - 73) 16 - 20 (1.6 - 2.1, 12 - 15)
N·m (kg-m, in-lb) N·m (kg-m, ft-lb)
SEM066G
14. Install intake manifold supports. Intake manifold supports
SEM030G
(0.39)
Engine front Unit: mm (in)
15. Remove old liquid gasket from mating surfaces of rocker cover and cylinder head. 16. Apply a continuous bead of liquid gasket to rocker cover gasket and cylinder head as shown in the illustrations. I Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent.
(0.39) 3 (0.12) BEM006
3 mm (0.12 in) dia.
SEM051G
EM-104
CYLINDER HEAD
SR20DE Installation (Cont’d)
Rocker cover
Engine front
Tighten in numerical order.
SEM052G
17. Install rocker cover and oil separator. I Be sure to install washers between bolts and rocker cover. I Tightening procedure STEP 1: Tighten bolts 1 - 10 - 11 - 13 - 8 in that order. STEP 2: Tighten bolts 1 - 13 in that order. : 8 - 10 N⋅m (0.8 - 1.0 kg-m, 69 - 87 in-lb) 18. Install the following parts: I Spark plugs and leads I Radiator Refit hoses and refill with coolant. Refer to MA-29, “Changing Engine Coolant”. I Front RH wheel I Engine undercovers 19. Connect the following: I Vacuum hoses I Fuel hoses I Wire harnesses and connectors I Air duct to intake manifold I Front exhaust tube
EM-105
SR20DE
ENGINE REMOVAL Components
Components SEC. 112 Rear engine slinger Front engine slinger
20.6 - 26.5 (2.1 - 2.7, 15 - 20) 20.6 - 26.5 (2.1 - 2.7, 15 - 20)
43 - 55 (4.9 - 5.6, 32 - 41)
43 - 55 (4.4 - 5.6, 32 - 41)
49 - 59 (5.0 - 6.0, 36 - 44)
43 - 55 (4.4 - 5.6, 32 - 41)
Front engine mounting Rear engine mounting
Mounting bracket
CVT models .
.
43 - 55 (4.4 - 5.6, 32 - 41)
49 - 59 (5.0 - 6.0, 36 - 44)
74 - 83 (7.5 - 8.5, 54 - 61) 43 - 55 (4.4 - 5.6, 32 - 41) .
64 - 74 (6.5 - 7.5, 47 - 54)
43 - 55 (4.4 - 5.6, 32 - 41)
43 - 55 (4.4 - 5.6, 32 - 41)
43 - 55 (4.4 - 5.6, 32 - 41)
64 - 74 (6.5 - 7.5, 47 - 54) 62 - 78 (6.3 - 8.0, 46 - 58)
55 - 65 (5.6 - 6.6, 41 - 48)
64 - 74 (6.5 - 7.5, 47 - 54) Front mounting bracket 49 - 59 (5.0 - 6.0, 36 - 44)
49 - 59 (5.0 - 6.0, 36 - 44)
Rear insulator Insulator
Center member
77 - 98 (7.9 - 100, 57 - 72) : N·m (kg-m, ft-lb)
NEM340
EM-106
ENGINE REMOVAL
SR20DE Components (Cont’d)
WARNING: I Position vehicle on a flat and solid surface. I Place chocks at front and back of rear wheels. I Do not remove engine until exhaust system has completely cooled; Otherwise, you may burn yourself and/or fire may break out in fuel line. I Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to “Releasing Fuel Pressure” in EC section. I Be sure to hoist engine and transaxle in a safe manner. I For engines not equipped with engine slingers, attach slingers and bolts described in PARTS CATALOG. CAUTION: I When lifting engine, be sure to clear surrounding parts. Use special care for accelerator cable, brake lines and brake master cylinder. I In hoisting the engine, always use engine slingers in a safe manner. I When removing drive shaft, be careful not to damage grease seal of transaxle.
Removal 1. 2. 3. 4. 5. 6. 7. 8. 9.
Remove engine under cover and hood. Drain coolant from both cylinder block, and radiator. Drain engine oil. Remove vacuum hoses, fuel hoses, wires, harness and connectors. Remove exhaust tubes, ball joints and drive shafts. Remove radiator and fans. Remove drive belts. Remove alternator, compressor and power steering oil pump from engine. Set a suitable transmission jack under transaxle. Hoist engine with engine slinger.
10. Remove center member. Center member
Transmission jack SEM092D
EM-107
ENGINE REMOVAL
SR20DE
Removal (Cont’d)
11. Remove engine mounting bolts from both sides and then slowly lower transmission jack.
Front engine mounting
SEM597D
.
Rear engine mounting NEM224
12. Remove engine with transaxle as shown.
SEM195F
Installation 1. Install engine mounting bracket and fixing bolts. Be sure that insulators are correctly positioned on the brackets. 2. Carefully lower the engine onto engine mounting insulators.
Rubber seat
Insulator SEM312D
EM-108
SR20DE
CYLINDER BLOCK
Components
Components SEC. 110⋅120⋅150 16 - 21 (1.6 - 2.1, 12 - 15)
4 p
1 p
2 p
p 3
6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5)
16 - 21 (1.6 - 2.1, 12 - 15) .
6.4 - 7.5 (0.65 - 0.76, 56.4 - 66.0)
★
5 p
★ .
6.4 - 7.5 (0.65 - 0.76, 56.6 - 66.0) 6 p
Gasket 16 - 19 (1.6 - 1.9, 12 - 14)
6.4 - 7.5 (0.65 - 0.76, 56.6 - 66.0)
24 p
pp p 23
22
21
83 - 93 (8.5 - 9.5, 61 - 69)
7 p
8 p 9 p
10 p
20 p
p 12 p 11
Snap ring
Refer to “Assembly”
13 p
Refer to “Assembly”
16 p
6.4 - 7.5 ü★ üü: Refer to LC section. (0.65 - 0.76, 56.6 - 66.0) ★★ : Refer to “Installation” in “OIL PAN”. 17 29 - 39 p (3.0 - 4.0, 22 - 29) : N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) : Apply liquid gasket. : Lubricate with new engine oil. üü
: Do not re-use
★★
14 p 15 p
★★ 19 p
Washer 6.4 - 7.5 (0.65 - 0.76, 56.6 - 66.4)
18 p
★★ 6.4 - 7.5 (0.65 - 0.76, 56.4 - 66.0)
NEM225
1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p
Rear oil seal retainer Cylinder block Water pump Power steering oil pump adjusting bar Front cover with oil pump Oil strainer Thrust bearing Crankshaft
9 p 10 p 11 p 12 p 13 p 14 p 15 p 16 p
Connecting rod bushing Piston rings Piston Piston pin Connecting rod Connecting rod bearing Aluminum oil pan Rear cover plate
EM-109
17 p 18 p 19 p 20 p 21 p 22 p 23 p 24 p
Drain plug Steel oil pan Baffle plate Main bearing cap Flywheel Pilot bushing Rear plate Main bearing
CYLINDER BLOCK
SR20DE
Components (Cont’d)
CAUTION: I When installing sliding parts (bearings, pistons, etc.), apply new engine oil to the sliding surfaces. I Place removed parts such as bearings and bearing caps in their correct order and direction. I When installing connecting rod nuts and main bearing cap bolts, apply new engine oil to threads and seating surfaces. I Do not allow any magnetic materials to contact the ring gear teeth of flywheel/drive plate.
Disassembly
: N·m (kg-m, ft-lb)
PISTON AND CRANKSHAFT 1. 2. 25 - 34 (2.5 -3.5, 18 - 25) Spacer [5 mm (0.20 in) thickness]
3. 4.
25 - 34 (2.5 - 3.5, 18 - 25)
Place engine on a work stand. Remove cylinder head. Refer to “Removal” in “CYLINDER HEAD” (EM-87). Remove oil pan. Refer to “Removal” in “OIL PAN” (EM-70). Remove timing chain. Refer to “Removal” in “TIMING CHAIN” (EM-76).
SEM141FA
5. I
Piston heater
Oil
6.
Remove pistons with connecting rods. When disassembling piston and connecting rod, remove snap ring first. Then heat piston to 60 to 70°C (140 to 158°F), or use piston pin press stand at room temperature. Remove rear oil seal retainer.
SEM877B
7. Front
I
4 p
8 p
10 p
6 p
2 p
3 p
7 p
9 p
5 p
1 p
I
Remove bearing caps and crankshaft in numerical order as shown in the figure. Before removing bearing cap, measure crankshaft end play. Bolts should be loosened in two or three steps.
NEM150
Inspection PISTON AND PISTON PIN CLEARANCE 1.
Measure inner diameter of piston pin hole “dp”. Standard diameter “dp”: 21.993 - 22.005 mm (0.8659 - 0.8663 in)
AEM023
EM-110
CYLINDER BLOCK
SR20DE Inspection (Cont’d)
2.
3.
Measure outer diameter of piston pin “Dp”. Standard diameter “Dp”: 21.989 - 22.001 mm (0.8657 - 0.8662 in) Calculate piston pin clearance. dp − Dp = 0.002 - 0.006 mm (0.0001 - 0.0002 in) If it exceeds the above value, replace piston assembly with pin.
Micrometer AEM024
PISTON RING SIDE CLEARANCE NG
Side clearance: Top ring 0.045 - 0.080 mm (0.0018 - 0.0031 in) 2nd ring 0.030 - 0.070 mm (0.0012 - 0.0028 in) Oil ring 0.065 - 0.135 mm (0.0026 - 0.0053 in) Max. limit of side clearance: 0.2 mm (0.008 in) If out of specification, replace piston and/or piston ring assembly.
Feeler gauge OK
Feeler gauge Ring
SEM024AA
PISTON RING END GAP
SEM822B Bend
Feeler gauge
End gap: Top ring 0.20 - 0.30 mm (0.0079 - 0.0118 in) 2nd ring 0.35 - 0.50 mm (0.0138 - 0.0197 in) Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in) Max. limit of ring gap: 1.0 mm (0.039 in) If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, do the following. Rebore cylinder and use over-sized piston and piston rings. Refer to SDS (EM-193). I When replacing the piston, inspect cylinder block surface for scratches or seizure. If scratches or seizure are found, hone or replace the cylinder block.
CONNECTING ROD BEND AND TORSION
SEM038F
Torsion
Feeler gauge
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.
SEM003F
EM-111
CYLINDER BLOCK
SR20DE
Inspection (Cont’d)
CYLINDER BLOCK DISTORTION AND WEAR
Straightedge
1.
2. Feeler gauge
Clean upper face of cylinder block and measure the distortion. Standard: Less than 0.03 mm (0.0012 in) Limit: 0.10 mm (0.0039 in) If out of specification, resurface it. The resurfacing limit is determined by cylinder head resurfacing in engine.
SEM123C
211.25 - 211.35 mm (8.3169 - 8.3208 in)
Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) Nominal cylinder block height from crankshaft center: 211.25 - 211.35 mm (8.3169 - 8.3208 in) 3. If necessary, replace cylinder block. SEM008D
PISTON-TO-BORE CLEARANCE
100 (3.94)
60 (2.36) 10 (0.39)
1.
SEM363E
Cylinder bore grade number
2. I
.
Using a bore gauge, measure cylinder bore for wear, out-ofround and taper. Standard inner diameter: 86.000 - 86.030 mm (3.3858 - 3.3870 in) Wear limit: 0.20 mm (0.0079 in) If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Out-of-round (X − Y) standard: Less than 0.015 mm (0.0006 in) Taper (A − B and A − C) standard: Less than 0.010 mm (0.0004 in) Check for scratches and seizure. If seizure is found, hone it. When replacing both cylinder block and piston with new ones, select piston making sure of grade numbers. Piston grade number should be the same as the grade number punched on cylinder block upper surface.
SEM011D
3.
SEM012D
Measure piston skirt diameter. Piston diameter “A”: Refer to SDS (EM-193). Measuring point “a” (Distance from the bottom): 13.1 mm (0.516 in) 4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance “B”: 0.010 - 0.030 mm (0.0004 - 0.0012 in) 5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to SDS (EM193).
EM-112
CYLINDER BLOCK
SR20DE Inspection (Cont’d)
6.
Cylinder bore size is determined by adding piston-to-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-bore clearance C: Honing allowance 0.02 mm (0.0008 in) 7. Install main bearing caps, and tighten to the specified torque. I Otherwise, cylinder bores may be distorted in final assembly. 8. Cut cylinder bores. I When any cylinder needs boring, all other cylinders must also be bored. I 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. 9. Hone cylinders to obtain specified piston-to-bore clearance. 10. Measure finished cylinder bore for out-of-round and taper. I Measurement should be done after cylinder bore cools down.
CRANKSHAFT 1. 2.
Taper: Out-of-round: SEM316A
3.
Check crankshaft main and pin journals for score, wear or cracks. With a micrometer, measure journals for taper and out-ofround. Out-of-round (X − Y) standard: Main journal: Less than 0.005 mm (0.0002 in) Pin journal: Less than 0.0025 mm (0.0001 in) Taper (A − B) standard: Main journal: Less than 0.005 mm (0.0002 in) Pin journal: Less than 0.0025 mm (0.0001 in)
Measure crankshaft runout. Runout (Total indicator reading) limit: Less than 0.05 mm (0.0020 in)
.
SEM434
EM-113
CYLINDER BLOCK
SR20DE
Inspection (Cont’d)
BEARING CLEARANCE I
Use either of the following two methods, however, method “A” gives more reliable results and is preferred.
Method A (Using bore gauge & micrometer) Main bearing 1.
Set main bearings in their proper positions on cylinder block and main bearing cap.
SEM685D
2. Install main bearing caps to cylinder block. Tighten all bolts in correct order in two or three stages. 3. Measure inner diameter “A” of each main bearing.
SEM100D
4. 5.
6. 7.
Measure outer diameter “Dm” of each crankshaft main journal. Calculate main bearing clearance. Main bearing clearance = A − Dm Standard: 0.004 - 0.022 mm (0.0002 - 0.0009 in) Limit: 0.050 mm (0.0020 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing.
AEM026
a.
b.
When grinding crankshaft journal, confirm that “L” dimension in fillet roll is more than the specified limit. “L”: 0.1 mm (0.004 in) Refer to SDS for grinding crankshaft and available service parts.
SEM964
8. Main journal grade number No. 5
a.
No. 1
If crankshaft is reused, measure main bearing clearances and select thickness of main bearings. If crankshaft is replaced with a new one, select thickness of main bearings as follows: Grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Roman numerals.
Engine front SEM313D
EM-114
SR20DE
CYLINDER BLOCK
Inspection (Cont’d) Type I
b.
Main journal grade number No. 5
c.
Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Roman numerals. Select main bearing with suitable thickness according to the following table.
No. 1 No. 4
Crankshaft front view Type II
SEM013D
How to select main bearings (Identification mark and color) Crankshaft main journal grade number
Main journal grade number No. 1
Cylinder block main journal grade number 0
1
2
3
0
0 (A, Black)
1 (B, Red)
2 (C, Green)
3 (D, Yellow)
1
1 (B, Red)
2 (C, Green)
3 (D, Yellow)
4 (E, Blue)
2
2 (C, Green)
3 (D, Yellow)
4 (E, Blue)
5 (F, Pink)
3
3 (D, Yellow)
4 (E, Blue)
5 (F, Pink)
6 (G, White)
No. 5 journal
Crankshaft front view
For example: Main journal grade number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 + 2 = 3 (D, Yellow)
SEM203D
Connecting rod bearing (Big end) 1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. 3. Measure inner diameter “C” of each bearing.
Inside micrometer
AEM027
4. 5.
6. 7.
Measure outer diameter “Dp” of each crankshaft pin journal. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C − Dp Standard: 0.020 - 0.045 mm (0.0008 - 0.0018 in) Limit: 0.065 mm (0.0026 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. Refer to step 7 of “BEARING CLEARANCE − Main bearing” (EM-114).
AEM028
EM-115
SR20DE
CYLINDER BLOCK Inspection (Cont’d) Type I
8.
If crankshaft is replaced with a new one, select connecting rod bearing according to the following table. Connecting rod bearing grade number: These numbers are punched in either Arabic or Roman numerals.
Main journal grade number No. 5
No. 1 No. 4
Crankshaft front view
Crank pin grade number
Connecting rod bearing grade number
0
0
1
1
2
2
SEM013D
Identification color: Grade 0; Black or Yellow Grade 1; Brown or Red Grade 2; Green or Blue
Type II No. 3 No. 2
No. 4 cylinder Grade 0 Grade 1
No. 1
Grade 2 Pin journal grade number
Crankshaft rear view
SEM204D
Method B (Using plastigage) CAUTION: I Do not turn crankshaft or connecting rod while plastigage is being inserted. I When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. If incorrect bearing clearance exists, use a thicker or undersized main bearing to ensure specified clearance. EM142
CONNECTING ROD BUSHING CLEARANCE (Small end) 1.
Measure inner diameter “C” of bushing. Refer to SDS EM-193 - “CONNECTING ROD”.
2. 3.
Measure outer diameter “Dp” of piston pin. Calculate connecting rod bushing clearance. Connecting rod bushing clearance = C − Dp Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in) Limit: 0.023 mm (0.0009 in) If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston set with pin.
AEM029
Micrometer AEM030
EM-116
SR20DE
CYLINDER BLOCK
Inspection (Cont’d)
REPLACEMENT OF CONNECTING ROD BUSHING (Small end) 1.
Align. SEM062A
Drive in small end bushing until it is flush with end surface of rod. Be sure to align the oil holes. 2. After driving in small end bushing, ream the bushing. This is to ensure the clearance between connecting rod bushing and piston pin is the specified value. Clearance between connecting rod bushing and piston pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (CVT) 1.
Remove pilot bushing or pilot converter using Tool or suitable tool.
2.
Install pilot bushing or pilot converter as shown.
SEM916AB
Crankshaft side
M/T
CVT SEM163B
FLYWHEEL/DRIVE PLATE RUNOUT Runout (Total indicator reading): Flywheel (M/T model) Less than 0.15 mm (0.0059 in) Drive plate (CVT model) Less than 0.20 mm (0.0079 in) CAUTION: Do not allow any magnetic materials to contact the ring gear teeth. .
SEM901E
Assembly PISTON 1.
Install new snap ring on one side of piston pin hole.
SEM166B
EM-117
CYLINDER BLOCK
SR20DE
Assembly (Cont’d)
2. I I I
Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, piston pin, connecting rod and new snap ring. Align the direction of piston and connecting rod. Numbers stamped on connecting rod and cap correspond to each cylinder. After assembly, make sure connecting rod swings smoothly.
SEM946C
Punchmark side up (if mark is present.)
3. Set piston rings as shown. CAUTION: I When piston rings are not replaced, make sure that piston rings are mounted in their original positions. I When replacing piston rings, those without punchmarks can be mounted with either side up.
SEM965E
Oil ring expander
● Top ring ● Oil ring
upper rail
Engine front
2nd ring
Oil ring lower rail NEM336
CRANKSHAFT 1. I I
Set main bearings in their proper positions on cylinder block and main bearing cap. Confirm that correct main bearings are used. Refer to “Inspection” of this section. Apply new engine oil to bearing surfaces.
SEM685D
EM-118
CYLINDER BLOCK
SR20DE Assembly (Cont’d)
2. Front
7 p
8 p
3 p
1 p
4 p
2 p
5 p
6 p
9 p
10 p
NEM151
I I I a. b. I
KV10112100
I
Install crankshaft and main bearing caps and tighten bolts to the specified torque and in numerical order as shown in the figure. Apply new engine oil to thread of bearing cap bolts. Prior to tightening bearing cap bolts, shift crankshaft back and forth to properly seat the bearing cap. Tightening procedure Tighten all bolts to 32 to 38 N·m (3.3 to 3.9 kg-m, 24 to 28 ft-lb). Turn all bolts 30 to 35 degrees clockwise with Tool or suitable angle wrench. If an angle wrench is not available, mark all bearing cap bolts on the side facing engine rear. Then, turn each bolt specified degrees clockwise. Confirm angle of degrees with a graduator, not by eye-measurement. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
NEM152
3.
Measure crankshaft end play. Crankshaft end play: Standard 0.10 - 0.26 mm (0.0039 - 0.0102 in) Limit 0.30 mm (0.0118 in) If beyond the limit, replace thrust bearings with new ones.
4.
Install connecting rod bearings in connecting rods and connecting rod caps. Confirm that correct bearings are used. Refer to “Inspection”. Install bearings so that oil hole in connecting rod aligns with oil hole of bearing. Apply new engine oil to bolt threads and bearing surfaces.
Feeler gauge
NEM153 Align oil hole.
I I I
SEM159B
5. a. I I I
Install pistons with connecting rods. Install them into corresponding cylinders with Tool. Be careful not to scratch cylinder wall by connecting rod. Arrange so that front mark on piston head faces toward front of engine. Apply new engine oil to piston rings and sliding surface of piston.
EM03470000 or suitable tool SEM554EA
EM-119
CYLINDER BLOCK
SR20DE
Assembly (Cont’d)
b.
Install connecting rod caps. Tighten connecting rod cap nuts to the specified torque. Tightening procedure: 1) Tighten nuts to 14 to 16 N·m (1.4 to 1.6 kg-m, 10 to 12 ft-lb). 2) Turn nuts 60 to 65 degrees clockwise with angle wrench. If angle wrench is not available, tighten nuts to 38 to 44 N·m (3.9 to 4.5 kg-m, 28 to 33 ft-lb).
6.
Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit 0.50 mm (0.0197 in) If beyond the limit, replace connecting rod and/or crankshaft.
7. a.
Install rear oil seal retainer. Before installing rear oil seal retainer, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block.
Engine front
Connecting rod cap nut
NEM154
Feeler gauge
NEM153
●
SEM218D
b. Liquid gasket
●
Apply a continuous bead of liquid gasket to mating surface of rear oil seal retainer. Use Genuine Liquid Gasket or equivalent.
2.0 - 3.0 mm (0.079 0.118 in)
SEM219D
EM-120
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Camshaft bearing noise
CD20T
Tappet noise Belt tensioner noise
Valve mechanism Timing belt
Belt tensioner noise
Water pump
Rotation mechanism Piston pin noise Drive belt
Piston slap noise
Main bearing noise
Connecting rod bearing noise
Drive belt noise (stick/slipping) Drive belt noise (Slipping) NEM333
EM-121
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
CD20T
NVH Troubleshooting Chart — Engine Noise
NVH Troubleshooting Chart — Engine Noise Use the chart below to help you find the cause of the problem. 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 Top of engine Rocker cover Cylinder head
Crankshaft pulley Cylinder block (Side of engine) Oil pan
Type of noise
When starting
When idling
When racing
While driving
Source of noise
Check item
Reference page
Ticking or clicking
C
A
—
A
B
—
Tappet noise
Valve clearance
—
Rattle
C
A
—
A
B
C
Camshaft bearing noise
Camshaft journal clearance Camshaft runout
EM-147
Slap or knock
—
A
—
B
B
—
Piston pin noise
Piston and piston pin clearance Connecting rod bushing clearance
EM-168, 171
EM-168, 169, 172, 174
Slap or rap
A
—
—
B
B
A
Piston slap noise
Piston-to-bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion
Knock
A
B
C
B
B
B
Connecting rod bearing noise
Connecting rod bushing clearance (Small end) Connecting rod bearing clearance (Big end)
EM-170, 171
Knock
A
B
—
A
B
C
Main bearing noise
Main bearing oil clearance Crankshaft runout
EM-169, 172
C
A
—
A
A
—
Timing belt noise (too tight)
Loose timing belt Belt contacting case
EM-135
Whine or Camshaft and injection hissing pump Timing belt Clatter cover
Squeaking or fizzing Front of engine
Before After warm-up warm-up
A
B
—
C
A
—
Timing belt noise (too loose)
A
B
—
B
—
C
Other drive belts (Sticking or slipping)
Drive belts deflection
Idler pulley bearing operation
Water pump operation
Creaking
A
B
A
B
A
B
Other drive belts (Slipping)
Squall Creak
A
B
—
B
A
B
Water pump noise
A: Closely related B: Related C: Sometimes related —: Not related *1: MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”) *2: LC section (“Water Pump Inspection”, “ENGINE COOLING SYSTEM”)
EM-122
*1
*2
CD20T
OUTER COMPONENT PARTS Right side SEC. 130⋅135⋅185⋅186⋅210⋅213⋅233 17 - 21 (1.7 - 2.1, 12 - 15) 2 - 4 (0.2 - 0.4, 18 - 35)
3 - 5 (0.3 0.5, 26 - 43)
16 - 21 (1.6 - 2.1, 12 - 15) 49 - 59 (5.0 - 6.0, 36 - 43)
49 - 59 (5.0 - 6.0, 36 - 43)
16 - 21 (1.6 - 2.1, 12 - 15) 16 - 21 (1.6 - 2.1, 12 - 15)
31 - 42 (3.2 - 4.3, 23 - 31)
22 - 25 (2.2 - 2.5, 16 - 18) 54 - 64 (5.5 - 6.5, 40 - 47) 16 - 21 (1.6 - 2.1, 12 - 15)
üü
: Apply liquid gasket : N·m (kg-m, in-lb)
üü
: N·m (kg-m, ft-lb) : Do not re-use NEM240
1 p 2 p 3 p 4 p 5 p 6 p 7 p
Starter motor Injection pump Injection tube Thermostat housing Injection nozzle Spill hose Water outlet
8 p 9 p 10 p 11 p 12 p 13 p 14 p
Belt cover Timing belt Injection pump sprocket Rear camshaft sprocket Tensioner Vacuum pump Rear back cover
EM-123
15 p 16 p 17 p 18 p 19 p
Oil cooler Gasket Bracket Power steering oil pump adjusting bar Gasket
CD20T
OUTER COMPONENT PARTS Left side SEC. 120⋅135⋅140⋅144⋅210⋅230
18 - 22 (1.8 - 2.2, 13 - 16) 3.8 - 4.5 (0.39 - 0.46, 33.6 - 39.8)
3 - 5 (0.3 - 0.5, 27 - 44)
37 - 50 (3.8 - 5.1, 27 - 37)
6.3 - 8.3 (0.64 - 0.85, 55.8- 73.5)
p
11 p
8
16 p
.
9 p
1 p
21 - 26 (2.1 - 2.7, 15 - 20)
10 p
8 p 12 p
6.4 - 8.4 (0.65 - 0.86, 56.6 - 74.3)
13 p
18 - 22 (1.8 - 2.2, 13 - 16)
2 p
8 p 3 p
p
8 p 7 p
3-5 (0.3 - 0.5, 26 - 44)
4 p
21 - 26 (2.1 - 2.7, 15 - 20)
14
39 - 49 (4.0 - 5.0, 29 - 36)
18 - 22 (1.8 - 2.2, 13 - 16) .
142 - 152 (14.5 - 15.5, 105 - 112)
6 p
18 - 22 (1.8 - 2.2, 13 - 16)
17 p
20 - 31 (2.0 - 3.2, 14 - 23)
15 p
4-5 (0.4 - 0.5, 35 - 44)
70 - 89 (7.1 - 9.1, 51 - 66)
16 - 21 (1.6 - 2.1, 12 - 15)
5 p
üü
: Apply liquid gasket : N·m (kg-m, in-lb)
16 - 21 (1.6 - 2.1, 12 - 15)
üü
: N·m (kg-m, ft-lb) : Do not re-use
41 - 52 (4.2 - 5.3, 30 - 38)
1 p 2 p 3 p 4 p 5 p 6 p
Belt cover upper Water pump pulley Belt cover lower Crankshaft pulley Alternator Alternator bracket
7 p 8 p 9 p 10 p
Exhaust manifold with turbocharger assembly Gasket Intake manifold EGR passage (To install, face EGR gas discharge port upward)
EM-124
11 p 12 p 13 p 14 p 15 p 16 p 17 p
NEM197
EGR valve Air inlet Air inlet hose EGR tube Exhaust manifold cover Blow-by gas control valve Turbocharger oil return hose
CD20T
OUTER COMPONENT PARTS Left side SEC. 140⋅144
2 p
20 - 31 (2.0 - 3.2, 14 - 23) 20 - 31 (2.0 - 3.2, 14 - 23)
12 p
13 p
3 p
4 p
20 - 31 (2.0 - 3.2, 14 - 23)
5.1 - 6.5 (0.52 - 0.66, 45.1 - 57.5)
1 p
6 p
22 - 29 (2.2 - 3.0, 16 - 22) 7 p
5 p
5.1 - 6.5 (0.52 - 0.66, 45.1 - 57.5)
8 p 3 p
p
14 p
3
9 p
13 - 19 (1.3 - 1.9, 9 - 14) .
10 p
7.2 - 9.6 (0.73 - 0.98, 63.7 - 85.0)
10 - 13 (1.0 - 1.3, 7.2 - 9.4)
20 - 31 (2.0 - 3.2, 14 - 23)
15 p
üü
: Apply liquid gasket : N·m (kg-m, in-lb)
22 - 29 (2.2 - 3.0, 16 - 22) üü
: N·m (kg-m, ft-lb) : Do not re-use
15 p
6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5)
11 p
NEM375
1 p 2 p 3 p 4 p 5 p
Turbocharger assembly Exhaust manifold Gasket Air inlet hose Air hose
6 p 7 p 8 p 9 p 10 p
Lock plate Exhaust outlet Exhaust outlet cover Turbocharger oil return pipe Turbocharger oil return hose
EM-125
11 p 12 p 13 p 14 p 15 p
Insulator Turbocharger oil feed tube Turbocharger water feed tube Turbocharger water return tube Bracket
COMPRESSION PRESSURE
CD20T
1. 2.
Warm up engine sufficiently. Remove spill hoses.
3.
Disconnect injection tubes on nozzle side and loosen injection tubes on pump side. Release clamps on injection tubes. Use two wrenches to prevent delivery holder on pump side from loosening.
NEM241
I
SEM501D
4.
Remove all injection nozzles using S.S.T. KV119E0030.
5.
Turn ignition switch off and disconnect harness connector (black colored) at injection pump.
6.
Fit compression gauge to cylinder head.
NEM242
NEM243
SEM505D
EM-126
CD20T
COMPRESSION PRESSURE 7.
8.
Crank engine and read compression gauge indication. Cranking speed: 200 rpm Compression pressure: kPa (bar, kg/cm2, psi) Standard 3,138 (31.4, 32, 455) Limit 2,452 (24.5, 25, 356) Limit of difference between cylinders 490 (4.9, 5, 71) If the pressure appears low, pour about 3 m (0.11 Imp fl oz) of engine oil through nozzle holes and repeat test. For indications of test, refer to the following table.
Gauge indication during tests
Trouble diagnosis
● Piston rings are worn or damaged.
● If two adjacent cylinders are low, gasket is damaged. ● Valve is sticking. ● Valve seat or valve contact surface is incorrect.
EM-127
COMPRESSION PRESSURE
Nozzle side
CD20T
9. Replace nozzle gaskets and re-install injection nozzles. New nozzle gaskets must be installed in the direction shown. Nozzle to cylinder head: : 54 - 64 N·m (5.5 - 6.5 kg-m, 40 - 47 ft-lb)
Combustion chamber side NEM244
10. Install injection tubes using two wrenches as shown. Injection tubes: : 22 - 25 N·m (2.2 - 2.5 kg-m, 16 - 18 ft-lb)
SEM501D
NEM242
11. Install spill hoses. 12. Initialize the ECM. Refer to EC-section (“HOW TO ERASE DTC”).
NEM241
EM-128
OIL PAN
CD20T Removal
Removal 1. 2. 1) I I
Drain oil. Remove oil pan using tool as illustrated. Insert Tool between oil pan and cylinder block. Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating surfaces will be damaged. Do not insert screwdriver, or oil pan flange will be deformed.
SEM230D
2)
Slide Tool by tapping it with a hammer, and remove oil pan.
SEM231D
Installation 1.
Scraper
I
Before installing oil pan, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block.
SEM350B
I Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide. Use Genuine Liquid Gasket or equivalent.
SLC906
2.
Apply liquid gasket to inner sealing surface as shown at left.
SEM909B
EM-129
OIL PAN
CD20T
Installation (Cont’d)
3.
Apply liquid gasket to oil pan front oil seal and rear oil seal.
4.
Apply a continuous bead of liquid gasket to mating surface of oil pan. Attaching should be done within 5 minutes after coating.
SEM894BA
Tube presser
I
SEM351B
5.
Install oil pan and tighten bolts in the order shown in the figure. Wait at least 30 minutes before refilling engine oil. Oil pan bolts: : 6.3 - 8.3 N·m (0.64 - 0.85 kg-m, 55.8 - 73.5 in-lb) Engine front
SEM369D
EM-130
CD20T
TIMING BELT
Camshaft Timing Belt
Camshaft Timing Belt CAUTION: a. Do not bend or twist timing belt. b. After removing timing belt, do not turn crankshaft and camshaft separately because valves will strike piston heads. c. Ensure that timing belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and free from oil and water. SEC. 112⋅120⋅130⋅135 87 - 107 (8.9 - 10.9, 64 - 79)
5.3 - 7.3 (0.54 - 0.74, 46.9 - 64.6)
3-5 (0.3 - 0.5, 27 - 44)
32 - 40 (3.3 - 4.1, 24 - 30)
32 - 40 (3.3 - 4.1, 24 - 30) 43 - 58 (4.4 - 5.9, 32 - 43)
142 - 152 (14.5 - 15.5, 105 - 112) : üDo not re-use Lubricate with new engine oil. N·m (kg-m, in-lb) N·m (kg-m, ft-lb)
6.4 - 8.4 (0.65 - 0.86, 56.6 - 74.3)
3 - 5 (0.3 - 0.5, 27 - 44)
Locking sealant SEM368FA
1 p 2 p 3 p 4 p
Front camshaft sprocket Idler Belt tensioner Crankshaft sprocket
5 p 6 p 7 p
Belt cover lower Belt cover center (Engine mounting bracket) Timing belt
8 p 9 p 10 p
Belt cover upper Gasket Front camshaft sprocket plate
REMOVAL 1. 2. 3.
Drain engine coolant from radiator. Remove upper radiator hose and upper belt cover. Remove water pump pulley.
Upper radiator hose SEM047F
EM-131
TIMING BELT
CD20T
Camshaft Timing Belt (Cont’d)
4.
Set No. 1 cylinder at TDC on its compression stroke. (TDC is indicated by crankshaft pulley notch without painted mark.)
5.
Remove starter motor, and install ring gear stopper using mounting bolt holes. Remove crank pulley bolt. Remove crank pulley using puller. Be sure to securely attach puller jaws. Attach jaws only to the rear side of pulley. Remove lower belt cover.
SEM369F
6. 7.
8.
SEM681D
9. Remove timing belt. (1) Loosen tensioner pulley bolt, turn tensioner pulley counterclockwise then tighten bolt. (2) Remove camshaft sprocket plate.
Tighten Loosen
SEM520D
(3) Remove idler pulley.
SEM515D
(4) Remove timing belt with crankshaft sprocket. CAUTION: Do not allow any magnetic materials to contact crankshaft sprocket. (5) Remove tensioner pulley and return spring.
SMA398A
EM-132
CD20T
TIMING BELT
Inspection
Inspection Timing belt Visually check the condition of timing belt. Replace if any abnormality is found. Item to check
Problem
Cause I Camshaft jamming I Damaged camshaft/crankshaft oil seal
Tooth is broken/tooth root is cracked.
SEM394A
I Tensioner jamming I Overheated engine I Interference with belt cover
Back surface is cracked/ worn.
SEM395A
I Improper installation of belt I Malfunctioning crankshaft pulley plate/timing belt plate
Side surface is worn.
I Belt corners are worn and round. I Wicks are frayed and coming out.
SEM396A
I I I I
Teeth are worn.
Poor belt cover sealing Coolant leakage at water pump Camshaft not functioning properly Excessive belt tension
Rotating direction
I Canvas on tooth face is worn down. I Canvas on tooth is fluffy, rubber layer is worn down and faded white, or weft is worn down and SEM397A invisible. I Poor oil sealing of each oil seal I Coolant leakage at water pump I Poor belt cover sealing
Oil, coolant or water is stuck to belt.
EM-133
TIMING BELT
CD20T
Inspection (Cont’d)
Belt tensioner, tensioner spring and idler 1. 2.
Check belt tensioner and idler for smooth turning. Check condition of tensioner spring.
SEM558
Crankshaft sprocket and front camshaft sprocket Check teeth for abnormal signs.
SEM516D
Installation 1.
Confirm that No. 1 piston is set at TDC on its compression stroke. (TDC is indicated by crankshaft pulley notch without painted mark.)
SEM517D
2. Install tensioner and return spring. Temporarily tighten bolts so that tensioner is set at the fully outside position. 3. Install idler and tighten bolt to the specified torque.
SEM518D Mark
Align
4. a.
43 cogs
b. 5.
Install timing belt with crankshaft sprocket. Align white lines on timing belt with punchmarks on camshaft sprocket and crankshaft sprocket. Point arrow on timing belt toward belt cover. Install camshaft sprocket plate and secure screws with Loctite.
Align
SEM519DA
EM-134
CD20T
TIMING BELT
Installation (Cont’d)
6. 1) 2) Tighten
3)
Loosen
SEM520D
Adjust timing belt tension. Loosen tensioner lock bolt to apply tension to timing belt. Rotate crankshaft clockwise two turns to apply the specified tension to timing belt. Tighten tensioner lock bolt while holding tensioner pulley with hexagon wrench. Belt tension: 147.1 ± 24.5 N (15 ± 2.5 kg, 33.1 ± 5.5 lb)
Injection Pump Timing Belt
SEC. 130⋅135 31 - 37 (3.2 - 3.8, 23 - 27)
3-5 (0.3 - 0.5, 27 - 44)
17 - 21 (1.7 - 2.1, 12 - 15)
87 - 107 (8.9 - 10.9, 64 - 79)
59 - 69 (6.0 - 7.0, 43 - 51) Engine front
N·m (kg-m, in-lb) N·m (kg-m, ft-lb) Lubricate with new engine oil 16 - 21 (1.6 - 2.1, 12 - 15)
SEM349F
1 p 2 p 3 p
Timing belt Tensioner spring Tensioner
4 p 5 p 6 p
Rear camshaft sprocket Injection pump sprocket Vacuum pump
7 p 8 p
Timing belt cover Grommet
REMOVAL 1. 2. 3. 4. 5.
Remove battery from engine room. Remove air cleaner case, air duct and resonator. Disconnect all piping connections from vacuum pump. Remove water pipe mounting bolt under injection pump timing belt cover, then remove water pipe. Remove timing belt cover.
EM-135
TIMING BELT
CD20T
Injection Pump Timing Belt (Cont’d)
6.
Set No. 1 cylinder at TDC on its compression stroke. (TDC is indicated by crankshaft pulley notch without painted mark.)
I
Make sure that alignment marks of rear camshaft sprocket and injection pump sprocket are positioned as shown.
7.
Apply alignment marks on the back of timing belt according to rear camshaft sprocket and injection pump sprocket alignment marks. Also apply a front mark on the back of timing belt.
SEM369F
Alignment mark
Alignment mark SEM350F Front mark Alignment mark
Alignment mark SEM351F
8.
Loosen tensioner mounting nut. Using a screwdriver, turn tensioner in direction of arrow to release belt tension. 9. Remove vacuum pump. 10. Remove timing belt.
Tensioner
.
SEM352F
INSTALLATION 1. I
Confirm that No. 1 piston is set at TDC on its compression stroke. (TDC is indicated by crankshaft pulley notch without painted mark.) If injection pump sprocket was removed, confirm that it is reinstalled as illustrated. Identification of alignment: Use mark “p B ”
SEM370F
EM-136
TIMING BELT
CD20T Injection Pump Timing Belt (Cont’d)
Front mark Alignment mark
2. 1) 2) 3)
Install timing belt. Set timing belt with the front mark facing front of engine. Install vacuum pump. Position timing belt matching the alignment marks with rear camshaft sprocket and injection pump sprocket alignment marks.
3. 1) I
Adjust belt tension. Loosen tensioner lock nut to apply tension to timing belt. Make sure that all sprocket and timing belt alignment marks are positioned as shown.
Alignment mark SEM351F
Alignment mark
Alignment mark SEM350F
2) Rotate crankshaft clockwise by two revolutions. Do not turn crankshaft by camshaft sprockets 3) Tighten tensioner lock nut while holding tensioner with a screwdriver. Belt tension: 98±49 N (10±5 kg, 22±11 lb) 4. Install timing belt cover. 5. Install remaining parts in the reverse order of removal. .
SEM353F
EM-137
OIL SEAL REPLACEMENT
CD20T
VALVE OIL SEAL 1. 2. 3. 4.
Remove both timing belts. Remove camshaft sprockets and back covers. Remove camshaft brackets by loosening bracket nuts from center to outside in two or three stages. Remove camshaft oil seals and camshaft.
SEM888
5. Remove valve lifters and mark order No. on each lifter. 6. Replace valve oil seal according to the following procedure. When replacing valve oil seal, set the corresponding piston at TDC. Failure to do so causes the valve to drop into the cylinder. 1) Set No. 1 cylinder at TDC. 2) Remove valve springs and valve oil seals for No. 1 and No. 4 cylinders. Valve spring seats should not be removed.
KV10107902
NEM200
12.2 ± 0.3 mm (0.480 ± 0.012 in)
3)
4) 5) 6) 7)
Install new valve oil seals for No. 1 and No. 4 cylinders as illustrated. Reinstall valve springs. (Narrow pitch side toward cylinder head) Install valve spring retainers on intake valves and valve rotators on exhaust valves, and remount valve assembly. Set No. 2 cylinder at TDC. Replace valve oil seals for No. 2 and No. 3 cylinders according to steps 2) and 3). Install valve lifters in original positions.
NEM201
CAMSHAFT AND CRANKSHAFT OIL SEAL INSTALLING DIRECTION AND MANNER I I
Engine outside
Engine inside
Oil seal lip
I
When installing camshaft and crankshaft oil seals, be careful to install them correctly, as shown in the figure. Apply engine oil to oil seal lip, outer face, camshaft and bracket. Wipe off excess oil after installing oil seal.
Dust seal lip
SEM715A
CAMSHAFT OIL SEALS 1. 2.
Tape
Remove timing belts, sprockets and back covers. Pull out oil seal with a suitable tool.
.
SEM887
EM-138
OIL SEAL REPLACEMENT
CD20T
3. Install new oil seals with a suitable tool. Confirm turning direction of both oil seals and camshaft.
Rear
Front
SEM240D
CRANKSHAFT FRONT OIL SEAL 1. 2.
Remove valve timing belt and crankshaft sprocket. Remove oil seal with a suitable tool.
3.
Apply engine oil to new oil seal and install oil seal using a suitable tool.
SEM889
SEM241D
CRANKSHAFT REAR OIL SEAL 1. 2. 3.
Remove transaxle assembly. (Refer to “REMOVAL AND INSTALLATION” in MT section.) Remove flywheel. Remove rear oil seal with a suitable tool.
SEM891
1.
Apply engine oil to new oil seal and install oil seal using a suitable tool.
SEM242D
EM-139
CD20T
CYLINDER HEAD Components
Components
SEM356F
1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p
Camshaft Front oil seal Collar Grommet Front back cover Front camshaft sprocket plate Front camshaft sprocket Spring
9 p 10 p 11 p 12 p 13 p 14 p 15 p
Selective cylinder head gasket Valve Spring seat Valve spring Valve oil seal Spring retainer (INT)/Valve rotator (EXH) Valve cotter
EM-140
16 p 17 p 18 p 19 p 20 p 21 p 22 p 23 p
Valve lifter with shim Rear back cover Rear camshaft sprocket Grommet Collar Rocker cover gasket Cam bracket Rear oil seal
CYLINDER HEAD
CD20T Removal
Removal 1. 2. 3. 4. 5.
Drain plug (cylinder block)
SEM373D
Drain coolant and disconnect front exhaust pipe from manifold. Remove water hoses, air duct and intake manifold. Remove heat shield and exhaust manifold. Remove rocker cover and injection tubes. Remove both timing belts. Set No. 1 cylinder at TDC on its compression stroke. Refer to “TIMING BELT” (EM-134). After timing belts have been removed, do not rotate crankshaft and/or camshaft separately as valves will hit piston heads. 6.
Remove cylinder head bolts in numerical order as shown in the figure.
SEM682D
Disassembly 1.
SEM864
Remove front camshaft sprocket plate, front and rear sprockets using special service tool or a suitable tool, and front back cover. 2. Remove camshaft brackets in order from outside to inside. I Loosen camshaft bracket nuts in two or three stages. 3. Remove camshaft and oil seals. 4. Remove valve lifters. For valve lifter I Attach tags to valve lifters for identification. 5. I
Remove valve component parts using special service tool or a suitable tool. Keep each valve and its components together and mark them so they can be reassembled in their original positions.
6.
Remove valve oil seals using special tool.
SEM716B
SEM745BA
EM-141
CYLINDER HEAD
CD20T
Inspection
Inspection CYLINDER HEAD DISTORTION 1. 2.
Warpage of surface: Less than 0.1 mm (0.004 in)
SEM595A
Visually check for cracks and deformation. Check cylinder head for distortion. Head surface flatness: Less than 0.1 mm (0.004 in) If beyond the specified limit, replace or resurface cylinder head. Resurfacing limit: The resurfacing limit of the cylinder head is related to the amount of resurfacing of the cylinder block. When: “A” is the amount of resurfacing needed for the cylinder head and “B” is the amount of resurfacing needed for the cylinder block, the maximum limit is determined by A + B = 0.1 mm (0.004 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, the cylinder head must be replaced. Nominal height of cylinder head: 137.9 - 138.1 mm (5.429 - 5.437 in)
VALVE GUIDE CLEARANCE 1.
Measure deflection across the cylinder head as illustrated. Valve deflection limit (dial gauge reading): 0.1 mm (0.004 in)
2. a)
If exceeding the limit, check valve-to-guide clearance. Measure valve stem diameter and valve guide inner diameter as illustrated. Check that clearance is within the specification. Valve stem to valve guide clearance limit: 0.1 mm (0.004 in) If exceeding the limit, replace valve or valve guide.
SEM870 Micrometer
b)
c) Top Center Bottom Valve guide Valve
SEM244D
VALVE GUIDE REPLACEMENT 1. 2.
Heat cylinder head in oil to 150 to 160°C (302 to 320°F). Drive out valve guide using a press or hammer and a suitable tool.
SEM871
EM-142
CD20T
CYLINDER HEAD
Inspection (Cont’d)
.
3.
Ream cylinder head valve guide bore. Reaming bore (service part): 11.185 - 11.196 mm (0.4404 - 0.4408 in)
4.
Heat cylinder head to 150 to 160°C (302 to 320°F) and press service valve guide onto cylinder head. Ream valve guide. Final size: 7.000 - 7.015 mm (0.2756 - 0.2762 in)
SEM245D
10.3 mm (0.406 in)
5.
SEM246DA
VALVE SEATS 1.
Check valve and valve seat for contact. Coat the valve face with prussian red lead. If contact is wrong, correct valve seat. If the valve red lead appears 360° around face, the valve stem and face are concentric. If not, repair or replace valve.
SEM722BA
2.
Check valve seats for pitting at contact surface. Resurface or replace if excessively worn. Correct valve seat surface. When repairing valve seat, check valve and valve guide for wear beforehand. If worn, replace them. Then correct valve seat.
VALVE SEAT REPLACEMENT 1. Recess diameter
SEM795A
Bore out old seat until it collapses. Set machine depth stop so that boring cannot contact bottom face of seat recess in cylinder head. 2. Ream the cylinder head recess. Reaming bore for service valve seat [Oversize 0.5 mm (0.020 in)]: Intake 41.432 - 41.454 mm (1.6312 - 1.6320 in) Exhaust 35.432 - 35.454 mm (1.3950 - 1.3958 in) Use the valve guide center for reaming to ensure valve seat will have the correct fit.
EM-143
CYLINDER HEAD
CD20T
Inspection (Cont’d)
3.
Heat cylinder head to a temperature of 150 to 160°C (302 to 320°F) and press fit seat until it seats on the bottom. 4. Install valve seats. When replacing valve seat, valve should be replaced as well.
5.
Cut or grind valve seat using a suitable tool at the specified dimensions as shown in SDS (EM-198). The cutting should be done with both hands to obtain a uniform and concentric finish.
SEM876
6.
Apply a small amount of fine grinding compound to the valve’s contacting face and put the valve into its guide. Lap valve against its seat until proper valve seating is obtained.
7.
Check valve seating condition.
SEM877
W: Refer to SDS.
SEM635AA
VALVE DIMENSIONS
T (Margin thickness)
1. 2.
Check dimensions of each valve. For dimensions, refer to SDS (EM-197). Correct or replace any valve that is faulty.
SEM188A
EM-144
CYLINDER HEAD
CD20T Inspection (Cont’d)
3.
Valve face or valve stem end surface should be refaced by using a valve grinder. When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace the valve. Grinding allowance for valve stem tip is 0.5 mm (0.020 in) or less.
EM111
VALVE SPRING SQUARENESS
SEM333
Check valve spring for squareness using a steel square and flat surface plate. If spring is out of square “S” more than specified limit, replace with new one. Out-of-square: Outer Less than 1.8 mm (0.071 in) — Intake — Less than 2.2 mm (0.087 in) — Exhaust — Inner Less than 1.6 mm (0.063 in) — Intake — Less than 1.8 mm (0.071 in) — Exhaust —
VALVE SPRING PRESSURE LOAD Measure the free length and the tension of each spring. If the measured value exceeds the specified limit, replace spring. Refer to SDS (EM-197).
EM113
VALVE LIFTER 1.
Check contact and sliding surfaces for wear or scratches.
SEM723B
EM-145
CYLINDER HEAD
CD20T
Inspection (Cont’d)
2.
Check diameter of valve lifters. Outer diameter: 34.959 - 34.975 mm (1.3763 - 1.3770 in)
3.
Check valve lifter guide bore. Bore diameter 34.998 - 35.018 mm (1.3779 - 1.3787 in) Standard clearance 0.023 - 0.059 mm (0.0009 - 0.0023 in)
SEM724B
SEM725B
COMBUSTION CHAMBER REPLACEMENT
SEM720B
Usually combustion chambers should not be removed. However, if they show cracks or extensive damage, they should be replaced. 1. Remove glow plug connecting plate, glow plugs and injection nozzle. 2. Heat cylinder head in oil to between 150 and 160°C (302 and 320°F). 3. Remove combustion chamber so that cylinder head will not be damaged. Be careful not to scratch inside of nozzle hole.
4. a. b.
.
Install combustion chamber. Heat cylinder head 150 to 160°C (302 to 320°F) in oil. Align combustion chamber knock pin with cylinder head notch, and install it into cylinder head using a plastic-tip hammer.
SEM721B
EM-146
CD20T
CYLINDER HEAD
Inspection (Cont’d)
CAMSHAFT VISUAL CHECK Check camshaft for scratches, seizure and wear.
CAMSHAFT END PLAY 1. 2. 3. SEM726B
Install camshaft in cylinder head. Tighten bracket bolts to the specified torque. Measure camshaft end play. Camshaft end play: Standard 0.115 - 0.188 mm (0.0045 - 0.0074 in)
CAMSHAFT RUNOUT 1.
2.
Measure camshaft runout at the center journal. Runout (Total indicator reading): Limit 0.05 mm (0.0020 in) If it exceeds the limit, replace camshaft.
SEM155
CAMSHAFT CAM HEIGHT 1. Measure camshaft cam height. Cam height: Standard Unit: mm (in)
2. .
Intake
48.70 - 48.75 (1.9173 - 1.9193)
Exhaust
49.15 - 49.20 (1.9350 - 1.9370)
If wear is beyond the limit, replace camshaft.
SEM730B
CAMSHAFT JOURNAL CLEARANCE Using micrometer 1.
Measure the inner diameter of camshaft bearings. Standard inner diameter: 30.000 - 30.021 mm (1.1811 - 1.1819 in) Tighten bracket bolts to the specified torque.
.
SEM727B
2.
Measure the outer diameter of camshaft journals. Standard outer diameter: 29.935 - 29.955 mm (1.1785 - 1.1793 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Standard clearance: 0.045 - 0.086 mm (0.0018 - 0.0034 in) Limit: 0.1 mm (0.004 in)
SEM728B
EM-147
CYLINDER HEAD
CD20T
Inspection (Cont’d)
Using plastigage 1. 2. 3.
Wipe off oil from camshaft journal bracket caps and brackets. Install camshaft in journal bracket caps and put plastigage on each camshaft journal. Install cam bracket caps and tighten cam bracket cap nuts in the correct order to the specified torque. : 18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
SEM879
4.
5. I
Remove cam bracket caps and measure maximum width of plastigage. Camshaft bearing clearance: Limit 0.1 mm (0.004 in) If clearance appears to exceed the limit, replace camshaft or cylinder head. Which parts to be replaced should be decided upon after measuring the diameters of the parts concerned.
SEM880
Valve clearance Checking Check valve clearance while engine is warm and not running. 1. Remove rocker cover. 2. Set No. 1 cylinder at TDC on its compression stroke. I Align pointer with TDC mark on crankshaft pulley. 1 and p 2 are loose and valve I Check that valve lifters No. p lifters No. p 7 and p 8 are tight. SEM369F
If not, turn crankshaft one revolution (360°) and align as described above.
3.
Check valve clearances of valve lifter No. 6 . p
SMA406A
EM-148
1 , p 2 , p 4 p
and
CYLINDER HEAD
CD20T Checking (Cont’d)
I I
Feeler gauge
Using a feeler gauge, measure clearance between valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement adjusting shim. Valve clearance for checking (Hot): Intake 0.25 - 0.35 mm (0.010 - 0.014 in) Exhaust 0.39 - 0.49 mm (0.015 - 0.019 in)
SEM634F
3. 4. I 5. I
Turn crankshaft one revolution (360°) until No. 4 cylinder is at TDC on its compression stroke. Check valve clearances of valve lifter No. p 3 , p 5 , p 7 and 8 . p Use the same procedure as mentioned in step 3. If all valve clearances are within specification, install the following parts: Rocker cover
SMA406A
Adjusting
Face directly upwards.
Adjust valve clearance while engine is cold. 1. Turn crankshaft. Position cam lobe upward on camshaft for valve that must be adjusted.
Notch .
SEM636F
Tool (B) KV10115120
Tool (A) KV10115110
.
SEM637F
2. Place Tool (A) around camshaft as shown in figure. Before placing Tool (A), rotate notch toward center of cylinder head. (See figure.) This will simplify shim removal later. CAUTION: Be careful not to damage cam surface with Tool (A). 3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down. 4. Place Tool (B) between camshaft and valve lifter to retain valve lifter. CAUTION: I Tool (B) must be placed as close to camshaft bracket as possible. I Be careful not to damage cam surface with Tool (B). 5. Remove Tool (A).
EM-149
CD20T
CYLINDER HEAD Adjusting (Cont’d)
6. 7.
Small screwdriver
I I
Magnetic finger SEM638F
Remove adjusting shim using a small screwdriver and a magnetic finger. Determine replacement adjusting shim size using the following formula. Use a micrometer to determine thickness of removed shim. Calculate thickness of new adjusting shim so valve clearance comes within specified values. R = Thickness of removed shim N = Thickness of new shim M = Measured valve clearance S = Standard valve clearance (neutral value for calculation) Unit: mm (in)
HOT COLD
SEM145D
Shim
Intake
0.30 (0.012)
Exhaust Intake Exhaust
0.44 (0.017) 0.25 (0.010) 0.38 (0.015)
Intake: N = R + [M − S] Exhaust: N = R + [M − S] Shims are available in 15 sizes from 2.20 mm (0.0866 in) to 2.90 mm (0.1142 in), in steps of 0.05 mm (0.0020 in). I Select the closest size shim to the calculated thickness. Refer to chart in SDS, EM-198.
Indicate T1 = 2.800 mm (0.1102 in) AEM236
8. I
Install new shim using a suitable tool. Install with the surface on which the thickness is stamped facing down. 9. Place Tool (A) as explained in steps 2 and 3. 10. Remove Tool (B). 11. Remove Tool (A). 12. Recheck valve clearance. Valve clearance: Unit: mm (in)
Intake Exhaust
For adjusting Hot Cold* (reference data) 0.25 - 0.35 0.20 - 0.30 (0.010 - 0.014) (0.008 - 0.012) 0.39 - 0.49 0.33 - 0.43 (0.015 - 0.019) (0.013 - 0.017)
*: At a temperature of approximately 20°C (68°F) Whenever valve clearances are adjusted to cold specifications, check that the clearances satisfy hot specifications and adjust again if necessary.
EM-150
CYLINDER HEAD
CD20T Assembly
Assembly Painted side Cylinder head side
Narrow pitch
Wide pitch
SEM202
1. Install valve component parts. Install valve spring with its narrow pitch side toward cylinder head side. I Always install new valve oil seals. Refer to oil seal replacement. I Before installing oil seal, install valve-spring seat. I When installing valve, apply engine oil on the valve stem and lip of valve oil seal. I Check whether the valve face is free from foreign matter. I I I I
Install valve spring retainers on the intake side and valve rotators on the exhaust side. Valve rotators cannot be disassembled. Install valve shims Adjust valve clearance
SEM731BA
2. Grade number Tightening sequence
I I I I
Facing front of engine (position 2) SEM528D
17.5 (0.689)
Install camshaft and brackets and tighten bracket nuts to the specified torque in two or three stages. Camshaft-bracket nuts: : 18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb) Tighten bracket from center to outside. Apply sealant to brackets No. 1 and No. 5. When installing brackets, set camshaft so that the pin of camshaft front head is uppermost. Install new camshaft oil seals. Refer to oil seal replacement.
13.0 (0.512)
No. 1 journal bracket No. 5 journal bracket Unit: mm (in) SEM676D
Installation Cylinder head bolt Cylinder head
1. I I I
Washer SEM675D
2.
Install cylinder head gasket. When replacing only cylinder head gasket, install same grade gasket as the one formerly used. When replacing or repairing cylinder block, piston, connecting rod and crankshaft, select gasket referring to “Selecting cylinder head gasket”. Pay attention to the direction of the cylinder head bolt washer as shown in the figure. Install cylinder head and tighten cylinder head bolts according to the following sequence.
EM-151
CYLINDER HEAD
CD20T
Installation (Cont’d)
CAUTION: The cylinder head bolts can be reused providing dimension “A” is not exceeded. Dimension “A”: 118.7 mm (4.6732 in)
Cylinder head bolt 12 mm
“A”
NEM328
EM-152
CD20T
CYLINDER HEAD
Installation (Cont’d)
Tightening procedure
Engine front
I
SEM672D
Apply engine oil to threads and underhead seating face of each bolt. Tighten bolts in the numerical order shown in the figure and following the steps below. a 31 - 37 N·m (3.2 - 3.8 kg-m, 23 - 27 ft-lb) p b p Tighten to 180 - 190° c Completely loosen the bolts in reverse order p d p 31 - 37 N·m (3.2 - 3.8 kg-m, 23 - 27 ft-lb) e Tighten to 90 - 95° p f Tighten to 90 - 95° p
SEM848F
Marking
NEM211
3. I
Install rocker cover. Install rocker cover in the sequence shown at left.
I
Apply sealing compound (THREE-BOND No. 10 or equivalent) to both ends of brackets No. 1 and No. 5.
SEM678D
Apply sealant.
SEM677D
EM-153
CD20T
CYLINDER HEAD Installation (Cont’d)
Selecting cylinder head gasket
SEM593A
When replacing only cylinder head gasket, install the same grade (Number of notches) gasket as the one formerly used. Step 1 Measure projection of piston to cylinder head surface. a) Set dial gauge and needle on cylinder block and adjust dial gauge to zero. b) Set dial gauge needle at measuring point on piston, taking care not to disturb its zero setting. c) Rotate crankshaft around the top dead center position. d) e)
25 25 (0.98) (0.98)
30 30 (1.18) (1.18)
Unit: mm (in) SEM529D
Record the maximum value. Reset dial gauge on cylinder block and confirm that zero setting has not been disturbed during measurement. f) Repeat steps b through d for all measuring points as illustrated and for each cylinder. I Be sure that piston whose projection is being measured is at its TDC. Step 2 Calculate the average value of measurements taken for each piston. Step 3 Calculate the average value of measurements for all pistons from the values obtained from step 2. Step 4 Round off the value obtained. Step 5 Determine required thickness of gasket, referring to chart A.
Relation between piston average projection and cylinder head gasket (Chart A)
Notch
Average value of piston projections mm (in)
SEM530D
Gasket thickness mm (in)
Grade (Number of notches)
New parts
In assembly
Less than 0.505 (0.0199)
1.30 (0.0512)
1.15±0.05 (0.0453±0.0020)
1
0.505 - 0.555 (0.0199 - 0.0219)
1.35 (0.0531)
1.20±0.05 (0.0472±0.0020)
2
Over 0.555 (0.0219)
1.40 (0.0551)
1.25±0.05 (0.0492±0.0020)
3
Step 6 Check if the average value of each projection obtained from step 2 is larger than the max. value of the standard projection (of selected gasket) incremented by 0.05 mm (0.0020 in). If so, use gasket that is 1 grade thicker. If not, use gasket as selected in step 4.
EM-154
CD20T
CYLINDER HEAD
Installation (Cont’d)
Example Unit: mm (in) Cylinder No. Step Item 1.
Measured value
2.
Average value of each piston
3.
Average value of all pistons
4.
Round off value
5.
Determined gasket thickness (Temporarily)
1 M1
M2
2 M3
M4
M1
M2
3 M3
M4
M1
M2
4 M3
M4
M1
M2
M3
M4
0.53 0.56 0.53 0.56 0.59 0.55 0.59 0.55 0.53 0.58 0.57 0.54 0.58 0.51 0.52 0.57 (0.0209) (0.0220) (0.0209) (0.0220) (0.0232) (0.0217) (0.0232) (0.0217) (0.0209) (0.0228) (0.0224) (0.0213) (0.0228) (0.0201) (0.0205) (0.0224) 0.545 (0.0215)
0.570 (0.0224)
0.555 (0.0219)
0.545 (0.0215)
0.55375 (0.02180) 0.554 (0.0218)*1
1.20 (0.0472) (Grade 2)
X: Maximum value of standard projection of selected gasket . . . 0.555 (0.0219) (in chart A) + 0.05 (0.0020) = 0.605 (0.0238) 6. Y: Maximum value in step 2 = 0.57 (0.0224) The relationship between X and Y is “X > Y”. *2 Determined 7. gasket thickness (Finally)
1.20 (0.0472) (Grade 2)*2
*1: If the average value of projections for all pistons is, for example, 0.553 (7) 5, as shown in the table above, it should be rounded off as follows: If the digit in the fourth decimal place (which is enclosed by a circle in this case) is smaller than 5, the average value should be regarded as 0.553 mm (0.0218 in); if it is larger than 5, the average value should be regarded as 0.554 mm (0.0218 in). *2: If X < Y, then the thicker grade 3 gasket must be used.
EM-155
TURBOCHARGER
CD20T
Removal
Removal
.
.
.
Turbocharger water return tube
1. 2. 3. 4. 5.
Disconnect radiator lower hose and drain coolant. Drain coolant from cylinder block. Remove engine under cover. Remove front exhaust tube. Remove air inlet hose from turbocharger unit.
6.
Remove connector bolts of turbocharger oil feed tube and hoses for turbocharger water feed and return tubes.
7. 8. 9.
Remove EGR tube. Remove exhaust manifold cover. Remove insulator.
Turbocharger water feed tube
Turbocharger oil feed tube
NEM204
EGR tube Air inlet hose
Exhaust manifold cover
Insulator
NEM202
10. Remove turbocharger oil return hose from oil pan. .
Turbocharger oil return hose
.
Oil pan .
NEM203
11. Remove exhaust manifold fixing nuts and bolts.
3 p
1 p
4 p
2 p
Loosen in numerical order NEM205
EM-156
CD20T
TURBOCHARGER
Removal (Cont’d)
12. Remove exhaust manifold with turbocharger unit.
Exhaust manifold
Turbocharger NEM206
Disassembly
Turbocharger water feed tube
1.
Remove oil tubes and water tubes. Before removing tubes, put mating marks on tube connectors and turbocharger.
2.
Unbend locking plates for turbocharger unit fastening nuts.
3.
Remove exhaust outlet cover, exhaust outlet, and heat insulator brackets.
4.
Remove exhaust manifold from turbocharger unit.
Turbocharger water return tube Turbocharger oil feed tube
Turbocharger oil return tube NEM207
Exhaust manifold side
Turbocharger side SEM367F
SEM026F
NEM208
EM-157
CD20T
TURBOCHARGER Inspection
Inspection Perform the following checks. If NG, replace turbocharger unit.
Check for cracks Actuator rod
Wastegate valve actuator
Compressor wheel Wastegate valve Compressor housing
Center housing
Check for leaks Check for leaks Turbine wheel Check for leaks
Turbine housing SEM366F
OIL AND WATER TUBES Check tubes for clogging.
SEM029F
ROTOR SHAFT 1.
Check rotor shaft for smooth rotation.
SEM030F
EM-158
CD20T
TURBOCHARGER
Inspection (Cont’d)
2.
Check rotor shaft for carbon deposits.
3.
Measure rotor shaft runout. Runout (Total indicator reading): Standard 0.056 - 0.127 mm (0.0022 - 0.0050 in)
4.
Measure rotor shaft end play. End play: Standard 0.013 - 0.097 mm (0.0005 - 0.0038 in) Do not allow wheels to turn when axial play is being measured.
Rotor shaft
.
SEM031F
SEM032F
I
SEM827D
TURBINE WHEEL Check turbine wheel for the following: I Oil I Carbon deposits I Deformed fins I Contact with turbine housing
SEM828D
COMPRESSOR WHEEL Check compressor wheel for the following: I Oil I Deformed fins I Contact with compressor housing
SEM829D
EM-159
TURBOCHARGER
CD20T
Inspection (Cont’d)
WASTEGATE VALVE Remove rod pin and check wastegate valve for cracks, deformation and smooth movement. Check valve seat surface for smoothness.
SEM830D
WASTEGATE VALVE ACTUATOR Apply compressed air to wastegate valve actuator and check it for smooth movement. I Do not apply compressed air to the actuator continuously. I The air pressure should be in the range of 73.3 to 101.3 kPa (733 to 1,013 mbar, 550 to 760 mmHg, 21.65 to 29.92 inHg).
SEM831D
Assembly
Small hanging flap
Assembly is the reverse order of disassembly. I Install gasket between exhaust manifold and turbocharger with small hanging flap side facing exhaust manifold.
NEM228
I Exhaust manifold side
Bend locking plates along the side of turbocharger fastening nuts. Always use new locking plates.
Turbocharger side SEM367F
Installation 1. 2 p
4 p
Install exhaust manifold fixing nuts.
1 p
3 p
Tighten in numerical order NEM209
EM-160
TURBOCHARGER
CD20T Installation (Cont’d)
2. I
Turbocharger water feed tube
Turbocharger water return tube
Installation is the reverse order of removal. Install oil tubes and water tubes in the following order, aligning the mating marks. a. Oil feed tube b. Water return tube c. Water feed tube d. Oil return tube
Turbocharger oil feed tube
Turbocharger oil return tube NEM207
EM-161
CD20T
ENGINE REMOVAL 43 - 55 (4.4 - 5.6, 32 - 41)
SEC. 112
43 - 55 (4.4 - 5.6, 32 - 41)
Rear engine mounting
64 - 74 (6.5 - 7.5, 47 - 54)
64 - 74 (6.5 - 7.5, 47 - 54)
49 - 59 (5.0 - 6.0, 36 - 44)
43 - 55 (4.4 - 5.6, 32 - 41)
62 - 78 (6.3 - 8.0, 46 - 58) Front mounting bracket
49 - 59 (5.0 - 6.0, 36 - 44)
Insulator
77 - 98 (7.9 - 100, 57 - 72)
49 - 59 (5.0 - 6.0, 36 - 44)
77 - 98 (7.9 - 100, 57 - 72)
43 - 55 (4.4 - 5.6, 32 - 41)
: N·m (kg-m, ft-lb) NEM226
EM-162
ENGINE REMOVAL
CD20T
WARNING: I Situate vehicle on a flat and solid surface. I Place chocks at front and back of rear wheels. I Do not remove engine until exhaust system has completely cooled down. I For safety during subsequent steps, the tension of wires should be slackened against the engine. I Before removing front axle from transaxle, place safety stands under designated front supporting points. Refer to GI section for lifting points and towing. I Be sure to hoist engine and transaxle in a safe manner. I For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG or Eurofast. CAUTION: I When lifting engine, be careful not to strike adjacent parts, especially accelerator wire casing, brake lines, and brake master cylinder. I Always use engine slingers when hoisting the engine. I When removing drive shaft, be careful not to damage transaxle oil seal. 1. 2. 3. 4. 5. 6. 7.
.
SEM531D
8. 9.
10. 11. 12. 13. 14.
Remove engine undercovers and splash covers. Remove front exhaust tube. Disconnect lower water hose from radiator and drain coolant. Drain transaxle oil. Remove power steering mounting bolt. (See left.) Drain coolant from cylinder head. Disconnect water hoses and electrical wiring from radiator and remove radiator. Disconnect fuel tubes and vacuum tubes. Release power steering belt adjusting nut and remove power steering pump from engine. Bind pump properly to the vehicle. Remove A/C compressor. Disconnect or remove electrical wiring where necessary. Release clutch lever cable. Release tachometer cable from transaxle housing. Remove front wheels.
15. Remove brake caliper mounting bolts and bind caliper properly to vehicle LH & RH.
SEM532D
EM-163
ENGINE REMOVAL 16. 17. 18. 1) 2)
CD20T
Disconnect tie rod ball joints and lower ball joints (LH & RH). Remove stabilizer. Remove drive shafts from transaxle. RH: Split drive shaft center thrust bearing. RH & LH: Remove hub mounting bolts and remove drive shaft carefully from transaxle.
19. Mount suitable slingers to cylinder head. Use a suitable hoist to release the force on the engine mountings.
SEM534D
20. Remove upper mounting (Right side).
SEM535D
21. Release transaxle shift linkages.
SEM536D
22. Release left engine mounting.
EM-164
ENGINE REMOVAL 23. Remove center member fixing bolts from chassis.
SEM538D
24. Remove engine with transaxle as shown.
.
SEM247D
EM-165
CD20T
CD20T
CYLINDER BLOCK Components
Components SEC. 110⋅120 30 - 40 (3.1 - 4.1, 266 - 354)
16 - 21 (1.6 - 2.1, 12 - 15) 30 - 40 (3.1 - 4.1, 22 - 30) 54 - 74 (5.5 - 7.5, 40 - 54)
83 - 93 (8.5 - 9.5, 61 - 69)
30 - 40 (3.1 - 4.1, 22 - 30)
8.4 - 11.0 (0.86 - 1.12, 74.35 - 97.36)
30 - 40 (3.1 - 4.1, 22 - 30)
16 - 21 (1.6 - 2.1, 12 - 15)
69 - 78 (7.0 - 8.0, 51 - 58)
: Do not re-use. : N·m (kg-m, in-lb) üü
: N·m (kg-m, ft-lb)
ü
: Lubricate with new engine oil.
1 p 2 p 3 p 4 p 5 p 6 p 7 p
Piston ring Piston Piston pin Connecting rod bearing Connecting rod Main bearing cap Rear plate
Refer to “Assembly” NEM376 8 p 9 p 10 p 11 p 12 p 13 p 14 p
Flywheel Rear oil seal Rear oil seal retainer Gusset Cylinder block Main bearing Crankshaft
EM-166
15 p 16 p 17 p 18 p 19 p 20 p
Main bearing Gusset Drain plug Pilot bushing Plate Oil jet
CD20T
CYLINDER BLOCK
Preparation
Preparation I
Drill a hole into the attachment (KV10108101).
SEM707D
Disassembly PISTON AND CRANKSHAFT
SEM895
Piston with connecting rod
Heater
Place engine on a work stand. Drain coolant and oil. Remove timing belt. Remove water pump. Remove oil pan and oil pump. Remove cylinder head. Remove pistons with connecting rods.
When disassembling piston and connecting rod, heat piston to 60 to 70°C (140 to 158°F) or use piston pin press stand at room temperature.
SEM360D
8. Remove main bearing cap and crankshaft. Place the bearings and caps in their proper order. Upper bearings (cylinder block side) have oil groove.
Engine front
Loosen in numerical order
1. 2. 3. 4. 5. 6. 7.
SEM359F
9.
Remove piston rings with a tool.
SEM291
EM-167
CD20T
CYLINDER BLOCK Inspection
Inspection PISTON AND PISTON PIN CLEARANCE 1.
Measure outer diameter of piston pin and inner diameter of piston pin hole. 2. Calculate piston to piston pin clearance. Pin diameter: 27.994 - 28.000 mm (1.1021 - 1.1024 in) Pin hole diameter: 27.991 - 27.999 mm (1.1020 - 1.1023 in) Clearance: −0.004 to 0 mm (−0.0002 to 0 in) (Interference fit) Service parts are available as a set of piston and piston pin.
PISTON RING SIDE CLEARANCE NG
Side clearance: Unit: mm (in)
Feeler gauge OK
Feeler gauge Ring
Standard
Limit
Top ring
0.020 - 0.040 (0.0008 - 0.0016)
0.10 (0.0039)
2nd ring
0.050 - 0.085 (0.0020 - 0.0033)
0.10 (0.0039)
Oil ring
0.030 - 0.070 (0.0012 - 0.0028)
0.10 (0.0039)
SEM024AA
If out of specification, replace piston and/or piston ring assembly.
EM-168
CD20T
CYLINDER BLOCK
Inspection (Cont’d)
PISTON RING END GAP
Piston Press-fit
End gap: Feeler gauge
Unit: mm (in)
Ring
Ring
SEM599A
Standard
Limit
Top ring
Bore grade 1, 2, 3 0.22 - 0.32 (0.0087 - 0.0126) Bore grade 4, 5 0.12 - 0.22 (0.0047 - 0.0087)
1.0 (0.039)
2nd ring
0.38 - 0.53 (0.0150 - 0.0209)
0.7 (0.028)
Oil ring
0.30 - 0.55 (0.0118 - 0.0217)
0.6 (0.024)
I
If out of specification, replace piston ring. If gap exceeds maximum limit with new ring, rebore cylinder and use oversize piston and piston rings. Refer to SDS (EM-199). I When replacing the piston, check the cylinder block surface for scratches or evidence of seizure. If scratches or evidence of seizure is found, hone or replace the cylinder block.
MAIN BEARING CLEARANCE 1. Install main bearings to cylinder block and main bearing cap. 2. Install main bearing cap with bearing to cylinder block. Tighten all bolts in two or three stages. : 69 - 78 N·m (7.0 - 8.0 kg-m, 51 - 58 ft-lb) 3. Measure inside diameter “A” of main journal.
SEM360F
4.
5.
I
Measure outside diameter “Dm” of main journal of crankshaft. Journal diameter: Refer to SDS (EM-199). Calculate main bearing clearance. Main bearing clearance = A − Dm Standard: 0.039 - 0.065 mm (0.0015 - 0.0026 in) If it exceeds the limit, replace the bearing.
SEM506A
EM-169
CD20T
CYLINDER BLOCK Inspection (Cont’d)
I I
Counter weight
I
Main journal
.
Maintain more than 0.13 mm (0.0051 in)
If crankshaft main journal is worn or shows any abnormality, regrind crank journal and use undersized bearings to maintain the specified oil clearance. Refer to SDS for regrinding crankshaft journal diameter and available service parts (EM-200). When regrinding crankshaft journal, do not grind fillet-roll.
SEM566B
I
If either bearing, crankshaft or cylinder block is replaced with a new one, select main bearing according to the following table. These numbers are punched in either Arabic or Roman numerals.
Crankshaft main journal grade number
0 1 2
Main bearing housing grade number 0 1 2 Main bearing grade number 0 1 2 1 2 3 2 3 4
Identification color: Grade 0
Yellow
Grade 1
Green
Grade 2
Brown
Grade 3
Black
Grade 4
Blue
SEM706DA
For example: Main journal grade number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 + 2 = 3 Main bearing thickness: Refer to SDS (EM-200).
SEM706A
CONNECTING ROD BEARING CLEARANCE (Big end) 1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap with bearing to connecting rod. Apply oil to the threaded portion of bolts and seating surface of nuts. : 37 - 45 N·m (3.8 - 4.6 kg-m, 27 - 33 ft-lb) 3. Measure inside diameter “C” of bearing.
Inside micrometer
AEM027
EM-170
CD20T
CYLINDER BLOCK
Inspection (Cont’d)
4. 5. Counter weight
Pin journal
.
Maintain more than 0.13 mm (0.051 in) SEM361D
I I I I
Measure outside diameter “Dp” of crankshaft pin journal. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C − Dp Standard: 0.031 - 0.055 mm (0.0012 - 0.0022 in) If it exceeds the limit, replace the bearing. If crankshaft pin journal is worn or shows any abnormality, regrind crank pin and use undersized bearings to maintain the specified oil clearance. Refer to SDS for regrinding diameter of crankshaft pin and available service parts (EM-200). When regrinding crankshaft pin, do not grind fillet-roll.
Selective connecting rod bearing I If either bearings or crankshaft are being replaced with new ones, select connecting rod bearings according to the following table. Grade numbers are punched in either Arabic or Roman numerals. Crankshaft pin journal grade number
Connecting rod bearing grade number
SEM705D
0
1
2
0
1
2
Identification color Grade 0: Black Grade 1: Yellow Grade 2: Blue
CONNECTING ROD AND PISTON PIN CLEARANCE (Small end) I
Clearance (D − d): 0.025 - 0.044 mm (0.0010 - 0.0017 in) If clearance exceeds the specifications, replace the bearing.
Clearance = D − d SEM575B
EM-171
CYLINDER BLOCK
CD20T
Inspection (Cont’d)
Bearing replacement I Remove bearing with a suitable tool. Do not scratch inner surface of connecting rod.
SEM906
1. 2.
Install new bearing with oil holes aligned correctly. Ream bore using a suitable tool. Ream bore: 28.025 - 28.038 mm (1.1033 - 1.1039 in)
SEM907
CONNECTING ROD BEND AND TORSION Bend and torsion [per 100 mm (3.94 in) length]: Bend Less than 0.025 mm (0.0010 in) Torsion Less than 0.025 mm (0.0010 in)
EM133
CRANKSHAFT 1. 2.
Taper:
Check crankshaft journals and pins for score, bias, wear or cracks. If faults are minor, correct with fine emery paper. Check journals and pins with a micrometer for taper and outof-round. Out-of-round (X − Y): Less than 0.005 mm (0.0002 in) Taper (A − B): Less than 0.005 mm (0.0002 in)
Out-of-round: SEM316A
3.
.
Check crankshaft runout. Runout (Total indicator reading): Less than 0.05 mm (0.0020 in)
SEM601A
EM-172
CD20T
CYLINDER BLOCK
Inspection (Cont’d)
CYLINDER BLOCK DISTORTION Clean upper face of cylinder block and measure the distortion. Limit: 0.10 mm (0.0039 in) If out of specification, resurface it. The resurfacing limit of cylinder block is determined by cylinder head resurfacing in an engine.
Measuring points
Warpage of surface: Less than 0.1 mm (0.004 in)
SEM655A
H = 227.75-227.85 mm (8.9665-8.9705 in)
Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.1 mm (0.004 in) Nominal cylinder block height from crankshaft center: 227.75 - 227.85 mm (8.9665 - 8.9705 in) If necessary, replace cylinder block.
NEM210
CYLINDER BORE 1. 2.
Check for scratches or seizure. If seizure is found, hone bore. Using a bore gauge, measure cylinder bore for wear, out-ofround or taper. Standard bore diameter: 84.500 - 84.550 mm (3.3268 - 3.3287 in) Unit: mm (in)
Bore wear limit
0.2 (0.008)
Out-of-round (X − Y) standard
0.015 (0.0006)
Taper (A − B) standard
0.010 (0.0004)
If it exceeds the limit, rebore all four cylinders. Replace cylinder block if necessary. If cylinder block or piston is replaced, match piston grade with grade number on cylinder block upper surface.
SEM704DA
EM-173
CYLINDER BLOCK
CD20T
Inspection (Cont’d)
Piston grade number
Front SEM176B
Reboring 1.
SEM904-A
The size to which cylinders must be honed, is determined by adding piston-to-cylinder clearance to the piston skirt diameter “A”. Dimension “a”: Approximately 62 mm (2.44 in) Rebored size calculation D = A + B − C = A + [0.03 to 0.05 mm (0.0012 to 0.0020 in)] where, D: Honed diameter A: Skirt diameter as measured B: Piston-to-wall clearance C: Machining allowance 0.02 mm (0.0008 in) 2. Install main bearing caps and tighten bolts to the specified torque. This will prevent distortion of cylinder bores. 3. Cut cylinder bores in the order of 2-4-1-3. Do not cut too much out of the cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. 4. Hone the cylinders to the required size referring to SDS (EM199). 5. Measure the finished cylinder bore for out-of-round and taper. Measurement of a just machined cylinder bore requires utmost care since it is expanded by cutting heat.
PISTON-TO-BORE CLEARANCE Using micrometer 1.
2.
Measure piston and cylinder bore diameter. Piston diameter “A”: Refer to SDS (EM-199). Measuring point “a” (Distance from the bottom): Approximately 62 mm (2.44 in) Bore diameter “D”: Refer to SDS (EM-199). Measuring point (Distance from the top): Approximately 70 mm (2.76 in) Check that piston clearance is within the specification. Piston clearance (D − A): 0.030 - 0.050 mm (0.0012 - 0.0020 in)
EM-174
CD20T
CYLINDER BLOCK
Inspection (Cont’d)
Using feeler gauge 1. 2.
Set piston and feeler gauge with spring scale. Measure extracting force while pulling up scale slowly. Feeler gauge used: 0.05 - 0.07 mm (0.0020 - 0.0028 in) Extracting force: 7.8 - 14.7 N (0.8 - 1.5 kg, 1.8 - 3.3 lb)
SEM550
Assembly PISTON I
Numbers stamped on connecting rod and cap correspond to each cylinder. Care should be taken to avoid a wrong combination including bearing and connecting rod direction.
I I
Install new snap ring on one side of piston pin hole. When assembling piston and connecting rod with piston pin, heat piston to between 60 and 80°C (140 and 176°F) and install piston pin with a suitable tool. Install new snap ring. After assembling, ascertain that piston swings smoothly.
SEM703D
I I
EM156
Punch mark side up
I Install piston rings with a suitable tool. Selective top ring; When installing new top ring or replacing cylinder block, select top ring to adjust ring gap.
Teflon tube set position
Cylinder bore grade
Top ring grade No.
1, 2, 3
4, 5
No mark
S
SEM251D
CRANKSHAFT 1. I I I Front
Set main bearings in the proper position on cylinder block and main bearing caps. If either crankshaft, cylinder block or main bearing is reused again, it is necessary to measure main bearing clearance. Upper bearings (cylinder block side) have oil groove. Apply new engine oil to bearing surfaces.
SEM617
EM-175
CYLINDER BLOCK
CD20T
Assembly (Cont’d) Bearing No.
2. 3. 4. I I
Engine front NEM377
I I
Engine front
Tighten in numerical order.
Apply engine oil to main bearing surfaces on crankshaft journal side. Install crankshaft and main bearing caps. Tighten main bearing cap bolts. : 69 - 78 N·m (7.0 - 8.0 kg-m, 51 - 58 ft-lb) Arrange the parts so that the indicated numbers on bearing caps are in a row from the front of engine. Tighten bearing cap bolts gradually in two or three stages and outwardly from center bearing in sequence. After securing bearing cap bolts, ascertain that crankshaft turns smoothly. Apply new engine oil to threads of bearing cap bolts.
SEM362F
5. Feeler gauge
Measure crankshaft free end play at center bearing. Crankshaft free end play: Standard 0.05 - 0.18 mm (0.0020 - 0.0071 in) Limit 0.30 mm (0.0118 in)
SEM363F
PISTON WITH CONNECTING ROD
Align oil hole.
1.
Install connecting rod bearings in the connecting rods and connecting rod caps. I Confirm that correct size of bearings is used. Refer to “Inspection” (EM-170). I Install the bearings so that the oil hole in the connecting rod aligns with the oil hole of the bearing. I Apply engine oil to connecting rod bearing surfaces on the crankshaft journal side. SEM159B
I
Set piston rings as shown.
SEM909
EM-176
CD20T
CYLINDER BLOCK
Assembly (Cont’d)
2. I I
EM03470000 or suitable tool
I I
Install pistons with connecting rods. Install them into corresponding cylinder using Tool. Be careful not to scratch cylinder wall with connecting rod. Apply engine oil to cylinder wall, piston and bearing. Arrange so that the front mark on piston head faces to the front of engine.
SEM620-A
3. I
KV10112100
SEM364F
Install connecting rod bearing caps. Apply engine oil to the thread of connecting rod bearing nut. (1) Tighten connecting rod bearing nut to 15±1 N·m (1.5±0.1 kg-m, 10.8±0.7 ft-lb). (2) Then tighten an additional 60+5° −0° turns with an angular tightening wrench. : 15±1 N·m (1.5±0.1 kg-m, 11±0.7 ft-lb) plus 60+5° −0° or : 37 - 45 N·m (3.8 - 4.6 kg-m, 27 - 33 ft-lb) 4.
Feeler gauge
Measure connecting rod side clearance. Connecting rod side clearance (Big end play): Limit 0.3 mm (0.012 in)
SEM365F
FLYWHEEL RUNOUT Runout (Total indicator reading): Less than 0.15 mm (0.0059 in)
EM426
EM-177
QG
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications
General Specifications Engine
NCEM0028
QG16DE
QG18DE
Classification
Gasoline
Cylinder arrangement
4, in-line
Displacement cm3 (cu in)
1,596 (97.39)
1,769 (107.94)
Bore × stroke mm (in)
76.0 × 88.0 (2.992 × 3.465)
80.0 × 88.0 (3.150 × 3.465)
Valve arrangement
DOHC
Firing order
1-3-4-2 Compression
2
Oil
1
Number of piston rings Number of main bearings
5
Compression ratio
9.5
EM120
a
b
c
d
e
f
QG16DE
222°
228°
-4° (16°)
52° (32°)
−2°
44°
QG18DE
222°
236°
0° (20°)
56° (36°)
−2°
44°
Valve timing
(
): Valve timing control ON
Compression Pressure
NJEM0029
Unit: kPa (bar, kg/cm2, psi)/350 rpm Standard
1,324 (13.24, 13.5, 192)
Minimum
1,128 (11.28, 11.5, 164)
Difference limit between cylinders
98 (0.98, 1.0, 14)
Cylinder Head
NCEM0030
Unit: mm (in)
Head surface flatness Height
Standard
Limit
Less than 0.03 (0.0012)
0.1 (0.004)
117.8 - 118.0 (4.638 - 4.646)
—
EM-178
QG
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve
Valve
NCEM0031
VALVE
NCEM0031S01
Unit: mm (in) T (Margin thickness)
SEM188A
Intake
29.9 - 30.2 (1.177 - 1.189)
Exhaust
24.9 - 25.2 (0.980 - 0.992)
Valve head diameter “D” Intake
92.00 - 92.50 (3.6220 - 3.6417)
Exhaust
92.37 - 92.87 (3.6366 - 3.6563)
Intake
5.465 - 5.480 (0.2152 - 0.2157)
Exhaust
5.445 - 5.460 (0.2144 - 0.2150)
Valve length “L”
Valve stem diameter “d” Valve face angle “α”
45°15′ - 45°45′
Valve margin “T” limit
More than 0.5 (0.020)
Valve stem end surface grinding limit
0.2 (0.008)
VALVE SPRING
NCEM0031S02
Free height mm (in)
40.0 (1.575) Standard
370.0 (37.73, 83.19) at 23.64 (0.9307)
Limit
347.8 (35.46, 78.19) at 23.64 (0.9307)
Pressure N (kg, lb) at height mm (in) Out-of-square mm (in)
Less than 1.75 (0.0689)
VALVE LIFTER
NCEM0031S10
Unit: mm (in) Valve lifter outside diameter
29.960 - 29.975 (1.1795 - 1.1801)
Lifter guide inside diameter
30.000 - 30.021 (1.1811 - 1.1819)
Clearance between valve lifter and valve lifter guide
0.025 - 0.061 (0.0010 - 0.0024)
VALVE CLEARANCE
NCEM0031S11
Unit: mm (in) For adjusting
For checking
Hot
Cold* (reference data)
Hot
Intake
0.32 - 0.40 (0.013 - 0.016)
0.25 - 0.33 (0.010 - 0.013)
0.21 - 0.49 (0.008 - 0.019)
Exhaust
0.37 - 0.45 (0.015 - 0.018)
0.32 - 0.40 (0.013 - 0.016)
0.30 - 0.58 (0.012 - 0.023)
*: At a temperature of approximately 20°C (68°F) Whenever valve clearances are adjusted to cold specifications, check that the clearances satisfy hot specifications and adjust again if necessary.
EM-179
QG
SERVICE DATA AND SPECIFICATIONS (SDS) Valve (Cont’d)
VALVE GUIDE
NCEM0031S04
Unit: mm (in)
MEM096A
Intake
Outer diameter
Exhaust
Standard
Service
Standard
Service
9.523 - 9.534 (0.3749 - 0.3754)
9.723 - 9.734 (0.3828 - 0.3832)
9.523 - 9.534 (0.3749 - 0.3754)
9.723 - 9.734 (0.3828 - 0.3832)
Valve guide Inner diameter [Finished size]
5.500 - 5.515 (0.2165 - 0.2171)
5.500 - 5.515 (0.2165 - 0.2171)
Cylinder head valve guide hole diameter
9.475 - 9.496 (0.3730 - 0.3739)
Interference fit of valve guide
0.027 - 0.059 (0.0011 - 0.027 - 0.049 (0.0011 - 0.027 - 0.059 (0.0011 - 0.027 - 0.049 (0.0011 0.0023) 0.0019) 0.0023) 0.0019)
Stem to guide clearance
9.685 - 9.696 (0.3813 - 0.3817)
9.475 - 9.496 (0.3730 - 0.3739)
0.020 - 0.050 (0.0008 - 0.0020)
Valve deflection limit (Dial gauge reading)
9.685 - 9.696 (0.3813 - 0.3817)
0.040 - 0.070 (0.0016 - 0.0028) 0.2 (0.008)
Projection length “L”
11.5 - 11.7 (0.453 - 0.461)
AVAILABLE SHIMS
NCEM0031S07
Thickness mm (in)
Identification mark
2.00 (0.0787)
2.00
2.02 (0.0795)
2.02
2.04 (0.0803)
2.04
2.06 (0.0811)
2.06
2.08 (0.0819)
2.08
2.10 (0.0827)
2.10
2.12 (0.0835)
2.12
2.14 (0.0843)
2.14
2.16 (0.0850)
2.16
2.18 (0.0858)
2.18
2.20 (0.0866)
2.20
2.22 (0.0874)
2.22
2.24 (0.0882)
2.24
2.26 (0.0890)
2.26
2.28 (0.0898)
2.28
2.30 (0.0906)
2.30
2.32 (0.0913)
2.32
EM-180
SERVICE DATA AND SPECIFICATIONS (SDS)
QG Valve (Cont’d)
Thickness mm (in)
Identification mark
2.34 (0.0921)
2.34
2.36 (0.0929)
2.36
2.38 (0.0937)
2.38
2.40 (0.0945)
2.40
2.42 (0.0953)
2.42
2.44 (0.0961)
2.44
2.46 (0.0969)
2.46
2.48 (0.0976)
2.48
2.50 (0.0984)
2.50
2.52 (0.0992)
2.52
2.54 (0.1000)
2.54
2.56 (0.1008)
2.56
2.58 (0.1016)
2.58
2.60 (0.1024)
2.60
2.62 (0.1031)
2.62
2.64 (0.1039)
2.64
2.66 (0.1047)
2.66
2.68 (0.1055)
2.68
2.70 (0.1063)
2.70
2.72 (0.1071)
2.72
2.74 (0.1079)
2.74
2.76 (0.1087)
2.76
2.78 (0.1094)
2.78
2.80 (0.1102)
2.80
2.82 (0.1110)
2.82
2.84 (0.1118)
2.84
2.86 (0.1126)
2.86
2.88 (0.1134)
2.88
2.90 (0.1142)
2.90
2.92 (0.1150)
2.92
2.94 (0.1157)
2.94
2.96 (0.1165)
2.96
2.98 (0.1173)
2.98
EM-181
QG
SERVICE DATA AND SPECIFICATIONS (SDS) Valve (Cont’d)
Indicate T1 = 2.800 mm (0.1102 in)
Shim
AEM236
VALVE SEAT
NCEM0031S05
Unit: mm (in) INTAKE Standard
EXHAUST Standard 1.20 - 1.68 (0.0472 - 0.0661)
1.06 - 1.34 (0.0417 - 0.0528)
5.9 (0.232)
5.65 (0.2224)
Oversize 1.20 - 1.68 (0.0472 - 0.0661)
Oversize 1.06 - 1.34 (0.0417 - 0.0528)
5.65 (0.2224)
5.9 (0.232)
Cylinder head machining data Cylinder head machining data
SEM574DA
SEM573DA
Dia.
QG
Dia.
QG
A
27.8 - 28.0 (1.094 - 1.102) dia.
E
24.5 - 24.7 (0.965 - 0.972)
B
29.5 - 29.7 (1.161 - 1.169) dia.
F
26.2 - 26.4 (1.031 - 1.039)
C
31.9 - 32.1 (1.256 - 1.264)
G
26.500 - 26.516 (1.0433 - 1.0439)
D
31.500 - 31.516 (1.2402 - 1.2408)
EM-182
QG
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve (Cont’d)
VALVE SEAT RESURFACE LIMIT
NCEM0031S08
Unit: mm (in)
AEM343
Intake
35.95 - 36.55 (1.4154 - 1.4390)
Exhaust
35.92 - 36.52 (1.4142 - 1.4378)
Depth (L)
Camshaft and Camshaft Bearing
NCEM0032
Unit: mm (in) Engine model Intake
QG16DE
QG18DE
40.220 - 40.410 (1.5835 - 1.5909)
40.610 - 40.800 (1.5988 - 1.6063)
Cam height “A” Exhaust
40.056 - 40.245 (1.5770 - 1.5844)
Cam wear limit
0.20 (0.0079)
EM671
Camshaft journal to bearing clearance
Standard
Limit
0.045 - 0.086 (0.0018 - 0.0034)
0.15 (0.0059)
Inner diameter of camshaft bearing
No. 1
28.000 - 28.021 (1.1024 - 1.1032)
No. 2 to No. 5
24.000 - 24.021 (0.9449 - 0.9457)
Outer diameter of camshaft journal
No. 1
27.935 - 27.955 (1.0998 - 1.1006)
No. 2 to No. 5
23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*] Camshaft end play
—
— Less than 0.02 (0.0008)
0.1 (0.004)
0.115 - 0.188 (0.0045 - 0.0074)
0.20 (0.0079)
*Total indicator reading
EM-183
QG
SERVICE DATA AND SPECIFICATIONS (SDS) Cylinder Block
Cylinder Block
NCEM0033
100 (3.94)
60 (2.36)
20 (0.79)
Unit: mm (in)
Crankshaft center SEM171D
QG16DE
QG18DE Limit Standard
Surface flatness Height “H” (nominal)
Cylinder bore inner diameter
Standard
Less than 0.03 (0.0012)
0.1 (0.004)
213.95 - 214.05 (8.4232 - 8.4271)
—
Grade No. 1
76.000 - 76.0610 (2.9921 - 2.9925)
80.000 - 80.010 (3.1496 - 3.1500)
Grade No. 2
76.010 - 76.020 (2.7957 - 2.7961)
80.010 - 80.020 (3.1500 - 3.1504)
Grade No. 3
76.020 - 76.030 (2.7961 - 2.9933)
80.020 - 80.030 (3.1504 - 3.1508)
0.2 (0.008)
Out-of-round (X − Y)
Less than 0.015 (0.0006)
—
Taper (A − B)
Less than 0.01 (0.0004)
—
0.05 (0.0020)
0.2 (0.008)
Difference in inner diameter between cylinders
EM-184
QG
SERVICE DATA AND SPECIFICATIONS (SDS)
Piston, Piston Ring and Piston Pin
Piston, Piston Ring and Piston Pin
NCEM0034
PISTON
NCEM0034S01
Unit: mm (in)
SEM882E
QG16DE
QG18DE
Grade No. 1
75.975 - 75.985 (2.9911 - 2.9915)
79.965 - 79.975 (3.1482 - 3.1486)
Grade No. 2
75.985 - 75.995 (2.9915 - 2.9919)
79.975 - 79.985 (3.1486 - 3.1490)
Grade No. 3
75.995 - 76.005 (2.9919 - 2.9923)
79.985 - 79.995 (3.1490 - 3.1494)
0.5 (0.002) oversize (service)
76.475 - 76.505 (3.0108 - 3.0120)
80.215 - 80.245 (3.1581 - 3.1592)
1.0 (0.039) oversize (service)
76.975 - 77.005 (3.0305 - 3.0317)
80.465 - 80.495 (3.1679 - 3.1691)
44.5 (1.7520)
42.3 (1.665)
Piston pin hole inner diameter
18.987 - 18.999 (0.7475 - 0.7080)
18.993 - 19.005 (0.7478 - 0.7482)
Piston to bore clearance
0.015 - 0.035 (0.0006 - 0.0014)
0.025 - 0.045 (0.0010 - 0.0018)
Piston skirt diameter “A”
Standard
“a” dimension
PISTON RING
NCEM0034S02
Unit: mm (in) QG16DE
QG18DE Limit Standard
Top Side clearance
0.045 - 0.080 (0.0018 - 0.0031)
2nd Oil
2nd
0.110 (0.0043)
0.030 - 0.070 (0.0012 - 0.0028) 0.065 - 0.135 (0.0026 - 0.0053)
Top End gap
0.040 - 0.080 (0.0016 - 0.0031)
0.100 (0.0039)
0.045 - 0.155 (0.0018 - 0.0061)
—
0.20 - 0.30 (0.0079 - 0.0118) 0.50 - 0.65 (0.0197 - 0.0256)
Oil
0.53 (0.0209)
0.32 - 0.47 (0.0126 - 0.0185)
0.98 (0.0386)
0.20 - 0.60 (0.0079 - 0.0236)
0.95 (0.0374)
PISTON PIN
NCEM0034S03
Unit: mm (in) QG16DE Piston pin outer diameter Piston pin to piston clearance Piston pin to connecting rod bushing clearance
QG18DE
18.989 - 19.001 (0.7476 - 0.7481) −0.004 to 0 (−0.0002 to 0) Standard
0.002 - 0.006 (0.0001 - 0.0002)
0.005 - 0.017 (0.0002 - 0.0007)
Limit
0.023 (0.0009)
EM-185
SERVICE DATA AND SPECIFICATIONS (SDS)
QG
Connecting Rod
Connecting Rod
NCEM0035
Unit: mm (in) Center distance
140.45 - 140.55 (5.5295 - 5.5335)
Bend limit [per 100 (3.94)]
0.15 (0.0059)
Torsion limit [per 100 (3.94)]
0.3 (0.012)
Connecting rod bushing inner diameter* (small end)
19.000 - 19.012 (0.7480 - 0.7485)
Connecting rod big end inner diameter
43.000 - 43.013 (1.6929 - 1.6934) Standard
0.200 - 0.470 (0.0079 - 0.0185)
Side clearance Limit
0.5 (0.020)
*After installing in connecting rod
Crankshaft
NCEM0036
Unit: mm (in)
Main journal dia. “Dm”
Pin journal dia. “Dp”
Grade No. 0
49.956 - 49.964 (1.9668 - 1.9671)
Grade No. 1
49.948 - 49.956 (1.9665 - 1.9668)
Grade No. 2
49.940 - 49.948 (1.9661 - 1.9665)
Grade No. 0
39.968 - 39.974 (1.5735 - 1.5738)
Grade No. 1
39.962 - 39.968 (1.5733 - 1.5735)
Grade No. 2
39.956 - 39.962 (1.5731 - 1.5733)
Center distance “r”
43.95 - 44.05 (1.7303 - 1.7342) Standard
Less than 0.003 (0.0001)
Limit
Less than 0.005 (0.0002)
Standard
Less than 0.004 (0.0002)
Limit
Less than 0.005 (0.0002)
Standard
Less than 0.04 (0.0016)
Limit
Less than 0.05 (0.0020)
Out-of-round (X − Y)
Taper (A − B)
Runout [TIR*] Standard
0.060 - 0.260 (0.0024 - 0.0102)
Free end play Limit
0.3 (0.012)
*: Total indicator reading
Main Bearing
NCEM0037
STANDARD
NCEM0037S01
Grade No.
Thickness “T” mm (in)
Identification color
0
1.826 - 1.830 (0.0719 - 0.0720)
Black
1
1.830 - 1.834 (0.0720 - 0.0722)
Red
2
1.834 - 1.838 (0.0722 - 0.0724)
Green
3
1.838 - 1.842 (0.0724 - 0.0725)
Yellow
4
1.842 - 1.846 (0.0725 - 0.0727)
Blue
UNDERSIZE
NCEM0037S02
Unit: mm (in) Thickness “T” 0.25 (0.0098)
1.960 - 1.964 (0.0772 - 0.0773)
0.50 (0.0197)
2.085 - 2.089 (0.0821 - 0.0822)
EM-186
QG
SERVICE DATA AND SPECIFICATIONS (SDS)
Connecting Rod Bearing
Connecting Rod Bearing
NCEM0038
STANDARD SIZE
NCEM0038S01
Unit: mm (in) Grade No.
Thickness
Identification color or number
0
1.503 - 1.506 (0.0592 - 0.0593)
—
1
1.506 - 1.509 (0.0593 - 0.0594)
Brown
2
1.509 - 1.512 (0.0594 - 0.0595)
Green
UNDERSIZE
NCEM0038S02
Unit: mm (in) Grade No.
Thickness
Identification color or number
0.08 (0.0031)
1.542 - 1.546 (0.0607 - 0.0609)
—
0.12 (0.0047)
1.562 - 1.566 (0.0615 - 0.0617)
—
0.25 (0.0098)
1.627 - 1.631 (0.0641 - 0.0642)
—
Bearing Clearance
NCEM0039
Unit: mm (in) Standard
0.020 - 0.044 (0.0008 - 0.0017)
Main bearing clearance Limit
0.1 (0.004)
Standard
0.014 - 0.039 (0.0006 - 0.0015)
Connecting rod bearing clearance Limit
0.1 (0.004)
Miscellaneous Components
NCEM0040
Unit: mm (in) Flywheel runout [TIR*]
Less than 0.15 (0.0059)
Camshaft sprocket runout [TIR*]
Less than 0.15 (0.0059)
*: Total indicator reading
EM-187
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications
General Specifications Cylinder arrangement cm3 (cu in)
Displacement
Valve timing
In-line 4
Bore and stroke
mm (in)
1,998 (121.92) 86 x 86 (3.39 x 3.39)
Valve arrangement
DOHC
Firing order
1-3-4-2
Number of piston rings Compression
2
Oil
1
Number of main bearings
5
Compression ratio
10.0
EM120
Unit: degree
SR20DE
a
b
c
d
e
f
232°
240°
6°
54°
3°
49°
Inspection and Adjustment COMPRESSION PRESSURE Unit: kPa (bar, kg/cm2, psi)/300 rpm Standard
1,275 (12.75, 13.0, 185)
Minimum
1,079 (10.79, 11.0, 156)
Differential limit between cylinders
98 (0.98, 1.0, 14)
CYLINDER HEAD Unit: mm (in)
Head surface distortion
Standard
Limit
Less than 0.03 (0.0012)
0.1 (0.004)
Nominal cylinder head height: H = 136.9 - 137.1 mm (5.390 - 5.398 in) SEM956C
EM-188
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
VALVE
Hydraulic lash adjuster (HLA) Unit: mm (in)
Unit: mm (in) HLA outer diameter
16.980 - 16.993 (0.6685 - 0.6690)
HLA guide inner diameter
17.000 - 17.020 (0.6693 - 0.6701)
Clearance between HLA and HLA guide
0.007 - 0.040 (0.0003 - 0.0016)
Valve guide Unit: mm (in)
SEM188
Valve head diameter “D” Intake
34.0 - 34.2 (1.339 - 1.346)
Exhaust
30.0 - 30.2 (1.181 - 1.189)
Valve length “L” Intake
98.17 - 98.63 (3.8650 - 3.8831)
Exhaust
99.09 - 99.55 (3.9012 - 3.9193)
Valve stem diameter “d” Intake
5.965 - 5.980 (0.2348 - 0.2354)
Exhaust
5.945 - 5.960 (0.2341 - 0.2346)
NEM032
Intake
45°15′ - 45°45′
Exhaust
Intake
10.023 - 10.034 (0.3946 - 0.3950)
10.223 - 10.234 (0.4025 - 0.4029)
Exhaust
10.023 - 10.034 (0.3946 - 0.3950)
10.223 - 10.234 (0.4025 - 0.4029)
Outer diameter
Valve margin “T” Intake
1.3 (0.051)
Exhaust
1.6 (0.063)
Valve margin “T” limit
More than 0.5 (0.020)
Valve stem end surface grinding limit
Less than 0.2 (0.008)
Valve guide Inner diam- Intake eter (Finished size) Exhaust Cylinder head valve guide hole diameter
Valve clearance Intake
0 (0)
Exhaust
0 (0)
mm (in)
49.36 (1.9433)
569.00 - 641.57 (58.02 - 65.42, 127.93 - 144.25) at 30.0 (1.181)
Standard
mm (in)
10.175 - 10.196 (0.4006 - 0.4014)
Exhaust
9.975 - 9.996 (0.3927 - 0.3935)
10.175 - 10.196 (0.4006 - 0.4014)
0.027 - 0.059 (0.0011 - 0.0023) Standard
Limit
Intake
0.020 - 0.053 (0.0008 - 0.0021)
0.08 (0.0031)
Exhaust
0.040 - 0.073 (0.0016 - 0.0029)
0.1 (0.004)
Valve deflection limit
0.2 (0.008)
Projection length “L”
14.0 - 14.2 (0.551 - 0.559)
549.2 (56.0, 123.5) at 30.0 (1.181)
Limit
6.000 - 6.018 (0.2362 - 0.2369)
Intake
Stem to guide clearance
Pressure N (kg, lb) at height mm (in)
6.000 - 6.018 (0.2362 - 0.2369)
9.975 - 9.996 (0.3927 - 0.3935)
Interference fit of valve guide
Valve spring
Out-of-square
Service
Valve guide
Valve seat angle “α”
Free height
Standard
Less than 2.2 (0.087)
EM-189
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d)
Valve seat SR20DE engine Unit: mm (in) Cylinder head INTAKE
EXHAUST
Standard
Standard
*29.35 - 29.65 (1.1555 - 1.1673)
*44°53′ - 45°07′ *33.6 - 33.8 (1.323 - 1.331) Contacting width (W): 1.385 - 1.401 (0.0545 - 0.0552)
*44°53′ - 45°07′
*29.4 -29.6 (1.157 - 1.165)
Contacting width (W): 1.385 - 1.401 (0.0545 - 0.0552)
Oversize
Oversize
*44°53′ - 45°07′ *33.6 - 33.8 (1.323 - 1.331) Contacting width (W): 1.385 - 1.401 (0.0545 - 0.0552) :* Machining data
*44°53′ - 45°07′
*29.4 - 29.6 (1.157 - 1.165)
Contacting width (W): 1.385 - 1.401 (0.0545 - 0.0552)
Standard
NEM212
Service
In.
35.000 - 35.016 (1.3780 - 1.3786)
35.500 - 35.516 (1.3976 - 1.3983)
Ex.
31.000 - 31.016 (1.2205 - 1.2211)
31.500 - 31.516 (1.2402 - 1.2408)
Cylinder head seat recess diameter (D) In.
0.064 - 0.096 (0.0025 - 0.0038)
Ex.
0.064 - 0.096 (0.0025 - 0.0038)
Valve seat interference fit In.
35.080 - 35.096 (1.3811 - 1.3817)
35.580 - 35.596 (1.4008 - 1.4014)
Ex.
31.080 - 31.096 (1.2236 - 1.2242)
31.580 - 31.596 (1.2433 - 1.2439)
Valve seat outer diameter (d) In.
6.25 (0.2461)
Ex.
6.25 (0.2461)
Depth (H) Height (h)
6.2 - 6.3 (0.244 - 0.248)
EM-190
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
Valve clearance adjustment Unit: mm (in) Rocker arm guide
Valve clearance Intake
0 (0)
Exhaust
0 (0)
Valve clearance “T”
T1±0.025 (0.001)
Valve
Available shim
Valve SEM095D
Thickness mm (in)
Identification mark
2.800 (0.1102)
28 00
2.825 (0.1112)
28 25
2.850 (0.1122)
28 50
2.875 (0.1132)
28 75
2.900 (0.1142)
29 00
2.925 (0.1152)
29 25
2.950 (0.1161)
29 50
2.975 (0.1171)
29 75
3.000 (0.1181)
30 00
3.025 (0.1191)
30 25
3.050 (0.1201)
30 50
3.075 (0.1211)
30 75
3.100 (0.1220)
31 00
3.125 (0.1230)
31 25
3.150 (0.1240)
31 50
3.175 (0.1250)
31 75
3.200 (0.1260)
32 00
Shim
Indicate T = 2.800 mm (0.1102 in) SEM096D
EM-191
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d)
CAMSHAFT AND CAMSHAFT BEARING
CYLINDER BLOCK
Unit: mm (in) Limit
0.030 - 0.071 (0.0012 - 0.0028)
0.15 (0.0059)
Inner diameter of camshaft bearing
28.000 - 28.021 (1.1024 - 1.1032)
—
Outer diameter of camshaft journal
27.950 - 27.970 (1.1004 - 1.1012)
—
Camshaft runout [TIR*]
Less than 0.02 (0.0008)
0.1 (0.004)
Camshaft sprocket runout [TIR*]
Less than 0.25 (0.0098)
—
Camshaft end play
0.055 - 0.139 (0.0022 - 0.0055)
0.20 (0.0079)
211.25 - 211.35 (8.3169 - 8.3208)
Standard Camshaft journal to bearing clearance
Unit: mm (in)
100 (3.94) 60 (2.36) 10 (0.39)
SEM008D
EM671
SR20DE
SEM010D
Surface flatness
Cam height “A”
Standard
Intake
37.775 (1.4872)
Exhaust
37.404 (1.4726)
Cam wear limit
Limit
Less than 0.03 (0.0012) 0.10 (0.0039)
Cylinder bore
0.2 (0.008)
Inner diameter
*Total indicator reading
Standard Grade No. 1
86.000 - 86.010 (3.3858 - 3.3862)
Grade No. 2
86.010 - 86.020 (3.3862 - 3.3866)
Grade No. 3
86.020 - 86.030 (3.3866 - 3.3870)
Wear limit
0.20 (0.0079)
Out-of-round (X − Y)
Less than 0.015 (0.0006)
Taper (A − B − C)
Less than 0.010 (0.0004)
Difference in inner diameter between cylinders Limit
Less than 0.05 (0.0020)
Main journal inner diameter
EM-192
Grade No. 0
58.944 - 58.950 (2.3206 - 2.3209)
Grade No. 1
58.950 - 58.956 (2.3209 - 2.3211)
Grade No. 2
58.956 - 58.962 (2.3211 - 2.3213)
Grade No. 3
58.962 - 58.968 (2.3213 - 2.3216)
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
PISTON, PISTON RING AND PISTON PIN
Piston pin Unit: mm (in)
Available piston Unit: mm (in)
Piston pin outer diameter Interference fit of piston pin to piston
21.989 - 22.001 (0.8657 - 0.8662) 0.002 - 0.006 (0.0001 - 0.0002)
Piston pin to connecting rod bushing clearance Standard Limit
0.005 - 0.017 (0.0002 - 0.0007) 0.023 (0.0009)
* Values measured at ambient temperature of 20°C (68°F)
CONNECTING ROD SEM750C
Piston skirt diameter “A”
Center distance
Standard 85.980 - 85.990 (3.3850 - 3.3854)
Grade No. 2
85.990 - 86.000 (3.3854 - 3.3858)
Grade No. 3
86.000 - 86.010 (3.3858 - 3.3862)
“a” dimension Piston clearance to cylinder block Piston pin hole diameter
136.30 (5.3661)
Bend, torsion [per 100 (3.94)]
Grade No. 1
0.20 (0.0079) oversize (Service)
Unit: mm (in)
Limit
0.15 (0.0059)
Torsion [per 100 (3.94)] Limit
86.180 - 86.210 (3.3929 - 3.3941) 13.1 (0.5157)
0.3 (0.0012)
Connecting rod small end inner diameter
24.980 - 25.000 (0.9835 - 0.9843)
Piston pin bushing inner diameter*
22.000 - 22.012 (0.8661 - 0.8666)
Connecting rod big end inner diameter
51.000 - 51.013 (2.0079 - 2.0084)
0.010 - 0.030 (0.0004 - 0.0012) 21.993 - 22.005 (0.8659 - 0.8663)
Side clearance Standard
Piston ring
Limit Unit: mm (in)
* After installing in connecting rod
Side clearance Top Standard Limit
0.045 - 0.080 (0.0018 - 0.0031) 0.2 (0.008)
2nd Standard Limit Oil ring
0.030 - 0.070 (0.0012 - 0.0028) 0.2 (0.008) 0.065 - 0.135 (0.0026 - 0.0053)
Ring gap Top Standard Limit
0.20 - 0.30 (0.0079 - 0.0118) 1.0 (0.039)
2nd Standard Limit
0.35 - 0.50 (0.0138 - 0.0197) 1.0 (0.039)
Oil Standard Limit
0.20 - 0.60 (0.0079 - 0.0236) 1.0 (0.039)
EM-193
0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d)
CRANKSHAFT
AVAILABLE MAIN BEARING Unit: mm (in)
Main journal dia. “Dm” Grade No. 0
54.974 - 54.980 (2.1643 - 2.1646)
Grade No. 1
54.968 - 54.974 (2.1641 - 2.1643)
Grade No. 2
54.962 - 54.968 (2.1639 - 2.1641)
Grade No. 3
54.956 - 54.962 (2.1636 - 2.1639)
Pin journal dia. “Dp” Grade No. 0
47.968 - 47.974 (1.8885 - 1.8887)
Grade No. 1
47.962 - 47.968 (1.8883 - 1.8885)
Grade No. 2
47.956 - 47.962 (1.8880 - 1.8883)
Center distance “r”
SEM021D
42.96 - 43.04 (1.6913 - 1.6945)
Out-of-round (X − Y) Pin journal: Less than 0.0025 (0.0001) Main journal: Less than 0.005 (0.0002)
Standard
Main bearing (Standard) Unit: mm (in)
Taper (A − B) Pin journal: Less than 0.0025 (0.0001) Main journal: Less than 0.005 (0.0002)
Standard
Grade number
Thickness “T”
0
1.977 - 1.980 (0.0778 - 0.0780)
Black (A)
1
1.980 - 1.983 (0.0780 - 0.0781)
Red (B)
2
1.983 - 1.986 (0.0781 - 0.0782)
Green (C)
3
1.986 - 1.989 (0.0782 - 0.0783)
4
1.989 - 1.992 (0.0783 - 0.0784)
Blue (E)
5
1.992 - 1.995 (0.0784 - 0.0785)
Pink (F)
6
1.995 - 1.998 (0.0785 - 0.0787)
White (G)
Runout [TIR] Standard
Less than 0.025 (0.0010)
Limit
Less than 0.05 (0.0020)
Free end play Standard
0.10 - 0.26 (0.0039 - 0.0102)
Limit
0.30 (0.0118)
Identification color (mark)
Width “W”
18.9 - 19.1 (0.744 - 0.752)
Yellow (D)
Main bearing (Undersize) Unit: mm (in) SEM954C
Out-of-round X - Y Taper A-B A
B
Y
X
EM715
EM-194
Undersize
Thickness “T”
Main journal diameter “Dm”
0.25 (0.0098)
2.109 - 2.117 (0.0830 - 0.0833)
Grind so that bearing clearance is the specified value.
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
AVAILABLE CONNECTING ROD BEARING
Bearing clearance Unit: mm (in)
Connecting rod bearing Main bearing clearance
Standard size
Standard
Unit: mm (in) Grade number
Thickness “T”
0
1.500 - 1.503 (0.0591 - 0.0592)
1
1.503 - 1.506 (0.0592 - 0.0593)
2
1.506 - 1.509 (0.0593 - 0.0594)
Width “W”
0.004 - 0.022 (0.0002 - 0.0009)
Limit
Identification color (mark)
0.05 (0.0020)
Connecting rod bearing clearance Standard
Black or Yellow
0.020 - 0.045 (0.0008 - 0.0018)
Limit 16.9 - 17.1 (0.665 - 0.673)
0.065 (0.00256)
Brown or Red Green or Blue
MISCELLANEOUS COMPONENTS Unit: mm (in)
Undersize Unit: mm (in) Undersize
Thickness “T”
0.08 (0.0031)
1.541 - 1.549 (0.0607 - 0.0610)
0.12 (0.0047)
1.561 - 1.569 (0.0615 - 0.0618)
0.25 (0.0098)
1.626 - 1.634 (0.0640 - 0.0643)
Camshaft sprocket runout limit [TIR]
0.25 (0.0098)
Flywheel runout limit [TIR]
0.15 (0.0059)
Drive plate runout limit [TIR]
Crank pin journal diameter “Dp”
Grind so that bearing clearance is the specified value.
EM-195
0.2 (0.008)
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications
General Specifications Cylinder arrangement Displacement
In-line 4 3
cm (cu in)
Bore and stroke
mm (in)
Valve timing
1,974 (120.45) 84.5 × 88.0 (3.329 × 3.465)
Valve arrangement
OHC
Firing order
1-3-4-2
Number of piston rings Compression
2
Oil
1
Number of main bearing
5
Compression ratio
22.2 EM120 Unit: degree a
b
c
d
e
f
248°
232°
14°
38°
12°
56°
Inspection and Adjustment COMPRESSION PRESSURE
CAMSHAFT AND CAMSHAFT BEARING
Unit: kPa (bar, kg/cm2, psi) at 200 rpm Standard
3,138 (31.4, 32, 455)
Limit
2,452 (24.5, 25, 356)
Difference limit between cylinders
490 (4.9, 5, 71)
CYLINDER HEAD Unit: mm (in)
Unit: mm (in) Standard
Max. tolerance
Camshaft journal clearance
0.045 - 0.086 (0.0018 - 0.0034)
0.1 (0.004)
Inner diameter of camshaft bearing
30.000 - 30.021 (1.1811 - 1.1819)
—
Outer diameter of camshaft journal
29.935 - 29.955 (1.1785 - 1.1793)
—
Camshaft runout
Less than 0.02 (0.0008)
0.05 (0.0020)
0.115 - 0.188 (0.0045 - 0.0074)
—
Head surface flatness Camshaft end play Standard Limit Nominal cylinder head height
Less than 0.03 (0.0012) 0.1 (0.004) 137.9 - 138.1 (5.429 - 5.437)
EM671
Cam height “A”
EM-196
Intake
48.70 - 48.75 (1.9173 - 1.9193)
Exhaust
49.15 - 49.20 (1.9350 - 1.9370)
SERVICE DATA AND SPECIFICATIONS (SDS)
CD20T
Inspection and Adjustment (Cont’d)
VALVE
Valve spring Unit: mm (in) Inner Free height
Outer
mm (in) Intake
36.57 (1.4398)
42.25 (1.6634)
Exhaust
41.27 (1.6248)
49.35 (1.9429)
Intake
233.21 (23.78, 52.43) at 22.2 (0.874)
437.69 (44.63, 98.41) at 25.7 (1.012)
Exhaust
233.4 (23.8, 52.5) at 22.2 (0.874)
437.4 (44.6, 98.3) at 25.7 (1.012)
Intake
208.01 (21.21, 46.77) at 22.2 (0.874)
392.28 (40.00, 88.20) at 25.7 (1.012)
Exhaust
208.69 (21.28, 46.92) at 22.2 (0.874)
390.42 (39.81, 87.78) at 25.7 (1.012)
Pressure N (kg, lb) at height
mm (in)
Standard SEM188
Valve head diameter “D” Intake
39.0 - 39.3 (1.535 - 1.547)
Exhaust
32.0 - 32.3 (1.260 - 1.272)
Valve length “L” Intake
99.53 - 99.97 (3.9185 - 3.9358)
Exhaust
99.38 - 99.82 (3.9126 - 3.9299)
Valve stem diameter “d”
Limit
Out-of-square
mm (in)
Intake
6.965 - 6.980 (0.2742 - 0.2748)
Intake
Less than 1.6 (0.063)
Less than 1.8 (0.071)
Exhaust
6.945 - 6.960 (0.2734 - 0.2740)
Exhaust
Less than 1.8 (0.071)
Less than 2.2 (0.087)
Valve seat angle “α”
45°30′
Valve margin “T” limit
0.5 (0.020)
Valve stem end surface grinding limit
0.5 (0.020)
Valve guide Unit: mm (in) Standard
Service
11.023 - 11.034 (0.4340 - 0.4344)
11.223 - 11.234 (0.4418 - 0.4423)
Valve guide Outer diameter Valve guide Inner diameter (Finished size)
7.000 - 7.015 (0.2756 - 0.2762)
Cylinder head valve guide hole diameter
10.985 - 10.996 (0.4325 - 0.4329)
Interference fit of valve guide
0.027 - 0.049 (0.0011 - 0.0019)
11.185 - 11.196 (0.4404 - 0.4408)
Standard
Max. tolerance
Intake
0.020 - 0.050 (0.0008 - 0.0020)
0.10 (0.0039)
Exhaust
0.040 - 0.070 (0.0016 - 0.0028)
0.10 (0.0039)
Stem to guide clearance
Valve deflection limit
EM-197
0.1 (0.004)
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d)
Valve seat resurfacing
Unit: mm (in)
VALVE LIFTER Unit: mm (in) Valve lifter outer diameter 34.959 - 34.975 (1.3763 - 1.3770)
Standard Cylinder head valve lifter hole diameter
34.998 - 35.018 (1.3779 - 1.3787)
Clearance 0.023 - 0.059 (0.0009 - 0.0023)
Standard Limit
0.1 (0.004)
AVAILABLE SHIMS Thickness mm (in)
Identification mark
2.20 (0.0866)
220
2.25 (0.0886)
225
2.30 (0.0906)
230
2.35 (0.0925)
235
2.40 (0.0945)
240
2.45 (0.0965)
245
2.50 (0.0984)
250
2.55 (0.1004)
255
2.60 (0.1024)
260
2.65 (0.1043)
265
2.70 (0.1063)
270
2.75 (0.1083)
275
2.80 (0.1102)
280
2.85 (0.1122)
285
2.90 (0.1142)
290
SEM917-B
VALVE CLEARANCE Unit: mm (in) For adjusting Hot Intake Exhaust
0.25 (0.010 0.39 (0.015
-
0.35 0.014) 0.49 0.019)
Cold* (reference data) 0.20 - 0.30 (0.008 - 0.012) 0.33 - 0.43 (0.013 - 0.017)
*: At a temperature of approximately 20°C (68°F)
SEM113FA
EM-198
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
CYLINDER BLOCK Unit: mm (in)
PISTON, PISTON RING AND PISTON PIN Piston Unit: mm (in)
Standard Piston skirt diameter
Grade No. 1
84.460 - 84.470 (3.3252 - 3.3256)
Grade No. 2
84.470 - 84.480 (3.3256 - 3.3260)
Grade No. 3
84.480 - 84.490 (3.3260 - 3.3264)
Grade No. 4
84.490 - 84.500 (3.3264 - 3.3268)
Grade No. 5
84.500 - 84.510 (3.3268 - 3.3272)
0.25 (0.0098)
84.710 - 84.760 (3.3350 - 3.3370)
0.5 (0.020)
84.960 - 85.010 (3.3449 - 3.3468)
Oversize
Measure position (From Top) SEM902-A
Surface flatness
Piston pin hole diameter
Standard
Limit
Less than 0.03 (0.0012)
0.10 (0.0039)
62 (2.44) 27.991 - 27.999 (1.1020 - 1.1023)
Grade No. 1 84.500 - 84.510 (3.3268 - 3.3272)
Piston ring
Grade No. 2
Unit: mm (in)
84.510 - 84.520 (3.3272 - 3.3276) Inner diameter Cylinder bore
Grade No. 3 84.520 - 84.530 (3.3276 - 3.3279)
Side clearance 0.2 (0.008)
Top Standard
Grade No. 4
Limit
84.530 - 84.540 (3.3279 - 3.3283)
Standard
Grade No. 5
Limit
0.050 - 0.085 (0.0020 - 0.0033) 0.10 (0.0039)
Oil
Out-ofround (X − Y)
Less than 0.015 (0.0006)
0.04 (0.0016)
Taper (A − B)
Less than 0.010 (0.0004)
0.04 (0.0016)
0.030 - 0.050 (0.0012 - 0.0020)
—
Standard
0.030 - 0.070 (0.0012 - 0.0028)
End gap Top Standard
Grade No. 0 56.654 - 56.663 (2.2305 - 2.2308) Main journal inner diameter
0.10 (0.0039)
2nd
84.540 - 84.550 (3.3283 - 3.3287)
Piston to cylinder clearance
0.020 - 0.040 (0.0008 - 0.0016)
0.22 - 0.32 (0.0087 - 0.0126)
Bore grade 4, 5
0.12 - 0.22 (0.0047 - 0.0087)
Limit
Grade No. 1 56.663 - 56.672 (2.2308 - 2.2312)
Bore grade 1, 2, 3
1.0 (0.039)
2nd
—
Standard
Grade No. 2
Limit
56.672 - 56.680 (2.2312 - 2.2315)
0.38 - 0.53 (0.0150 - 0.0209) 0.7 (0.028)
Oil Standard Limit
EM-199
0.30 - 0.55 (0.0118 - 0.0217) 0.6 (0.024)
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d)
Piston pin
CRANKSHAFT Unit: mm (in)
Unit: mm (in)
27.994 - 28.000 (1.1021 - 1.1024)
Piston pin outer diameter Interference fit of piston pin to piston
Main journal dia.
Grade No. 0 52.967 - 52.975 (2.0853 - 2.0856) Grade No. 1 52.959 - 52.967 (2.0850 - 2.0853) Grade No. 2 52.951 - 52.959 (2.0847 - 2.0850)
Pin journal dia.
Grade No. 0 49.968 - 49.974 (1.9672 - 1.9675) Grade No. 1 49.961 - 49.968 (1.9670 - 1.9672) Grade No. 2 49.954 - 49.961 (1.9667 - 1.9670)
−0.004 to 0 (−0.0002 to 0)
Piston pin to connecting rod clearance
0.025 - 0.044 (0.0010 - 0.0017)
CONNECTING ROD Unit: mm (in) Bend [per 100 mm (3.94 in)] Standard
Less than 0.025 (0.0010)
Torsion Standard
Less than 0.025 (0.0010) Out-of-round (X − Y) and taper (A − B)
28.025 - 28.038 (1.1033 - 1.1039)
Piston pin bore dia.
Standard
Less than 0.005 (0.0002)
Big end play Runout Limit
0.3 (0.012) Standard
Less than 0.05 (0.0020)
Free end play Standard
0.05 - 0.18 (0.0020 - 0.0071)
Limit
0.3 (0.012)
Width “W” mm (in)
Identification color
AVAILABLE MAIN BEARINGS No. 1, No. 2, No. 4 and No. 5 main bearings Grade number
Thickness “T” mm (in)
0
1.816 - 1.820 (0.0715 - 0.0717)
Yellow
1
1.820 - 1.824 (0.0717 - 0.0718)
Green
2
1.824 - 1.828 (0.0718 - 0.0720)
3
1.828 - 1.832 (0.0720 - 0.0721)
Black
4
1.832 - 1.836 (0.0721 - 0.0723)
Blue
20.0 (0.787) 17.8 (0.701)*
Brown
*: Contacting width
No. 3 main bearings Grade number
Thickness “T” mm (in)
0
1.816 - 1.820 (0.0715 - 0.0717)
Width “W” mm (in)
Yellow
1
1.820 - 1.824 (0.0717 - 0.0718)
Green
2
1.824 - 1.828 (0.0718 - 0.0720)
3
1.828 - 1.832 (0.0720 - 0.0721)
Black
4
1.832 - 1.836 (0.0721 - 0.0723)
Blue
27.95 (1.1004) 21.35 (0.8405)*
*: Contacting width
EM-200
Identification color
Brown
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
Main bearing undersize
Bearing clearance Unit: mm (in) Crank journal diameter
STD
52.951 - 52.975 (2.0847 - 2.0856)
0.25 (0.0098) undersize
52.701 - 52.725 (2.0748 - 2.0758)
Unit: mm (in) Main bearing clearance 0.039 - 0.065 (0.0015 - 0.0026)
Standard Connecting rod bearing clearance Standard
0.031 - 0.055 (0.0012 - 0.0022)
Connecting rod bearing undersize Unit: mm (in)
TURBOCHARGER Unit: mm (in)
Crank pin diameter Grade 0 STD
Grade 1 Grade 2
Black
49.968 - 49.974 (1.9672 - 1.9675)
Yellow
49.961 - 49.968 (1.9670 - 1.9672)
Blue
49.954 - 49.961 (1.9667 - 1.9670)
0.08 (0.0031) undersize
49.874 - 49.894* (1.9635 - 1.9643)
0.12 (0.0047) undersize
49.834 - 49.854* (1.9620 - 1.9628)
0.25 (0.0098) undersize
49.704 - 49.724* (1.9568 - 1.9576)
*: Reference value
Rotor shaft Runout [TIR*]
0.056 - 0.127 (0.0022 - 0.0050)
End play
0.013 - 0.097 (0.0005 - 0.0038)
*: Total indicator reading
MISCELLANEOUS COMPONENTS Unit: mm (in) Flywheel Runout [TIR*] *: Total indicator reading
EM-201
Less than 0.15 (0.0059)
SERVICE DATA AND SPECIFICATIONS (SDS) NOTE
EM-202
CD20T
ENGINE LUBRICATION & COOLING SYSTEMS SECTION
LC
CONTENTS PRECAUTION..................................................................2 PREPARATION................................................................3 Special Service Tools ..................................................3 QG ENGINE LUBRICATION SYSTEM..................................4 Lubrication Circuit ........................................................4 Oil Pressure Check......................................................5 Oil Pump ......................................................................5 Oil Filter .......................................................................7 ENGINE COOLING SYSTEM..........................................8 Cooling Circuit .............................................................8 System Check..............................................................8 Water Pump ...............................................................10 Thermostat.................................................................11 Radiator .....................................................................13 SR20DE ENGINE LUBRICATION SYSTEM................................15 Lubrication Circuit ......................................................15 Oil Pressure Check....................................................16 Oil Pump ....................................................................17 Oil Filter .....................................................................19 Oil Cooler...................................................................20 ENGINE COOLING SYSTEM........................................21 Cooling Circuit ...........................................................21 System Check............................................................21 Cooling System Inspection ........................................21 Water Pump ...............................................................22 Thermostat.................................................................23 Radiator .....................................................................25 CD20T ENGINE LUBRICATION SYSTEM ................................26 Lubrication Circuit ......................................................26
Oil Pressure Check....................................................27 Oil Pump ....................................................................27 Oil Cooler...................................................................30 ENGINE COOLING SYSTEM........................................31 Cooling Circuit ...........................................................31 System Check............................................................32 Water Pump ...............................................................33 Thermostat.................................................................34 Radiator .....................................................................36
Overheating Cause Analysis .....................................37 QG SERVICE DATA AND SPECIFICATIONS (SDS) ..........39 Oil Pressure Check....................................................39 Oil Pump Inspection ..................................................39 Regulator Valve Inspection........................................39 Thermostat.................................................................39 Radiator .....................................................................39 SR20DE Oil Pressure Check....................................................40 Oil Pump Inspection ..................................................40 Regulator Valve Inspection........................................40 Thermostat.................................................................40 Radiator .....................................................................40 CD20T Oil Pressure Check....................................................41 Oil Pump Inspection ..................................................41 Thermostat.................................................................41 Radiator .....................................................................41
LC
PRECAUTION LIQUID GASKET APPLICATION PROCEDURE 1.
Inner side
2. 쐌
Groove
Bolt hole SEM164
쐌 3. 4. 5.
Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also, completely clean any oil from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.) Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) wide for SR engine and 3.5 to 4.5 mm (0.138 to 0.177 in) wide for QG and CD engine (for oil pan). Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oil pan). Apply liquid gasket around the inner side of bolt holes (unless otherwise specified). Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant.
Inner side Groove .
AEM080
LC-2
PREPARATION Special Service Tools
Special Service Tools The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number Tool name
Engine application
Description SR
CD
QG
X
X
X
X
X
X
X
—
X
—
X
—
X
X
X
X
X
X
Measuring oil pressure
ST25051001* Oil pressure gauge PS1/4x19/in
Maximum measuring range: 2,452 kPa (24.5 bar, 25 kg/cm2, 356 psi)
NT558
ST25052000* Hose
PS1/8x28/in PS1/4x19/in
Adapting oil pressure gauge to cylinder block
NT559
Removing oil filter
KV10115801 or KV10115800 Oil filter wrench
15 faces, Inner span: 64.3 mm (2.531 in) (Face to opposite face)
NT362
99545R2500 (KV10106S0) Oil filter wrench
Removing oil filter 15 faces, Inner span: 92.5 mm (3.642 in) (Face to opposite corner) NT631
Pressing the tube of liquid gasket
WS39930000 Tube presser
NT052
Adapting radiator cap tester to radiator filler neck
EG17650301 Radiator cap tester adapter
a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in)
NT564
*:Special tool or commercial equivalent
LC-3
QG
ENGINE LUBRICATION SYSTEM Lubrication Circuit
Lubrication Circuit
NCLC0003
Oil drop
Exhaust camshaft
Intake camshaft
VTC Main gallery
Timing chain guide Chain tensioner
Oil jet Relief valve
Oil filter Oil pump Oil strainer
SEM852F
Oil passage Oil pan
Oil strainer Oil gallery in cylinder block By-pass passage Oil pump
Regulator valve
Oil jet Drain
Oil pressure relief valve
Oil filter
Cylinder head oil gallery
Main oil gallery
Main bearing
Timing chain oil jet
Connecting rod bearing
Timing chain
Valve timing control solenoid (OFF)
Connecting rod
#1 Intake camshaft journal
#1 Exhaust camshaft journal
Exhaust camshaft journal
#1 Intake camshaft
#1 Exhaust camshaft
Exhaust camshaft
Intake camshaft
Valve lifter
Valve lifter
Intake camshaft journal
Chain tensioner
(ON)
Valve timing controller
Piston
SEM938F
LC-4
QG
ENGINE LUBRICATION SYSTEM
Oil Pressure Check
Oil Pressure Check
Oil pressure switch
Front
NCLC0004
WARNING: 쐌 Be careful not to burn yourself, as the engine and oil may be hot. 쐌 Put gearshift lever in Neutral “N” position. 1. Check oil level. 2. Remove oil pressure switch.
SEM853F
3. 4. 5.
Install pressure gauge. Start engine and warm it up to normal operating temperature. Check oil pressure with engine running under no-load.
ST25051001
Engine speed rpm
Approximate discharge pressure kPa (bar, kg/cm2, psi)
600
More than 98 (0.98, 1.0, 14)
2,000
More than 294 (2.94, 3.0, 43)
6,000
More than 392 (3.92, 4.0, 57)
ST25052000 SLC926-A
쐌 6.
If difference is extreme, check oil passage and oil pump for oil leaks. Install oil pressure switch with sealant.
Oil Pump REMOVAL AND INSTALLATION 쐌 쐌 쐌 1. 2. 3. 4. 5. 6. 7.
NCLC0005
Always replace oil seal with a new one. Refer to EM section (“OIL SEAL REPLACEMENT”). When installing oil pump, apply engine oil to gears. Make sure that O-ring is fitted properly. Drain engine oil. Remove drive belts. Remove oil pan. Refer to EM section (“OIL PAN”). Remove oil strainer. Remove front cover. Refer to EM section (“TIMING CHAIN”). Install front cover. Reinstall parts in reverse order of removal.
LC-5
QG
ENGINE LUBRICATION SYSTEM Oil Pump (Cont’d)
DISASSEMBLY AND ASSEMBLY
NCLC0006
SEC. 135⋅150 7.8 - 10.8 (0.80 - 1.10, 69.4 - 95.5)
7.8 - 12.7 (0.80 - 1.30, 69.4 - 112.8)
: Lubricate with new engine oil. 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
: Use Genuine Liquid Gasket or equivalent. : Do not re-use. : N·m (kg-m; in-lb)
39 - 59 (4.0 - 6.0, 29 - 43)
: N·m (kg-m, ft-lb)
1. 2. 3. 4.
SEM854FA
5. 6. 7.
Oil pump cover Inner gear Outer gear Front cover
Gasket Oil strainer Regulator valve
8. Spring 9. Washer 10. Plug
INSPECTION Feeler gauge
NCLC0007
Using a feeler gauge, check the following clearances. Standard clearance: Unit: mm (in) Body to outer gear radial clearance 1 Inner gear to outer gear tip clearance 2
Front cover SEM855F
0.250 - 0.325 (0.0098 - 0.0128) Below 0.18 (0.0071)
Body to inner gear clearance 3
0.030 - 0.085 (0.0012 - 0.0033)
Body to outer gear axial clearance 4
0.030 - 0.090 (0.0012 - 0.0035)
Inner gear to brazed portion of housing clearance 5
0.045 - 0.091 (0.0018 - 0.0036)
Straightedge
Front cover
Feeler gauge SEM856F
LC-6
QG
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d) Inside micrometer
쐌 쐌
If the tip clearance (2) exceeds the limit, replace gear set. If body to gear clearances (1, 3, 4, 5) exceed the limit, replace front cover assembly.
Front cover Micrometer
Inner gear SEM857F
REGULATOR VALVE INSPECTION Spring Regulator valve
NCLC0008
1. 2.
Visually inspect components for wear and damage. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil. Check that it falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set or front cover assembly.
Washer Plug
SLC986AA Front cover
4.
Check regulator valve to front cover clearance. Clearance: 6 : 0.052 - 0.088 mm (0.0020 - 0.0035 in) If it exceeds the limit, replace front cover assembly.
Regulator valve
SLC101B
Oil Filter
Oil filter body Relief valve Filtering paper Screw
Body color (gray)
Label (red) Packing
NCLC0010
The oil filter is a small, full-flow cartridge type and is provided with a relief valve. 쐌 The new and previous oil filter designs differ from each other and are not interchangeable. 쐌 Use Tool KV10115801 for removing oil filter.
SLC972A
LC-7
QG
ENGINE COOLING SYSTEM Cooling Circuit
Cooling Circuit
Radiator
NCLC0016
Thermostat: CLOSED
Reservoir tank
Thermostat: OPEN Water inlet
Thermostat
Heater
Thermostat housing
Water pump
Cylinder block
EGR valve
Throttle body
Cylinder head
Thermostat housing
Water outlet
SEM939F
System Check
NCLC0017
WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure fluid 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.
CHECKING COOLING SYSTEM HOSES Check hoses for the following: 쐌 Improper attachment 쐌 Leaks 쐌 Cracks 쐌 Damage 쐌 Loose connections 쐌 Chafing 쐌 Deterioration
LC-8
NCLC0017S01
QG
ENGINE COOLING SYSTEM
System Check (Cont’d)
CHECKING COOLING SYSTEM FOR LEAKS
NCLC0017S02
To check for leakage, apply pressure to the cooling system with a tester. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher pressure than specified may cause radiator damage.
EG17650301
ULC015
CHECKING RADIATOR
NCLC0017S04
Check radiator for mud or clogging. If necessary, clean radiator as follows. 쐌 Be careful not to bend or damage the radiator fins. 쐌 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 download. 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 download. 쐌 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). 5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
CHECKING RADIATOR CAP
NCLC0017S03
To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure: Standard 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi) SLC613-A
Pull the negative pressure valve to open it. Check that it closes completely when released.
SMA967B
LC-9
ENGINE COOLING SYSTEM
QG
Water Pump
Water Pump REMOVAL AND INSTALLATION SEC. 210
NCLC0018
Gasket 17 - 24 (1.7 - 2.4, 12 - 17)
Water pump
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
Do not re-use
Water pump pulley
: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb)
17 - 24 (1.7 - 2.4, 12 - 17) SEM858F
CAUTION: 쐌 When removing water pump assembly, be careful not to get coolant on drive belt. 쐌 Water pump cannot be disassembled and should be replaced as a unit. 쐌 After installing water pump, and check for leaks using radiator cap tester.
1.
2. 3. 4. 5.
Drain coolant from radiator and cylinder block. Refer to MA section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Remove cylinder head front mounting bracket. Remove drive belts and idler pulley. Loosen water pump pulley bolts. Remove water pump pulley.
6. 7. 8.
Remove water pump bolts. Remove water pump with gasket. Reinstall parts in reverse order of removal.
Drain plug
SEM869F
Water pump
SEM859F
LC-10
QG
ENGINE COOLING SYSTEM
Thermostat
INSPECTION 쐌 쐌
NCLC0019
Check body assembly and vane for rust or corrosion. Check for rough operation due to excessive end play.
SEM860F
Thermostat REMOVAL AND INSTALLATION
NCLC0021
17 - 24 (1.7 - 2.4, 12 - 17)
SEC. 210
Thermostat housing Bracket
Gasket
Water outlet 6.0 - 7.7 (0.61 - 0.79, 52.9 - 68.6)
To upper radiator hose Engine front
Washer
Thermostat Water inlet 6.7 - 7.8 (0.68 - 0.80, 59.0 - 69.4)
Do not re-use.
17 - 24 (1.7 - 2.4, 12 - 17) Gum ring
: N·m (kg-m, in-lb) 17 - 24 (1.7 - 2.4, 12 - 17)
: N·m (kg-m, ft-lb)
From lower radiator hose
쐌
Gum ring
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
Upper Jiggle valve (top side)
SEM861F
쐌 1. 2. 3.
Be careful not to spill coolant over engine compartment. Use a rag to absorb coolant. Use Genuine Liquid Gasket or equivalent. Drain engine coolant. Remove lower radiator hose. Remove water inlet, then take out thermostat.
4.
Install gum ring to thermostat.
Thermostat flange
SEM862F
LC-11
QG
ENGINE COOLING SYSTEM Thermostat (Cont’d) Jiggle valve position
Jiggle valve
Thermostat housing
5. 쐌
Install thermostat with jiggle valve or air bleeder at upper side. After installation, run engine for a few minutes, and check for leaks.
Thermostat SEM863F
INSPECTION 1. 2.
Valve opening temperature Valve lift
3.
NCLC0022
Check for valve seating condition at normal room temperature. It should seat tightly. Check valve opening temperature and valve lift.
mm/°C (in/°F)
°C (°F)
82 (180) More than 9/95 (0.35/203)
Then check if valve closes at 5°C (41°F) below valve opening temperature.
SLC343
LC-12
QG
ENGINE COOLING SYSTEM
Radiator
Radiator COMPONENTS
=NCLC0025
4.0 - 4.5 (0.41 - 0.45, 36 - 39) 4.0 - 4.5 (0.41 - 0.45, 36 - 39)
3.8 - 4.5 (0.39 - 0.45, 34 - 39)
3.25 - 4.25 (0.34 - 0.43, 29 - 37)
: N·m (kg-m, in-lb)
NLC086
1 쑗 2 쑗 3 쑗 4 쑗
Reservoir tank Reservoir hose Radiator cap Mounting bracket
5 쑗 6 쑗 7 쑗 8 쑗
Upper radiator hose Mounting rubber Cooling fan motor Radiator
LC-13
9 쑗 10 쑗 11 쑗
Lower radiator hose Cooling fan Cooling fan motor shield
ENGINE COOLING SYSTEM
QG
Radiator (Cont’d)
Cooling Fan Control System
NCLC0026
Cooling fans are controlled by the ECM. For details, refer to EC section [TROUBLE DIAGNOSIS FOR OVERHEAT (COOLING SYSTEM)].
Refilling Engine Coolant
NCLC0027
For details on refilling engine coolant, refer to MA section (“ENGINE MAINTENANCE”, “Changing Engine Coolant”, MA-30)
LC-14
SR20DE
ENGINE LUBRICATION SYSTEM
Lubrication Circuit
Lubrication Circuit Return
Camshaft
Feed Relief valve
Hydraulic lash adjuster
Oil filter
Oil filter bracket
Oil cooler
Oil pump
Oil pan
Oil strainer
SLC093B
Oil pan
Oil strainer
Oil pump
Regulator valve (Built into oil pump)
Oil filter
Relief valve
Oil cooler
Relief valve (Built into oil filter)
Main gallery
Chain tensioner Timing chain
Main bearing
Connecting rod bearing
Cylinder head oil gallery
Connecting rod Camshaft journal
Hydraulic lash adjuster
Oil gallery Oil passage By-pass passage
Piston and cylinder
To oil pan
NLC043
LC-15
ENGINE LUBRICATION SYSTEM
SR20DE
Oil Pressure Check .
Oil Pressure Check
SR20DE models .
.
Oil pressure switch
WARNING: 쐌 Be careful not to burn yourself, as the engine and oil may be hot. 쐌 Oil pressure check should be done in “Neutral position”. 1. Check oil level. 2. Remove oil pressure switch.
Oil cooler .
NLC045
3. 4. 5.
.
SLC717A
Install pressure gauge. Start engine and warm it up to normal operating temperature. Check oil pressure with engine running under no-load. Engine speed rpm
Approximate discharge pressure kPa (bar, kg/cm2, psi)
Idle speed
More than 78 (0.78, 0.8, 11)
3,200
314 - 392 (3.14 - 3.92, 3.2 - 4.0, 46 - 57)
If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant.
LC-16
SR20DE
ENGINE LUBRICATION SYSTEM
Oil Pump
Oil Pump REMOVAL AND INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8.
Drain engine oil Remove drive belts. Remove cylinder head. (Refer to EM section). Remove oil pan. (Refer to EM section). Remove oil strainer and baffle plate. Remove front cover assembly. Install front cover assembly. Reinstall any parts removed in reverse order of removal
DISASSEMBLY AND ASSEMBLY SEC. 135⋅150 3.7 - 5.0 (0.38 - 0.51, 32.7 - 44.3) 6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5)
Gasket
.
: N·m (kg-m, ft-lb)
16 - 19 (1.6 - 1.9, 12 - 14)
: N·m (kg-m, in-lb) : Apply engine oil.
50 - 70 (5.1 - 7.1, 37 - 51)
NLC050
: Apply liquid gasket. 1 쑗 2 쑗 3 쑗
Oil pump cover Front cover Inner gear
4 쑗 5 쑗 6 쑗
Outer gear Regulator valve Spring
쐌 쐌 쐌
7 쑗 8 쑗 9 쑗
Plug Regulator valve set Oil strainer
Always replace oil seal, gasket and O-ring with new ones. When installing oil pump, apply engine oil to inner and outer gears. Be sure that O-rings are properly fitted.
LC-17
SR20DE
ENGINE LUBRICATION SYSTEM Oil Pump (Cont’d)
Feeler gauge
Front cover
Straightedge
Feeler gauge SLC494A
SLC495A
Front cover
Inner gear SLC450A SLC860A
INSPECTION Using a feeler gauge, check the following clearances: Unit: mm (in) 1 쑗 Inner gear to outer gear tip clearance 쑗 2 Body to inner gear clearance 쑗 3 Body to outer gear clearance (axial) 쑗 4
Body to outer gear clearance (radial)
0.114 - 0.200 (0.0045 - 0.0079) Below 0.18 (0.0071) 0.05 - 0.09 (0.0020 - 0.0035) 0.05 - 0.11 (0.0020 - 0.0043)
Inner gear to brazed portion of housing clear- 0.045 - 0.091 (0.0018 - 0.0036) ance 쑗 5
쐌 쐌
If the tip clearance (쑗 2 ) exceeds the limit, replace gear set. If body to gear clearances (쑗 1 , 쑗 3 , 쑗 4 , 쑗 5 ) exceed the limit, replace front cover assembly.
LC-18
SR20DE
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)
REGULATOR VALVE INSPECTION Spring Regulator valve
Washer Cap
1. 2.
Visually inspect components for wear and damage. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil. Check that regulator valve falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set or oil pump cover.
SLC986AA
4.
Oil pump cover
Regulator valve
Check regulator valve to oil pump cover clearance. Clearance: 6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in) 쑗 If it exceeds the limit, replace oil pump cover.
SLC451A
Oil Filter
Oil filter body
The oil filter is a small, full-flow cartridge type and is provided with a relief valve. 쐌 The new and existing oil filter designs differ from each other and are not interchangeable. 쐌 Use Tool KV10115801 or KV10115800 for removing oil filter.
Relief valve Filtering paper Thread
Gasket
NLC046
LC-19
SR20DE
ENGINE LUBRICATION SYSTEM Oil Cooler
Oil Cooler SEC. 213 Gasket
Oil cooler
Coolant flow O-ring Oil filter
Oil pressure switch 13 - 17 N·m (1.3 - 1.7 kg-m, 9 - 12 ft-lb) Oil cooler assembly : Do not re-use .
: Locking sealant.
34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-lb)
: N·m (kg-m, ft-lb)
NLC047
REMOVAL AND INSTALLATION 1. 2. 3. 쐌 쐌 쐌
Drain engine oil and coolant. Remove oil cooler. Installation is in reverse order of removal Be careful not to burn yourself as engine oil is hot After installation, run engine for a few minutes and check for oil leaks. Do not spill coolant on drive belts.
INSPECTION 1. 2.
Check oil cooler for cracks. Check oil cooler for clogging by blowing through coolant inlet. If necessary, replace oil cooler assembly.
LC-20
ENGINE COOLING SYSTEM
SR20DE Cooling Circuit
Cooling Circuit
YLC029
System Check 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.
Cooling System Inspection CHECKING HOSES Check water hoses for proper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.
CHECKING RADIATOR CAP To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure: Standard 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi) SLC613-A
LC-21
ENGINE COOLING SYSTEM
SR20DE
Cooling System Inspection (Cont’d)
Pull the negative pressure valve to open it. Check that it closes completely when released.
SMA967B
CHECKING COOLING SYSTEM FOR LEAKS Hose adapter
.
To check for leakage, apply pressure to the cooling system with a tester. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage.
SLC546AA
Water Pump Drain plug
REMOVAL AND INSTALLATION 1. 2.
8 - 12 N·m (0.8 - 1.2 kg-m, 69 - 104 in-lb) Oil level gauge guide .
SEC. 210
16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
3. 4. 5.
Drain coolant from radiator. Remove cylinder block drain plug located at left front of cylinder block and drain coolant. Remove front RH wheel and engine side cover. Remove drive belts. Remove front engine mounting.
SLC557AA
6. Remove water pump. CAUTION: 쐌 When removing water pump assembly, be careful not to get coolant on drive belt. 쐌 Water pump cannot be disassembled and should be replaced as a unit. 쐌 After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester.
Liquid gasket
Water pump SLC556AA
7. 쐌
Before installing, remove all traces of liquid gasket from mating surface of water pump using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block.
SLC433A
LC-22
SR20DE
ENGINE COOLING SYSTEM
Water Pump (Cont’d)
8. Liquid gasket 2.0 - 3.0 mm (0.079 - 0.118 in)
쐌 9.
Apply a continuous bead of liquid gasket to mating surface of water pump. Use Genuine Liquid Gasket or equivalent. Install any parts removed in reverse order of removal
SLC434A
INSPECTION 1. 2.
Check body assembly for rust or corrosion. Check for rough operation due to excessive end play.
SLC408C
Thermostat SEC. 210 6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5) 6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5)
Thermostat housing
Air relief plug (if so equipped)
16 - 21 (1.6 - 2.1, 12 - 15)
Thermostat
Water inlet 16 - 21 (1.6 - 2.1, 12 - 15) 16 - 21 (1.6 - 2.1, 12 - 15)
2.0 - 3.0 mm (0.079 - 0.118 in) .
2.0 - 3.0 mm (0.079 - 0.118 in)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Apply liquid gasket
SLC050B
LC-23
SR20DE
ENGINE COOLING SYSTEM Thermostat (Cont’d)
REMOVAL AND INSTALLATION
Upper Jiggle valve
1. 2. 3. 4.
SLC767
쐌 5. 쐌 쐌
Remove lower radiator hose and drain engine coolant. Remove water inlet, then take out thermostat. Before installing, remove all traces of liquid gasket from mating surface of each part using a scraper. Apply a continuous bead of liquid gasket to mating surface of each part. Use Genuine Liquid Gasket or equivalent. Install thermostat with jiggle valve or air bleeder facing upward. After installation, run engine for a few minutes, and check for leaks. Be careful not to spill coolant over engine compartment. Use a rag to absorb coolant.
INSPECTION 1. 2.
Check valve seating condition at ordinary temperatures. It should seat tightly. Check valve opening temperature and valve lift.
Valve opening temperature Valve lift
3. SLC343
°C(°F)
mm/°C (in/°F)
82 (180) More than 9/95 (0.35/203)
Then check if valve closes at 5°C (41°F) below valve opening temperature.
LC-24
SR20DE
ENGINE COOLING SYSTEM
Radiator
Radiator SEC. 214 3.8 - 4.5 (0.39 - 0.46, 33.9 - 39.9)
3.7 - 5.0 (0.38 - 0.51, 32.7 - 44.3)
쑗 2
4 쑗
3 쑗
10 쑗
1 쑗
5 쑗
11 쑗
10 쑗 8 쑗
4.0 - 4.5 (0.41 - 0.46, 35.4 - 39.8) 6 쑗
9 쑗
1 쑗 2 쑗 3 쑗 4 쑗
Reservoir tank Reservoir tank hose Radiator cap Mounting bracket
12 쑗
3.25 - 4.25 (0.33 - 0.43, 28.8 - 37.6)
5 쑗 6 쑗 7 쑗 8 쑗
N·m (kg-m, in-lb)
11 쑗
7 쑗
7 쑗
Upper hose Mounting rubber Oil cooler hose (A/T models) Radiator
NLC090
9 쑗 10 쑗 11 쑗 12 쑗
Lower hose Cooling fan Cooling fan motor Cooling fan motor shield
Cooling fan control system 쐌
Cooling fans are controlled by the ECM. For details, refer to EC-section (“COOLING SYSTEM”, “Diagnostic Procedure”, EC-SR-284).
Refilling engine coolant 쐌
For details on refilling engine coolant, refer to MA section (“ENGINE MAINTENANCE”, “Changing Engine Coolant”, MA-41).
LC-25
ENGINE LUBRICATION SYSTEM
CD20T
Lubrication Circuit
Lubrication Circuit
: Oil gallery in cylinder block : Oil passage : By-pass passage
Oil cooler
Oil filter
Oil pump
Relief valve
Relief valve Regulator valve
Cylinder head oil gallery Oil strainer
Turbocharger
Main bearing
Crankshaft
Camshaft bracket Hydraulic valve lifter
Connecting rod bearing
Camshaft journal Oil feed hose
Connecting rod Vacuum pump
Cam lobe
Piston and cylinder wall Oil return hose Oil pan SLC083B
LC-26
CD20T
ENGINE LUBRICATION SYSTEM
Oil Pressure Check
Oil Pressure Check
Oil filter Oil pressure switch
WARNING: 쐌 Be careful not to burn yourself, as the engine and oil may be hot. 쐌 Oil pressure check should be done in “Neutral” gear position. 1. Check oil level. 2. Remove oil pressure switch.
SLC461
3. 4. 5.
Install pressure gauge. Start engine and warm it up to normal operating temperature. Check oil pressure with engine running under no-load.
ST2051001
Engine rpm
Approximate discharge pressure kPa (bar, kg/cm2, psi)
Idle speed
More than 59 (0.59, 0.6, 9)
2,000
294 (2.9, 3, 43)
ST25052000 SLC926-A
If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant.
Oil Pump REMOVAL AND INSTALLATION
Rear engine gusset
1. 2. 3.
Drain engine coolant and engine oil. Remove upper radiator hose, drive belts, crank pulley, timing belt covers and timing belt. (Refer to EM section). Remove exhaust front tube, timing belt pulley and rear engine gusset (bar type), then remove oil pan. (Refer to EM section).
SLC462A
9.2 - 10.8 N·m (0.94 - 1.10 kg-m, 81.4 - 95.6 in-lb)
4. 5. 6.
Crankshaft position sensor (TDC)
쐌 쐌 쐌 쐌 12 - 16 N·m (1.2 - 1.6 kg-m, 9 - 12 ft-lb)
Remove crankshaft position sensor (TDC). Remove oil pump assembly with oil strainer. Reinstall any part removed. Refill engine oil and engine coolant. Apply liquid gasket to oil pump. Apply liquid gasket to oil pan. Apply liquid gasket to both ends of oil pan oil seals. Install oil pan, fitting oil seals in the correct position.
SLC087B
LC-27
CD20T
ENGINE LUBRICATION SYSTEM Oil Pump (Cont’d)
DISASSEMBLY AND ASSEMBLY SEC. 150
6 - 8 (0.6 - 0.8, 52 - 69) Cover
Oil pump body
Regulator valve
Spring
.
Inner gear
Shim
39 - 69 (4.0 - 7.0, 29 - 51) Gasket
Plug
N·m (kg-m, ft-lb)
Outer gear
N·m (kg-m, in-lb) 16 - 19 (1.6 - 1.9, 12 - 14) :
2.5 ± 0.5 (0.098 ± 0.020) dia.
Unit: mm (in)
Bolt hole
Apply engine oil
SLC097B
쐌
When installing oil pump, apply engine oil to inner and outer gears.
쐌
Apply liquid gasket when installing oil pump onto engine.
2.5 ± 0.5 (0.098 ± 0.020) dia. SLC566A
LC-28
CD20T
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)
INSPECTION Using a feeler gauge, check the following clearances. Unit: mm (in) Body to outer gear clearance
1 쑗
2 쑗 Housing to inner gear clearance 쑗 3 Housing to outer gear clearance 쑗 4 Inner gear to housing clearance 쑗 5
Outer gear to inner gear clearance
SLC560A
0.114 - 0.200 (0.0045 - 0.0079) Less than 0.18 (0.0071) 0.05 - 0.09 (0.0020 - 0.0035) 0.05 - 0.11 (0.0020 - 0.0043) 0.045 - 0.091 (0.0018 - 0.0036)
If it exceeds the limit, replace gear set or entire oil pump assembly.
SLC561C
SLC567A
SLC568A
REGULATOR VALVE INSPECTION Spring Regulator valve
1. 2.
Visually inspect components for wear and damage. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil. Check that it falls freely into the valve hole by its own weight. If damaged, replace regulator valve set or oil pump assembly.
Plug Shim
SLC049B
LC-29
CD20T
ENGINE LUBRICATION SYSTEM Oil Pump (Cont’d)
OIL PRESSURE RELIEF VALVE INSPECTION Inspect oil pressure relief valve (indicated by arrow) for movement, cracks and breaks by pushing the ball. If replacement is necessary, remove valve by prying it out with a suitable tool. Install a new valve by tapping it into place.
SLC446
Oil Cooler SEC. 150⋅213 34 - 44 (3.5 - 4.5, 25 - 33)
.
6 쑗
Front
16 - 21 (1.6 - 2.1, 12 - 15)
Do not re-use
16 - 21 (1.6 - 2.1, 12 - 15)
N·m (kg-m, ft-lb)
1 쑗 2 쑗
SLC084B
3 쑗 4 쑗
Oil cooler Connector
O-ring Oil filter bracket
5 쑗 6 쑗
Gasket Gasket
INSPECTION 1. 2.
Check oil cooler element and housing for cracks. Check coolant inlet of oil cooler for clogging by blowing through it. Replace it if necessary.
Oil cooler
SLC465A
LC-30
CD20T
ENGINE COOLING SYSTEM
Cooling Circuit
Cooling Circuit
Bottom by-pass
To radiator
Oil cooler
From turbocharger
Thermostat
Radiator cap
Reservoir tank
Radiator
Water inlet
Thermostat
Water pump Heater unit
Cylinder block
Oil cooler
Turbocharger Cylinder head
Water outlet : By-pass passage SLC085B
LC-31
ENGINE COOLING SYSTEM
CD20T
System Check
System Check 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 cap and carefully loosen it a quarter turn to release built-up pressure. Then remove the cap completely.
CHECKING COOLING SYSTEM HOSES Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.
CHECKING RADIATOR CAP To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure: Standard 98 - 118 kPa (0.98 - 1.18 bar, 1.0 - 1.2 kg/cm2, 14 - 17 psi) Limit 59 - 118 kPa (0.59 - 1.18 bar, 0.6 - 1.2 kg/cm2, 8.6 - 17.1 psi) SLC613-A
Pull the negative pressure valve to open it. Check that it closes completely when released.
SMA967B
CHECKING COOLING SYSTEM FOR LEAKS To check for leakage, apply pressure to the cooling system with a tester. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage. SLC422A
LC-32
ENGINE COOLING SYSTEM
CD20T Water Pump
Water Pump REMOVAL AND INSTALLATION . .
Radiator lower . hose
Radiator
.
NLC040
Drain plug (cylinder block)
CAUTION: 쐌 When removing water pump assembly, be careful not to get coolant on drive belt. 쐌 Water pump cannot be disassembled and should be replaced as a unit. 쐌 After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester. 1. Remove radiator lower hose from radiator and drain engine coolant. 2. Drain engine coolant from cylinder block. 3. Remove upper radiator hose, timing belt covers, front engine mounting bracket and timing belt. (Refer to EM section). 4. Remove timing belt tensioner and idler and timing belt lower back cover.
NLC041
5.
Remove water pump.
쐌
When installing water pump, replace the gasket with a new one.
Water pump
.
SLC562AA
22 - 25 N·m (2.2 - 2.6 kg-m, 16 - 19 ft-lb) SLC086B
INSPECTION 쐌 쐌
Check body assembly for rust or corrosion. Check for rough operation due to excessive end play.
SLC760
LC-33
CD20T
ENGINE COOLING SYSTEM Thermostat
Thermostat REMOVAL AND INSTALLATION SEC. 210-211
Water outlet 16 - 21 (1.6 - 2.1, 12 - 15)
From oil cooler 16 - 21 (1.6 - 2.1, 12 - 15)
From heater unit Up
Thermostat Thermostat housing Water inlet 16 - 21 (1.6 - 2.1, 12 - 15)
2.5±0.5 (0.098±0.020) dia.
2.5 (0.098) 3.5 (0.138) Bolt hole
Unit: mm (in) : N·m (kg-m, ft-lb)
Bolt hole 2.5±0.5 (0.098±0.020) dia. 2.5±0.5 (0.098±0.020) dia.
2.5±0.5 (0.098±0.020) dia. 2.5±0.5 (0.098±0.020) dia. SLC564AA
1. 2. 3. 4. 5.
6. 쐌
Upper Jiggle valve
Drain engine coolant. Remove lower radiator hose. Remove water inlet, then take out thermostat. Before installing thermostat, remove all traces of liquid gasket from mating surface of each part using a scraper. Apply liquid gasket to water outlet, thermostat housing and water inlet.
Install thermostat with jiggle valve uppermost. After installation, run engine for a few minutes, and check for leaks.
Air bleeder
SLC097
LC-34
CD20T
ENGINE COOLING SYSTEM
Thermostat (Cont’d)
INSPECTION 1. 2.
Check valve seating condition at ordinary temperatures. It should seat tightly. Check valve opening temperature and valve lift.
Valve opening temperature Valve lift
3. SLC343
°C (°F) 82 (180) mm/°C (in/°F) More than 10/95 (0.39/203)
Then check if valve closes at 5°C (41°F) below valve opening temperature.
LC-35
CD20T
ENGINE COOLING SYSTEM Radiator
Radiator
4.0 - 4.5 (0.41 - 0.45, 36 - 39) 4.0 - 4.5 (0.41 - 0.45, 36 - 39)
3.8 - 4.5 (0.39 - 0.45, 34 - 39)
3.25 - 4.25 (0.33 - 0.43, 28.8 - 37.6) : N·m (kg-m, in-lb) NLC089
1 쑗 2 쑗 3 쑗 4 쑗
Reservoir tank Reservoir tank hose Radiator cap Mounting bracket
5 쑗 6 쑗 7 쑗 8 쑗
Upper radiator hose Mounting rubber Radiator Lower radiator hose
9 쑗 10 쑗 11 쑗
Cooling fan Cooling fan motor Cooling fan motor shield
Cooling fan control system 쐌
Cooling fans are controlled by the ECM. For details, refer to EC section (“COOLING FAN”, “Diagnostic Procedure”, EC-CD90).
Refilling engine coolant 쐌
For details on refilling engine coolant, refer to MA section (“ENGINE MAINTENANCE”, “Changing Engine Coolant”, MA-52).
LC-36
ENGINE COOLING SYSTEM Overheating Cause Analysis
Overheating Cause Analysis Symptom
Check items
Water pump malfunction
Worn or loose drive belt
Thermostat stuck closed Poor heat transfer
NCLC0028
— Dust contamination or paper clogging
Damaged fins
—
Mechanical 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
—
—
—
—
—
—
—
—
—
—
—
Damaged fan blades Damaged radiator shroud Improper coolant mixture Cooling sys- ratio tem parts malfunction Poor coolant quality
Loose clamp Cooling hose Cracked hose Water pump
Poor sealing Loose
Radiator cap Poor sealing
Coolant leaks
O-ring for damage, deterioration or improper fitting
Insufficient coolant Radiator
Cracked radiator tank Cracked radiator core
Reservoir tank
Cracked reservoir tank Cylinder head deterioration
Overflowing reservoir tank
LC-37
Exhaust gas leaks into cooling system
Cylinder head gasket deterioration
ENGINE COOLING SYSTEM Overheating Cause Analysis (Cont’d) 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
LC-38
—
QG
SERVICE DATA AND SPECIFICATIONS (SDS)
Oil Pressure Check
Oil Pressure Check
NCL0011
Engine speed rpm
Approximate discharge pressure kPa (bar, kg/cm2, psi)
600
More than 98 (0.98, 1.0, 14)
2,000
More than 294 (2.94, 3.0, 43)
6,000
More than 392 (3.92, 4.0, 57)
Oil Pump Inspection
NCLC0013
Unit: mm (in) Body to outer gear radial clearance
0.250 - 0.325 (0.0098 - 0.0128)
Inner gear to outer gear tip clearance
Below 0.18 (0.0071)
Body to inner gear clearance
0.030 - 0.085 (0.0012 - 0.0033)
Body to outer gear axial clearance
0.030 - 0.090 (0.0012 - 0.0035)
Inner gear to brazed portion of housing clearance
0.045 - 0.091 (0.0018 - 0.0036)
Regulator Valve Inspection
NCLC0012
Unit: mm (in) Regulator valve to oil pump cover clearance
0.052 - 0.088 (0.0020 - 0.0035)
Thermostat Valve opening temperature Valve lift
°C (°F)
NCLC0029
82 (180)
mm/°C (in/°F)
More than 9/95 (0.35/203)
Radiator
NCLC0030
Unit: kPa (bar, kg/cm2, psi) Standard
78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Limit
59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Cap relief pressure Leakage test pressure
157 (1.57, 1.6, 23)
LC-39
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS) Oil Pressure Check
Oil Pressure Check Engine speed rpm
Approximate discharge pressure kPa (bar, kg/cm2, psi)
Idle speed
More than 78 (0.78, 0.8, 11)
3,200
314 - 392 (3.14 - 3.92, 3.2 - 4.0, 46 - 57)
Oil Pump Inspection Unit: mm (in) Body to outer gear clearance (radial)
0.114 - 0.200 (0.0045 - 0.0079)
Inner gear to outer gear tip clearance
Below 0.18 (0.0020 - 0.0071)
Body to inner gear clearance
0.05 - 0.09 (0.0020 - 0.0035)
Body to outer gear clearance (axial)
0.05 - 0.11 (0.0020 - 0.0043)
Inner gear to brazed portion of housing clearance
0.045 - 0.091 (0.0018 - 0.0036)
Regulator Valve Inspection Unit: mm (in) Regulator valve to oil pump cover clearance
0.040 - 0.097 (0.0016 - 0.0038)
Thermostat Valve opening temperature Valve lift
°C (°F)
82 (180)
mm/°C (in/°F)
More than 9/95 (0.35/203)
Radiator Unit: kPa (bar, kg/cm2, psi) Standard
78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Limit
59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Cap relief pressure Leakage test pressure
157 (1.57, 1.6, 23)
LC-40
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS)
Oil Pressure Check
Oil Pressure Check Engine speed rpm
Approximate discharge pressure kPa (bar, kg/cm2, psi)
Idle speed
More than 59 (0.59, 0.6, 9)
2,000
294 (2.9, 3, 43)
Oil Pump Inspection Unit: mm (in) Body to outer gear clearance (radial)
0.114 - 0.200 (0.0045 - 0.0079)
Outer gear to inner gear clearance
Less than 0.18 (0.0071)
Housing to inner gear clearance
0.05 - 0.09 (0.0020 - 0.0035)
Housing to outer gear clearance (axial)
0.05 - 0.11 (0.0020 - 0.0043)
Inner gear to housing clearance
0.045 - 0.091 (0.0018 - 0.0036)
Thermostat Valve opening temperature Valve lift
°C (°F)
82 (180)
mm/°C (in/°F)
More than 10/95 (0.39/203)
Radiator Unit: kPa (bar, kg/cm2, psi) Standard
98 - 118 (0.98 - 1.18, 1.0 - 1.2, 14 - 17)
Limit
59 - 118 (0.59 - 1.18, 0.6 - 1.2, 8.6 - 17.1)
Cap relief pressure Leakage test pressure
157 (1.57, 1.6, 23)
LC-41
SERVICE DATA AND SPECIFICATIONS (SDS) NOTE
LC-42
CD20T
ENGINE CONTROL SYSTEM SECTION
EC EC
CONTENTS QG16I18DE TROUBLE DIAGNOSIS - INDEX ....................................6 Alphabetical & P No. Index for DTC ...........................6 PRECAUTIONS ...............................................................9 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............9 Precautions for On Board Diagnostic (OBD) System of Engine ........................................................9 Engine Fuel & Emission Control System ..................10 Precautions ................................................................11 Wiring Diagrams and Trouble Diagnosis...................12 PREPARATION..............................................................13 Special Service Tools ................................................13 Commercial Service Tool...........................................13 ENGINE AND EMISSION CONTROL OVERALL SYSTEM.........................................................................14 Engine Control Component Parts Location...............14 Circuit Diagram ..........................................................17 System Diagram ........................................................18 Vacuum Hose Drawing ..............................................19 System Chart .............................................................20 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ...............................................21 Multiport Fuel Injection (MFI) System .......................21 Electronic Ignition (EI) System ..................................23 Air Conditioning Cut Control......................................24 Fuel Cut Control (at no load & high engine speed) ........................................................................25 Evaporative Emission System ...................................25 Positive Crankcase Ventilation ..................................28 BASIC SERVICE PROCEDURE ...................................29 Fuel Pressure Release ..............................................29 Fuel Pressure Check .................................................29 Fuel Pressure Regulator Check ................................30 Injector .......................................................................30 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment .................................................................32
Idle Air Volume Learning ...........................................33 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................36 Introduction ................................................................36 Two Trip Detection Logic ...........................................36 Emission-related Diagnostic Information ...................37 Malfunction Indicator (MI) ..........................................45 OBD System Operation Chart ...................................50 CONSULT-II ...............................................................55 Generic Scan Tool (GST) ..........................................66 TROUBLE DIAGNOSIS - INTRODUCTION..................68 Introduction ................................................................68 Work Flow..................................................................70 TROUBLE DIAGNOSIS - BASIC INSPECTION...........72 Basic Inspection.........................................................72 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................80 DTC Inspection Priority Chart....................................80 Fail-safe Chart ...........................................................81 Symptom Matrix Chart...............................................82 CONSULT-II Reference Value in Data Monitor Mode ..........................................................................86 Major Sensor Reference Graph in Data Monitor Mode ..........................................................................88 ECM Terminals and Reference Value .......................91 TROUBLE DIAGNOSIS - SPECIFICATION VALUE ....98 Description .................................................................98 Testing Condition .......................................................98 Inspection Procedure.................................................98 Diagnostic Procedure ................................................99 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.....................................................................102 Description ...............................................................102 Diagnostic Procedure ..............................................102 TROUBLE DIAGNOSIS FOR POWER SUPPLY........103 Main Power Supply and Ground Circuit..................103
CONTENTS DTC P0100 MASS AIR FLOW SENSOR (MAFS)......110 Component Description ...........................................110 CONSULT-II Reference Value in Data Monitor Mode ........................................................................110 ECM Terminals and Reference Value .....................110 On Board Diagnosis Logic.......................................110 DTC Confirmation Procedure .................................. 111 Wiring Diagram ........................................................112 Diagnostic Procedure ..............................................113 Component Inspection.............................................115 DTC P0110 INTAKE AIR TEMPERATURE SENSOR ......................................................................116 Component Description ...........................................116 On Board Diagnosis Logic.......................................116 DTC Confirmation Procedure ..................................116 Wiring Diagram ........................................................117 Diagnostic Procedure ..............................................118 Component Inspection.............................................119 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT) .......................................120 Component Description ...........................................120 CONSULT-II Reference Value in Data Monitor Mode ........................................................................120 On Board Diagnosis Logic.......................................120 DTC Confirmation Procedure ..................................121 Wiring Diagram ........................................................122 Diagnostic Procedure ..............................................123 Component Inspection.............................................124 DTC P0120 THROTTLE POSITION SENSOR ...........125 Component Description ...........................................125 CONSULT-II Reference Value in Data Monitor Mode ........................................................................125 ECM Terminals and Reference Value .....................126 On Board Diagnosis Logic.......................................126 DTC Confirmation Procedure ..................................126 Wiring Diagram ........................................................128 Diagnostic Procedure ..............................................129 Component Inspection.............................................131 DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT).....................................................132 Component Description ...........................................132 CONSULT-II Reference Value in Data Monitor Mode ........................................................................132 ECM Terminals and Reference Value .....................132 On Board Diagnosis Logic.......................................133 DTC Confirmation Procedure ..................................133 Overall Function Check ...........................................134 Wiring Diagram ........................................................135 Diagnostic Procedure ..............................................136 Component Inspection.............................................137
(Cont’d)
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING) .....................139 Component Description ...........................................139 CONSULT-II Reference Value in Data Monitor Mode ........................................................................139 ECM Terminals and Reference Value .....................139 On Board Diagnosis Logic.......................................140 DTC Confirmation Procedure ..................................140 Overall Function Check ...........................................141 Diagnostic Procedure ..............................................141 Component Inspection.............................................143 DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING) ......................145 Component Description ...........................................145 CONSULT-II Reference Value in Data Monitor Mode ........................................................................145 ECM Terminals and Reference Value .....................145 On Board Diagnosis Logic.......................................146 DTC Confirmation Procedure ..................................146 Overall Function Check ...........................................147 Diagnostic Procedure ..............................................147 Component Inspection.............................................149 DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING).......................151 Component Description ...........................................151 CONSULT-II Reference Value in Data Monitor Mode ........................................................................151 ECM Terminals and Reference Value .....................151 On Board Diagnosis Logic.......................................152 DTC Confirmation Procedure ..................................152 Overall Function Check ...........................................153 Wiring Diagram ........................................................154 Diagnostic Procedure ..............................................155 Component Inspection.............................................158 DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)........................................160 Component Description ...........................................160 CONSULT-II Reference Value in Data Monitor Mode ........................................................................160 ECM Terminals and Reference Value .....................160 On Board Diagnosis Logic.......................................161 DTC Confirmation Procedure ..................................161 Wiring Diagram ........................................................162 Diagnostic Procedure ..............................................163 Component Inspection.............................................164 DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER.......................................................166 Description ...............................................................166 CONSULT-II Reference Value in Data Monitor Mode ........................................................................166 ECM Terminals and Reference Value .....................166 On Board Diagnosis Logic.......................................166
EC-2
CONTENTS DTC Confirmation Procedure ..................................167 Wiring Diagram ........................................................168 Diagnostic Procedure ..............................................169 Component Inspection.............................................170 DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)...................171 Component Description ...........................................171 CONSULT-II Reference Value in Data Monitor Mode ........................................................................171 ECM Terminals and Reference Value .....................171 On Board Diagnosis Logic.......................................171 DTC Confirmation Procedure ..................................172 Overall Function Check ...........................................173 Wiring Diagram ........................................................174 Diagnostic Procedure ..............................................175 Component Inspection.............................................178 DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING) .................180 Component Description ...........................................180 CONSULT-II Reference Value in Data Monitor Mode ........................................................................180 ECM Terminals and Reference Value .....................180 On Board Diagnosis Logic.......................................180 DTC Confirmation Procedure ..................................181 Overall Function Check ...........................................182 Wiring Diagram ........................................................183 Diagnostic Procedure ..............................................184 Component Inspection.............................................186 DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING).........................188 Component Description ...........................................188 CONSULT-II Reference Value in Data Monitor Mode ........................................................................188 ECM Terminals and Reference Value .....................188 On Board Diagnosis Logic.......................................188 DTC Confirmation Procedure ..................................189 Overall Function Check ...........................................190 Wiring Diagram ........................................................191 Diagnostic Procedure ..............................................192 Component Inspection.............................................195 DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE) ..........................................197 Component Description ...........................................197 CONSULT-II Reference Value in Data Monitor Mode ........................................................................197 ECM Terminals and Reference Value .....................197 On Board Diagnosis Logic.......................................197 DTC Confirmation Procedure ..................................198 Overall Function Check ...........................................198 Wiring Diagram ........................................................199 Diagnostic Procedure ..............................................200 Component Inspection.............................................201
(Cont’d)
DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR) .........................................................203 Description ...............................................................203 CONSULT-II Reference Value in Data Monitor Mode ........................................................................203 ECM Terminals and Reference Value .....................203 On Board Diagnosis Logic.......................................204 DTC Confirmation Procedure ..................................204 Wiring Diagram ........................................................205 Diagnostic Procedure ..............................................206 Component Inspection.............................................207 DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE) ............................................208 On Board Diagnosis Logic.......................................208 DTC Confirmation Procedure ..................................208 Wiring Diagram ........................................................210 Diagnostic Procedure ..............................................211 DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE) .............................................215 On Board Diagnosis Logic.......................................215 DTC Confirmation Procedure ..................................215 Wiring Diagram ........................................................217 Diagnostic Procedure ..............................................218 DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE................222 On Board Diagnosis Logic.......................................222 DTC Confirmation Procedure ..................................222 Diagnostic Procedure ..............................................223 DTC P0325 KNOCK SENSOR (KS) ...........................228 Component Description ...........................................228 ECM Terminals and Reference Value .....................228 On Board Diagnosis Logic.......................................228 DTC Confirmation Procedure ..................................228 Wiring Diagram ........................................................229 Diagnostic Procedure ..............................................230 Component Inspection.............................................231 DTC P0335 CRANKSHAFT POSITION SENSOR (POS)............................................................................232 Component Description ...........................................232 ECM Terminals and Reference Value .....................232 On Board Diagnosis Logic.......................................233 DTC Confirmation Procedure ..................................233 Wiring Diagram ........................................................234 Diagnostic Procedure ..............................................235 Component Inspection.............................................237 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE).........................................................238 Component Description ...........................................238 ECM Terminals and Reference Value .....................238 On Board Diagnosis Logic.......................................238 DTC Confirmation Procedure ..................................239 Wiring Diagram ........................................................240
EC-3
CONTENTS Diagnostic Procedure ..............................................241 Component Inspection.............................................243 DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED)..................................................................244 Description ...............................................................244 CONSULT-II Reference Value in Data Monitor Mode ........................................................................245 ECM Terminals and Reference Value .....................245 On Board Diagnosis Logic.......................................245 DTC Confirmation Procedure ..................................246 Wiring Diagram ........................................................248 Diagnostic Procedure ..............................................249 Component Inspection.............................................251 DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) (IF SO EQUIPPED)....................................252 Description ...............................................................252 CONSULT-II Reference Value in Data Monitor Mode ........................................................................253 ECM Terminals and Reference Value .....................253 On Board Diagnosis Logic.......................................253 DTC Confirmation Procedure ..................................253 Wiring Diagram ........................................................255 Diagnostic Procedure ..............................................256 Component Inspection.............................................257 DTC P0420 THREE WAY CATALYST FUNCTION ...258 On Board Diagnosis Logic.......................................258 DTC Confirmation Procedure ..................................258 Overall Function Check ...........................................259 Diagnostic Procedure ..............................................259 DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT) .................262 Description ...............................................................262 CONSULT-II Reference Value in Data Monitor Mode ........................................................................262 ECM Terminals and Reference Value .....................263 On Board Diagnosis Logic.......................................263 DTC Confirmation Procedure ..................................263 Wiring Diagram ........................................................264 Diagnostic Procedure ..............................................265 Component Inspection.............................................266 DTC P0500 VEHICLE SPEED SENSOR (VSS) .........267 Component Description ...........................................267 ECM Terminals and Reference Value .....................267 On Board Diagnosis Logic.......................................267 DTC Confirmation Procedure ..................................267 Wiring Diagram ........................................................269 Diagnostic Procedure ..............................................271 DTC P0505 IDLE AIR CONTROL VALVE (IACV) AUXILIARY AIR CONTROL (AAC) VALVE ................274 Description ...............................................................274 CONSULT-II Reference Value in Data Monitor Mode ........................................................................275
(Cont’d)
ECM Terminals and Reference Value .....................275 On Board Diagnosis Logic.......................................275 DTC Confirmation Procedure ..................................275 Wiring Diagram ........................................................276 Diagnostic Procedure ..............................................277 Component Inspection.............................................281 DTC P0605 ECM .........................................................282 Component Description ...........................................282 On Board Diagnosis Logic.......................................282 DTC Confirmation Procedure ..................................282 Diagnostic Procedure ..............................................282 DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE ......................................................284 Component Description ...........................................284 Operation .................................................................284 CONSULT-II Reference Value in Data Monitor Mode ........................................................................284 ECM Terminals and Reference Value .....................284 On Board Diagnosis Logic.......................................284 DTC Confirmation Procedure ..................................285 Wiring Diagram ........................................................286 Diagnostic Procedure ..............................................287 Component Inspection.............................................288 DTC P1217 OVERHEAT (COOLING SYSTEM) .........289 System Description..................................................289 CONSULT-II Reference Value in Data Monitor Mode ........................................................................289 ECM Terminals and Reference Value .....................290 On Board Diagnosis Logic.......................................290 Overall Function Check ...........................................291 Wiring Diagram ........................................................292 Diagnostic Procedure ..............................................294 Main 12 Causes of Overheating..............................298 Component Inspection.............................................299 DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED) ...........................................................300 Component Description ...........................................300 On Board Diagnosis Logic.......................................300 DTC Confirmation Procedure ..................................300 Wiring Diagram ........................................................302 Diagnostic Procedure ..............................................303 Component Inspection.............................................304 DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED)..................................................................305 Description ...............................................................305 CONSULT-II Reference Value in Data Monitor Mode ........................................................................306 ECM Terminals and Reference Value .....................306 On Board Diagnosis Logic.......................................306 DTC Confirmation Procedure ..................................307 Wiring Diagram ........................................................309 Diagnostic Procedure ..............................................310
EC-4
CONTENTS Component Inspection.............................................311 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH .......................................................................313 Component Description ...........................................313 CONSULT-II Reference Value in Data Monitor Mode ........................................................................313 ECM Terminals and Reference Value .....................313 On Board Diagnosis Logic.......................................313 DTC Confirmation Procedure ..................................313 Overall Function Check ...........................................314 Wiring Diagram ........................................................315 Diagnostic Procedure For M/T Models....................316 INJECTOR ...................................................................318 Component Description ...........................................318 CONSULT-II Reference Value in Data Monitor Mode ........................................................................318 ECM Terminals and Reference Value .....................318 Wiring Diagram ........................................................319 Diagnostic Procedure ..............................................320 Component Inspection.............................................322 IGNITION SIGNAL.......................................................323 Component Description ...........................................323 CONSULT-II Reference Value in Data Monitor Mode ........................................................................323 ECM Terminals and Reference Value .....................323 Wiring Diagram ........................................................324 Diagnostic Procedure ..............................................326 Component Inspection.............................................331 START SIGNAL ...........................................................332 CONSULT-II Reference Value in Data Monitor Mode ........................................................................332 ECM Terminals and Reference Value .....................332 Wiring Diagram ........................................................333 Diagnostic Procedure ..............................................334 FUEL PUMP.................................................................336 System Description..................................................336 Component Description ...........................................336 CONSULT-II Reference Value in Data Monitor Mode ........................................................................336 ECM Terminals and Reference Value .....................337 Wiring Diagram ........................................................338 Diagnostic Procedure ..............................................339
(Cont’d)
Component Inspection.............................................341 POWER STEERING OIL PRESSURE SWITCH.........342 Component Description ...........................................342 CONSULT-II Reference Value in Data Monitor Mode ........................................................................342 ECM Terminals and Reference Value .....................342 Wiring Diagram ........................................................343 Diagnostic Procedure ..............................................344 Component Inspection.............................................346 REFRIGERANT PRESSURE SENSOR ......................347 Description ...............................................................347 ECM Terminals and Reference Value .....................347 Wiring Diagram ........................................................348 Diagnostic Procedure ..............................................349 ELECTRICAL LOAD SIGNAL.....................................351 CONSULT-II Reference Value in Data Monitor Mode ........................................................................351 ECM Terminals and Reference Value .....................351 Wiring Diagram ........................................................352 MI & DATA LINK CONNECTORS...............................354 Wiring Diagram ........................................................354
SERVICE DATA AND SPECIFICATIONS (SDS) ........355 Fuel Pressure Regulator..........................................355 Idle Speed and Ignition Timing................................355 Mass Air Flow Sensor..............................................355 Intake Air Temperature Sensor................................355 Engine Coolant Temperature Sensor ......................355 Throttle Position Sensor ..........................................355 Heated Oxygen Sensor 1 Heater (Front) ................355 Heated Oxygen Sensor 2 Heater (Rear).................355 Crankshaft Position Sensor (POS)..........................356 Camshaft Position Sensor (PHASE) .......................356 EGR Volume Control Valve (If so equipped)...........356 EGR Temperature Sensor (If so equipped).............356 EVAP Canister Purge Volume Control Valve ..........356 IACV-AAC Valve ......................................................356 Injector .....................................................................356 Ignition Coil with Power Transistor ..........................357 Fuel Pump ...............................................................357
EC-5
QG16I18DE
TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC
Alphabetical & P No. Index for DTC
NCEC0001
ALPHABETICAL INDEX FOR DTC
NCEC0001S01
DTC*5 Items (CONSULT-II screen terms)
Reference page
CONSULT-II GST*2
ECM*1
Unable to access ECM
—
—
EC-QG-81
AIR TEMP SEN/CIRC*6
P0110
0110
EC-QG-116
CMP SEN/CIRCUIT
P0340
0340
EC-QG-238
COOLANT T SEN/CIRC*3
P0115
0115
EC-QG-120
CKP SEN/CIRCUIT*6
P0335
0335
EC-QG-232
CYL 1 MISFIRE*6
P0301
0301
EC-QG-222
CYL 2 MISFIRE*6
P0302
0302
EC-QG-222
CYL 3 MISFIRE*6
P0303
0303
EC-QG-222
CYL 4 MISFIRE*6
P0304
0304
EC-QG-222
ECM*6
P0605
0605
EC-QG-282
EGR SYSTEM*6*7
P0400
0400
EC-QG-244
EGR SYSTEM*6*7
P1402
1402
EC-QG-305
EGR TEMP SEN/CIRC*6*7
P1401
1401
EC-QG-300
EGR VOL CON/V CIR*6*7
P0403
0403
EC-QG-252
ENG OVER TEMP
P1217
P1217
EC-QG-289
HO2S1 HTR (B1)*6
P0135
0135
EC-QG-166
HO2S1 (B1)*6
P0130
0130
EC-QG-132
HO2S1 (B1)*6
P0131
0131
EC-QG-139
HO2S1 (B1)*6
P0132
0132
EC-QG-145
HO2S1 (B1)*6
P0133
0133
EC-QG-151
HO2S1 (B1)*6
P0134
0134
EC-QG-160
HO2S2 (B1)*6
P0137
0137
EC-QG-171
HO2S2 (B1)*6
P0138
0138
EC-QG-180
HO2S2 (B1)*6
P0139
0139
EC-QG-188
HO2S2 (B1)*6
P0140
0140
EC-QG-197
HO2S2 HTR (B1)*6
P0141
0141
EC-QG-203
FUEL SYS-LEAN/BK1*6
P0171
0171
EC-QG-208
FUEL SYS-RIGH/BK1*6
P0172
0172
EC-QG-215
IACV/AAC VLV/CIRC*6
P0505
0505
EC-QG-274
INT/V TIM V/CIR-B1*6
P1111
1111
EC-QG-284
KNOCK SEN/CIRC-B1
P0325
0325
EC-QG-228
MAF SEN/CIRCUIT*3
P0100
0100
EC-QG-110
MULTI CYL MISFIRE*6
P0300
0300
EC-QG-222
NATS MALFUNCTION
P1610 - P1615
1610 - 1615
Refer to EL section.
P0000
0000
—
NO SELF DIAGNOSTIC FAILURE INDICATED
EC-6
TROUBLE DIAGNOSIS — INDEX
QG16I18DE
Alphabetical & P No. Index for DTC (Cont’d) DTC*5 Items (CONSULT-II screen terms)
Reference page
CONSULT-II GST*2
ECM*1
No DTC
Flashing*4
EC-QG-46
P-N POS SW/CIRCUIT*6
P1706
1706
EC-QG-313
PURG VOLUME CONT/V*6
P0443
0443
EC-QG-262
THRTL POS SEN/CIRC*3
P0120
0120
EC-QG-125
TW CATALYST SYS-B1*6
P0420
0420
EC-QG-258
VEH SPEED SEN/CIRC
P0500
0500
EC-QG-267
NO SELF DIAGNOSTIC FAILURE INDICATED
*1: *2: *3: *4: *5: *6: *7:
In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO15031-6. When the fail-safe operation occurs, the MI illuminates. While engine is running. 1st trip DTC No. is the same as DTC No. Not available for “Eastern Europe model”. If so equipped
P NO. INDEX FOR DTC
NCEC0001S02
DTC*5 CONSULT-II GST*2
ECM*1
—
—
No DTC
Items (CONSULT-II screen terms)
Reference page
Unable to access ECM
EC-QG-81
Flashing*4
NO SELF DIAGNOSTIC FAILURE INDICATED
EC-QG-46
P0000
0000
NO SELF DIAGNOSTIC FAILURE INDICATED
—
P0100
0100
MAF SEN/CIRCUIT*3
EC-QG-110
P0110
0110
AIR TEMP SEN/CIRC*6
EC-QG-116
P0115
0115
COOLANT T SEN/CIRC*3
EC-QG-120
P0120
0120
THRTL POS SEN/CIRC*3
EC-QG-125
P0130
0130
HO2S1 (B1)*6
EC-QG-132
P0131
0131
HO2S1 (B1)*6
EC-QG-139
P0132
0132
HO2S1 (B1)*6
EC-QG-145
P0133
0133
HO2S1 (B1)*6
EC-QG-151
P0134
0134
HO2S1 (B1)*6
EC-QG-160
P0135
0135
HO2S1 HTR (B1)*6
EC-QG-166
P0137
0137
HO2S2 (B1)*6
EC-QG-171
P0138
0138
HO2S2 (B1)*6
EC-QG-180
P0139
0139
HO2S2 (B1)*6
EC-QG-188
P0140
0140
HO2S2 (B1)*6
EC-QG-197
P0141
0141
HO2S2 HTR (B1)*6
EC-QG-203
P0171
0171
FUEL SYS-LEAN/BK1*6
EC-QG-208
P0172
0172
FUEL SYS-RICH/BK1*6
EC-QG-215
P0300
0300
MULTI CYL MISFIRE*6
EC-QG-222
P0301
0301
CYL 1 MISFIRE*6
EC-QG-222
EC-7
TROUBLE DIAGNOSIS — INDEX
QG16I18DE
Alphabetical & P No. Index for DTC (Cont’d) DTC*5
*1: *2: *3: *4: *5: *6: *7:
Items (CONSULT-II screen terms)
Reference page
CONSULT-II GST*2
ECM*1
P0302
0302
CYL 2 MISFIRE*6
EC-QG-222
P0303
0303
CYL 3 MISFIRE*6
EC-QG-222
P0304
0304
CYL 4 MISFIRE*6
EC-QG-222
P0325
0325
KNOCK SEN/CIRC-B1
EC-QG-228
P0335
0335
CKP SEN/CIRCUIT *6
EC-QG-232
P0340
0340
CMP SEN/CIRCUIT
EC-QG-238
P0400
0400
EGR SYSTEM*6*7
EC-QG-244
P0403
0403
EGR VOL CON/V CIR*6*7
EC-QG-252
P0420
0420
TW CATALYST SYS-B1*6
EC-QG-258
P0443
0443
PURG VOLUME CONT/V*6
EC-QG-262
P0500
0500
VEH SPEED SEN/CIRC
EC-QG-267
P0505
0505
IACV/AAC VLV/CIRC*6
EC-QG-274
P0605
0605
ECM
EC-QG-282
P1111
1111
INT/V TIM V/CIR-B1*6
EC-QG-284
P1217
1217
ENG OVER TEMP
EC-QG-289
P1401
1401
EGR TEMP SEN/CIRC*6*7
EC-QG-300
P1402
1402
EGR SYSTEM*6*7
EC-QG-305
P1610 - 1615
1610 - 1615
P1706
1706
NATS MALFUNCTION P-N POS SW/CIRCUIT*6
In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO15031-6. When the fail-safe operation occurs, the MI illuminates. While engine is running. 1st trip DTC No. is the same as DTC No. Not available for “Eastern Europe model”. If so equipped
EC-8
Refer to EL section. EC-QG-313
PRECAUTIONS
QG16I18DE
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
NCEC0002
The Supplemental Restraint System “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: I 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 dealer. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors).
Precautions for On Board Diagnostic (OBD) System of Engine
NCEC0003
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: I Be sure to turn the ignition switch “OFF” and disconnect the negative battery terminal before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. I 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.) I 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 EL section, “Description”, “HARNESS CONNECTOR”. I 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. I 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 EGR system or fuel injection system, etc. I Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before returning the vehicle to the customer.
EC-9
PRECAUTIONS
QG16I18DE
Engine Fuel & Emission Control System
Engine Fuel & Emission Control System
NCEC0004
SEF331WB
EC-10
PRECAUTIONS
QG16I18DE Precautions
Precautions
NCEC0005
I
Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned off.
I
When connecting or disconnecting ECM harness connector, use lever as shown. When connecting, fasten connector securely with lever moved until it stops.
I
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 terminals when connecting pin connectors.
I
Before replacing ECM, perform Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-QG-91.
I
After performing each TROUBLE DIAGNOSIS, perform “Overall Function Check” or “DTC Confirmation Procedure”. 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.
SEF289H
SEF908W
SEF291H
MEF040D
SAT652J
EC-11
PRECAUTIONS
QG16I18DE
Precautions (Cont’d)
I
I
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
Wiring Diagrams and Trouble Diagnosis
NCEC0006
When you read Wiring diagrams, refer to the followings: I “HOW TO READ WIRING DIAGRAMS” in GI section I “POWER SUPPLY ROUTING” for power distribution circuit in EL section When you perform trouble diagnosis, refer to the followings: I “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” in GI section I “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” in GI section
EC-12
QG16I18DE
PREPARATION
Special Service Tools
Special Service Tools Tool number Tool name
NCEC0007
Description
KV10117100 Heated oxygen sensor wrench
Loosening or tightening front heated oxygen sensor with 22 mm (0.87 in) hexagon nut
NT379
KV10114400 Heated oxygen sensor wrench
Loosening or tightening rear heated oxygen sensor a: 22 mm (0.87 in)
NT636
Commercial Service Tool Tool name
NCEC0008
Description
Fuel filler cap adapter
Checking fuel tank vacuum relief valve opening pressure
NT653
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 dia. with pitch 1.5 mm for Zirconia Oxygen Sensor b: 12 mm dia. with pitch 1.25 mm for Titania Oxygen Sensor
NT778
Anti-seize lubricant (PermatexTM 133AR or equivalent meeting MIL specification MIL-A-907)
Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads.
NT779
EC-13
ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE Engine Control Component Parts Location
Engine Control Component Parts Location
NCEC0009
YEC128A
EC-14
ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE Engine Control Component Parts Location (Cont’d)
YEC129A
EC-15
ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE Engine Control Component Parts Location (Cont’d)
SEF911W
EC-16
ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE Circuit Diagram
Circuit Diagram
NCEC0010
YEC062A
EC-17
ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE System Diagram
System Diagram
NCEC0011
YEC116A
EC-18
ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE Vacuum Hose Drawing
Vacuum Hose Drawing
NCEC0012
Refer to “System Diagram” on EC-QG-18 for vacuum control system.
Fuel pressure regulator EVAP canister purge pipe (to EVAP canister)
To air control valve (Power steering)
To air duct
EVAP canister purge volume control solenoid valve EVAP canister
Air Fuel tank NEF231A
EC-19
ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE System Chart
System Chart Input (Sensor) I I I I I I I I I I I I I I I I I I
Camshaft position sensor (PHASE) Mass air flow sensor Engine coolant temperature sensor Heated oxygen sensor 1 (front) Ignition switch Throttle position sensor PNP switch Air conditioner switch Knock sensor EGR temperature sensor*1*3 Crankshaft position sensor (POS) Battery voltage Power steering oil pressure switch Vehicle speed sensor or ABS actuator and electric unit (control unit) Intake air temperature sensor Heated oxygen sensor 2 (rear)*2 Electrical load Refrigerant pressure sensor
NCEC0013
ECM Function
Output (Actuator)
Fuel injection & mixture ratio control
Injectors
Electronic ignition system
Power transistor
Idle air control system
IACV-AAC valve
Valve timing control
Intake valve timing control solenoid valve
Fuel pump control
Fuel pump relay
Heated oxygen sensor 1 monitor & on board diagnostic system
Malfunction indicator (On the instrument panel)
EGR control*3
EGR volume control valve*3
Heated oxygen sensor 1, 2 heater control
Heated oxygen sensor heater
EVAP canister purge flow control
EVAP canister purge volume control solenoid valve
Cooling fan control
Cooling fan relay
Air conditioning cut control
Air conditioner relay
*1: This sensor is not used to control the engine system. They are used only for the on board diagnosis. *2: Under normal conditions, this sensor is not for engine control operation. *3: If so equipped
EC-20
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
QG16I18DE
Multiport Fuel Injection (MFI) System
Multiport Fuel Injection (MFI) System DESCRIPTION Input/Output Signal Chart
NCEC0014 NCEC0014S01
Sensor
Input Signal to ECM
Crankshaft position sensor (POS)
Engine speed and piston position
Camshaft position sensor (PHASE)
Cylinder number
Mass air flow sensor
Amount of intake air
Engine coolant temperature sensor
Engine coolant temperature
Heated oxygen sensor 1 (front)
Density of oxygen in exhaust gas
Throttle position sensor
Throttle position Throttle valve idle position
PNP switch
Gear position
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Ignition switch
Start signal
Air conditioner switch
Air conditioner operation
Knock sensor
Engine knocking condition
Electrical load
Electrical load signal
Battery
Battery voltage
Power steering oil pressure switch
Power steering operation
Heated oxygen sensor 2 (rear)*
Density of oxygen in exhaust gas
ECM function
Fuel injection & mixture ratio control
Actuator
Injector
* Under normal conditions, this sensor is not for engine control operation.
Basic Multiport Fuel Injection System
NCEC0014S02
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 both the camshaft position sensor and the mass air flow sensor.
Various Fuel Injection Increase/Decrease Compensation
NCEC0014S03
In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. I During warm-up I When starting the engine I During acceleration I Hot-engine operation I High-load, high-speed operation I During deceleration I During high engine speed operation I During high vehicle speed operation (M/T models) I Extremely high engine coolant temperature
EC-21
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
QG16I18DE
Multiport Fuel Injection (MFI) System (Cont’d)
Mixture Ratio Feedback Control (Closed loop control)
NCEC0014S04
SEF336WA
The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The three way catalyst can then better reduce CO, HC and NOx emissions. This system uses a heated oxygen sensor 1 (front) in the exhaust manifold to monitor if the engine operation is rich or lean. The ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about the heated oxygen sensor 1 (front), refer to EC-QG-132. 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 (rear) is located downstream of the three way catalyst. Even if the switching characteristics of the heated oxygen sensor 1 (front) shift, the air-fuel ratio is controlled to stoichiometric by the signal from the heated oxygen sensor 2 (rear).
Open Loop Control
NCEC0014S05
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. I Deceleration and acceleration I High-load, high-speed operation I Malfunction of heated oxygen sensor 1 (front) or its circuit I Insufficient activation of heated oxygen sensor 1 (front) at low engine coolant temperature I High engine coolant temperature I During warm-up I When starting the engine
Mixture Ratio Self-learning Control
NCEC0014S06
The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the heated oxygen sensor 1 (front). 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 film) and characteristic changes during operation (i.e., 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 the heated oxygen sensor 1 (front) 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-22
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
QG16I18DE
Multiport Fuel Injection (MFI) System (Cont’d)
Fuel Injection Timing
NCEC0014S07
SEF337W
Two types of systems are used. Sequential Multiport Fuel Injection System NCEC0014S0701 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 NCEC0014S0702 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 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
NCEC0014S08
Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.
Electronic Ignition (EI) System DESCRIPTION Input/Output Signal Chart Sensor
NCEC0015 NCEC0015S01
Input Signal to ECM
Crankshaft position sensor (POS)
Engine speed and piston position
Camshaft position sensor (PHASE)
Cylinder number
Mass air flow sensor
Amount of intake air
Engine coolant temperature sensor
Engine coolant temperature
Throttle position sensor
Throttle position Throttle valve idle position
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Ignition switch
Start signal
Knock sensor
Engine knocking
PNP switch
Gear position
Battery
Battery voltage
EC-23
ECM function
Actuator
Ignition timPower transistor ing control
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
QG16I18DE
Electronic Ignition (EI) System (Cont’d)
System Description
NCEC0015S02
SEF742M
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. This data forms the map shown above. The ECM receives information such as the injection pulse width, crankshaft position sensor signal and camshaft position sensor signal. Computing this information, ignition signals are transmitted to the power transistor. e.g., N: 1,800 rpm, Tp: 1.50 msec A°BTDC During the following conditions, the ignition timing is revised by the ECM according to the other data stored in the ECM. I At starting I During warm-up I At idle I 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.
Air Conditioning Cut Control DESCRIPTION Input/Output Signal Chart Sensor
NCEC0016 NCEC0016S01
Input Signal to ECM
Air conditioner switch
Air conditioner “ON” signal
Throttle position sensor
Throttle valve opening angle
Crankshaft position sensor (POS)
Engine speed
Engine coolant temperature sensor
Engine coolant temperature
Ignition switch
Start signal
Refrigerant pressure sensor
Refrigerant pressure
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Power steering oil pressure switch
Power steering operation
ECM function
Air conditioner cut control
Actuator
Air conditioner relay
System Description
NCEC0016S02
This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned off. I When the accelerator pedal is fully depressed. I When cranking the engine. I At high engine speeds. I When the engine coolant temperature becomes excessively high. I When operating power steering during low engine speed or low vehicle speed. I When engine speed is excessively low.
EC-24
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
QG16I18DE
Fuel Cut Control (at no load & high engine speed)
Fuel Cut Control (at no load & high engine speed) DESCRIPTION Input/Output Signal Chart Sensor
NCEC0017 NCEC0017S01
Input Signal to ECM
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
PNP switch
Neutral position
Throttle position sensor
Throttle position
Engine coolant temperature sensor
Engine coolant temperature
Crankshaft position sensor (POS)
Engine speed
ECM function
Fuel cut control
Actuator
Injectors
If the engine speed is above 3,950 rpm with no load, (for example, in Neutral and engine speed over 4,000 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 1,150 rpm, then fuel cut is cancelled. NOTE: This function is different from deceleration control listed under “Multiport Fuel Injection (MFI) System”, EC-QG-21.
Evaporative Emission System DESCRIPTION
NCEC0018
SEF916WA
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-25
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
QG16I18DE
Evaporative Emission System (Cont’d)
INSPECTION EVAP Canister
NCEC0019 NCEC0019S01
Check EVAP canister as follows: 1. Block port B. Orally blow air through port A. Check that air flows freely through port C with check valve resistance. 2. Block port A. Orally blow air through port B. Check that air flows freely through port C.
SEF917W
Fuel Tank Vacuum Relief Valve (Built into fuel fillerNCEC0019S03 cap) 1. 2.
SEF918W
3.
Wipe clean valve housing. Check valve opening pressure and vacuum. Pressure: 16.0 - 20.0 kPa (0.16 - 0.20 bar, 0.163 - 0.204 kg/cm2, 2.32 - 2.90 psi) Vacuum: −6.0 to −3.5 kPa (−0.060 to −0.035 bar, −0.061 to −0.036 kg/cm2, −0.87 to −0.51 psi) If out of specification, replace fuel filler cap as an assembly.
Evaporative Emission (EVAP) Canister Purge Volume Control Solenoid Valve NCEC0019S07 Refer to EC-QG-266.
SEF943S
EC-26
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
QG16I18DE
Evaporative Emission System (Cont’d)
EVAPORATIVE EMISSION LINE DRAWING
NCEC0020
SEF919W
EC-27
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
QG16I18DE
Positive Crankcase Ventilation
Positive Crankcase Ventilation DESCRIPTION
NCEC0022
SEF921W
This system returns blow-by gas to the intake collector. 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 duct 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 intake collector under all conditions.
INSPECTION PCV (Positive Crankcase Ventilation) Valve
NCEC0023 NCEC0023S01
With engine running at idle, remove PCV valve from breather separator. 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 the valve inlet.
SEC137A
Ventilation Hose 1. 2.
NCEC0023S02
Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.
ET277
EC-28
BASIC SERVICE PROCEDURE
QG16I18DE Fuel Pressure Release
Fuel Pressure Release
NCEC0024
Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.
WITH CONSULT-II 1. 2. 3. PEF823K
4.
WITHOUT CONSULT-II 1. 2. 3. 4.
NCEC0024S01
Start engine. Perform “FUEL PRES RELEASE” in “WORK SUPPORT” mode with CONSULT-II. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. NCEC0024S02
Remove fuse for fuel pump. Refer to fuse block cover for fuse location. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF and reconnect fuel pump fuse.
SEF922W
Fuel Pressure Check I I I I I
SEF925W
1. 2. 3. 4. 5.
NCEC0025
When reconnecting fuel line, always use new clamps. Make sure that clamp screw does not contact adjacent parts. Use a torque driver to tighten clamps. Use Pressure Gauge to check fuel pressure. Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false readings. Release fuel pressure to zero. Disconnect fuel hose between fuel filter and fuel tube (engine side). Install pressure gauge between fuel filter and fuel tube. Start engine and check for fuel leakage. Read the indication of fuel pressure gauge. At idle speed: With vacuum hose connected Approximately 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) With vacuum hose disconnected Approximately 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi)
EC-29
BASIC SERVICE PROCEDURE
QG16I18DE
Fuel Pressure Regulator Check
If results are unsatisfactory, perform Fuel Pressure Regulator Check, EC-QG-30.
Fuel Pressure Regulator Check
NCEC0026
1.
Stop engine and disconnect fuel pressure regulator vacuum hose from intake manifold. 2. Plug intake manifold with a rubber cap. 3. Connect variable vacuum source to fuel pressure regulator. 4. Start engine and read indication of fuel pressure gauge as vacuum is changed. Fuel pressure should decrease as vacuum increases. If results are unsatisfactory, replace fuel pressure regulator. SEF718B
Injector REMOVAL AND INSTALLATION 1. 2.
SEF926W
3. 4. I I I 5. I I I I I
SEF927W
I 6. I
NCEC0027
Release fuel pressure to zero. Remove fuel tube assemblies in numerical sequence as shown in the Figure at left. Expand and remove clips securing fuel injectors. Extract fuel injectors straight from fuel tubes. Be careful not to damage injector nozzles during removal. Do not bump or drop fuel injectors. Do not disassemble or adjust fuel injectors. Install fuel injectors. Carefully install O-rings, including the one used with the pressure regulator. Use bare hands to install O-rings. Do not wear gloves. Apply a coat of engine oil (with a low viscosity of 5W-30, etc.) to O-rings before installation. Do not use solvent to clean O-rings and other parts. Make sure that O-rings and other parts are clean and free from foreign particles. Be careful not to damage O-rings with service tools or finger nails. Do not expand or twist O-rings. If stretched, do not insert them into fuel tubes immediately after stretching. Always insert O-rings straight into fuel tubes. Do not tilt or rotate them during installation. Position clips in grooves on fuel injectors. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.
EC-30
BASIC SERVICE PROCEDURE
QG16I18DE Injector (Cont’d)
SEF928W
7. 8. I
Align protrusions of fuel tubes with those of fuel injectors. Insert fuel injectors straight into fuel tubes. After properly inserting fuel injectors, check to make sure that fuel tube protrusions are engaged with those of fuel injectors, and that flanges of fuel tubes are engaged with clips. Discard old clips; replace with new ones.
9.
SEF929W
Tighten fuel tube assembly mounting nuts in numerical sequence (indicated in the Figure at left) and in two stages. : Tightening torque N⋅m (kg-m, ft-lb) 1st stage: 12 - 13 (1.2 - 1.4, 9 - 10) 2nd stage: 17 - 23 (1.7 - 2.4, 13 - 17) 10. Insert fuel hoses into fuel tubes so that ends of fuel hoses butt up against fuel tubes; fasten with clamps, avoiding bulges. CAUTION: After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage.
EC-31
BASIC SERVICE PROCEDURE
QG16I18DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment
NCEC0028
DIRECT IGNITION SYSTEM — HOW TO CHECK IDLE SPEED AND IGNITION TIMING NCEC0028S03 Idle Speed NCEC0028S0301 I
Using CONSULT-II Check idle speed in “DATA MONITOR” mode with CONSULTII.
NEF059A
Ignition Timing
NCEC0028S0302
Any of following two methods may be used. I Method A a) Attach timing light to loop wire as shown. b) Check ignition timing.
SEF931W
I a) b)
c)
Method B Remove No. 1 ignition coil. Connect No. 1 ignition coil and No. 1 spark plug with suitable high-tension wire as shown, and attach timing light clamp to this wire. Check ignition timing.
SEF933W
SEF284G
EC-32
BASIC SERVICE PROCEDURE
QG16I18DE Idle Air Volume Learning
SEF311Q
Idle Air Volume Learning DESCRIPTION
NCEC0541 NCEC0541S01
“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: I Each time IACV-AAC valve, throttle body or ECM is replaced. I Idle speed or ignition timing is out of specification.
PRE-CONDITIONING SEF452Y
SEF454Y
OPERATION PROCEDURE With CONSULT-II 1. 2. 3. 4. SEF455Y
NCEC0541S04
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. I Battery voltage: More than 12.9V (At idle) I Engine coolant temperature: 70 - 99°C (158 - 210°F) I PNP switch: ON I 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. I Cooling fan motor: Not operating I Steering wheel: Neutral (Straight-ahead position) I Vehicle speed: Stopped I Transmission: warmed-up (Drive vehicle for 10 minutes.) NCEC0541S02 NCEC0541S0201
Turn ignition switch “ON” and wait at least 1 second. Turn ignition switch “OFF” and wait at least 9 seconds. Start the engine and warm it up to normal operating temperature. Check that all items listed under the topic “PRE-CONDITIONING” (previously mentioned) are in good order.
EC-33
QG16I18DE
BASIC SERVICE PROCEDURE Idle Air Volume Learning (Cont’d)
5. 6. 7. 8. 9.
Turn ignition switch “OFF” and wait at least 9 seconds. Start the engine and let it to idle for at least 28 seconds. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode. Touch “START” and wait 20 seconds. Make sure that “CMPLT” is displayed on CONSULT-II screen. If “INCMP” is displayed, “Idle Air Volume Learning” will not be carried out successfully. In this case, find the cause of the problem by referring to the NOTE below. 10. Rev up the engine two or three times. Make sure that idle speed and ignition timing are close to or within specifications.
Throttle body
.
Remove or install throttle position sensor harness connector (brown)
IACV-AAC valve harness connector NEF246A
ITEM
SPECIFICATION
Idle speed
700 ± 50 rpm
Ignition timing
8° ± 5° BTDC
Without CONSULT-II
NCEC0541S0202
1. 2. 3.
Turn ignition switch “ON” and wait at least 1 second. Turn ignition switch “OFF” and wait at least 9 seconds. Start the engine and warm it up to normal operating temperature. 4. Check that all items listed under the topic “PRE-CONDITIONING” (previously mentioned) are in good order. 5. Turn ignition switch “OFF” and wait at least 9 seconds. 6. Start the engine and let it to idle for at least 28 seconds. 7. Disconnect throttle position sensor harness connector (brown), then re-connect it within 5 seconds. 8. Wait 20 seconds. 9. Make sure that idle speed is within specifications. If not, the result will be incomplete. In this case, find the cause of the problem by referring to the NOTE below. 10. Rev up the engine two or three times. Make sure that idle speed and ignition timing are within specifications. ITEM
SPECIFICATION
Idle speed
700 ± 50 rpm
Ignition timing
8° ± 5° BTDC
NOTE: 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) Adjust closed throttle position switch and reset memory. (Refer to Basic Inspection, EC-QG-72.) 5) When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the problem. 6) If any of the following conditions occur after the engine has started, eliminate the cause of the problem and perform “Idle air volume learning” all over again:
EC-34
BASIC SERVICE PROCEDURE
QG16I18DE Idle Air Volume Learning (Cont’d)
I I I
Engine stalls. Erroneous idle. Blown fuses related to IACV-AAC valve system.
EC-35
QG16I18DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Introduction
Introduction
NCEC0029
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: Diagnostic Trouble Code (DTC)
Mode 3 of ISO15031-5
Freeze Frame data
Mode 2 of ISO15031-5
System Readiness Test (SRT) code
Mode 1 of ISO15031-5
1st Trip Diagnostic Trouble Code (1st Trip DTC)
Mode 7 of ISO15031-5
1st Trip Freeze Frame data Test values and Test limits
Mode 6 of ISO15031-5
Calibration ID
Mode 9 of ISO15031-5
The above information can be checked using procedures listed in the table below. X: Applicable
—: Not applicable
DTC
1st trip DTC
Freeze Frame data
1st trip Freeze Frame data
SRT code
Test value
ECM*3
X
X*1
—
—
—
—
CONSULT-II*4
X
X
X
X
X
—
GST*4
X
X*2
X
—
X
X
*1: *2: *3: *4:
When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other. 1st trip DTCs for self-diagnoses concerning SRT items cannot be shown on the GST display. In diagnostic test mode II (Self-diagnostic results), DTC is displayed on MI. DTC uses a set of four digit numbers. In SELF-DIAGNOSTIC RESULTS mode, DTC is displayed. DTC uses “P” and a set of four digit numbers.
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-QG-81.)
Two Trip Detection Logic
NCEC0030
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. X: 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
—
—
—
X
—
X
—
—
X
—
—
X
—
—
X*1
—
X*1
—
—
—
X
—
X
X
X
Blinking
Lighting up
Blinking
Lighting up
Misfire (Possible three way catalyst damage) — DTC: P0300 - P0304 (0300 - 0304) is being detected
X
—
—
Misfire (Possible three way catalyst damage) — DTC: P0300 - P0304 (0300 - 0304) is being detected
—
—
Fail-safe items (Refer to EC-QG-81.)
—
Except above
—
*1: Except “ECM”.
EC-36
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Emission-related Diagnostic Information
Emission-related Diagnostic Information DTC AND 1ST TRIP DTC
NCEC0031 NCEC0031S01
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 “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”. Refer to EC-QG-44. For malfunctions in which 1st trip DTCs are displayed, refer to EC-QG-42. 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 Mode 7 of ISO15031-5. 1st trip DTC detection occurs without lighting up the MI and therefore does not warn the driver of a problem. 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 II, refer to page EC-QG-70. Then perform “DTC Confirmation Procedure” or “Overall Function Check” to try to duplicate the problem. If the malfunction is duplicated, the item requires repair.
How to read DTC and 1st Trip DTC
NCEC0031S0101
DTC and 1st trip DTC can be read by the following methods. 1) No Tools The number of blinks of MI in the Diagnostic Test Mode II (Self-Diagnostic Results) Examples: 0340, 1320, 0705, 0750, etc. These DTCs are controlled by NISSAN. With CONSULT-II 2) With GST CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P1320, P0705, P0750, etc. These DTCs are prescribed by ISO15031-6. (CONSULT-II also displays the malfunctioning component or system.) I 1st trip DTC No. is the same as DTC No. I Output of a DTC indicates a malfunction. However, Mode II and GST 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 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]”.
DTC display
1st trip DTC display
NEF065A
EC-37
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Emission-related Diagnostic Information (Cont’d)
FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA
NCEC0031S02
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 and absolute pressure sensor 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-QG-58. 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
Items Freeze frame data
2 3
Misfire — DTC: P0300 - P0304 (0300 - 0304) Fuel Injection System Function — DTC: P0171 (0171), P0172 (0172) Except the above 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 “HOW TO ERASE EMISSIONRELATED DIAGNOSTIC INFORMATION”. Refer to EC-QG-44.
SYSTEM READINESS TEST (SRT) CODE
NCEC0031S03
System Readiness Test (SRT) code is specified in Mode 1 of ISO15031-5. It indicates whether the self-diagnostic tests for non-continuously monitored items have been completed or not. Inspection/Maintenance (I/M) tests of the on board diagnostic (OBD) II system may become the legal requirements in some states/areas. All SRT codes must be set in this case. Unless all SRT codes are set, conducting the I/M test may not be allowed. SRT codes are set after self-diagnosis has been performed one or more times. This occurs regardless of whether the diagnosis is in “OK” or “NG”, and whether or not the diagnosis is performed in consecutive trips. The following table lists the four SRT items (14 test items) for the ECM used in P11 models. SRT items
Self-diagnostic test items
Catalyst monitoring
I Three way catalyst function P0420 (0420)
Oxygen sensor monitoring
I I I I I I I I I
Oxygen sensor heater monitoring
I Heated oxygen sensor 1 (front) heater P0135 (0135) I Heated oxygen sensor 2 (rear) heater P0141 (0141)
EGR system monitoring (If so equipped)
I EGR function (Close) P0400 (0400) I EGR function (Open) P1402 (1402)
Heated Heated Heated Heated Heated Heated Heated Heated Heated
oxygen oxygen oxygen oxygen oxygen oxygen oxygen oxygen oxygen
sensor sensor sensor sensor sensor sensor sensor sensor sensor
EC-38
1 1 1 1 1 2 2 2 2
(front) (Circuit) P0130 (0130) (front) (Lean shift monitoring) P0131 (0131) (front) (Rich shift monitoring) P0132 (0132) (front) (Response monitoring) P0133 (0133) (front) (High voltage) P0134 (0134) (rear) (Min. voltage monitoring) P0137 (0137) (rear) (Max. voltage monitoring) P0138 (0138) (rear) (Response monitoring) P0139 (0139) (rear) (High voltage) P0140 (0140)
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Emission-related Diagnostic Information (Cont’d)
Together with the DTC, the SRT code is cleared from the ECM memory using the method described later (Refer to EC-QG-44). In addition, after engine control components/system are repaired or if the battery terminals remain disconnected for more than 24 hours, all SRT codes may be cleared from the ECM memory.
How to Display SRT Code 1.
NCEC0031S0301
With CONSULT-II Selecting “SRT STATUS” in “DTC 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 as shown below.
SEF821Y
2.
With GST Selecting Mode 1 with GST (Generic Scan Tool)
How to Set SRT Code
NCEC0031S0302
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. 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-39
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Emission-related Diagnostic Information (Cont’d)
Driving Pattern
NCEC0031S0303
YEC130A
EC-40
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Emission-related Diagnostic Information (Cont’d)
I
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: I The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F) (where the voltage between the ECM terminals 70 and 58 is 3.0 - 4.3V). I 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 terminals 70 and 58 is lower than 1.4V). Pattern 2: I 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 CONSULT-II or GST is advised. *3: The driving pattern may be omitted when all the followings are performed using the “DTC WORK SUPPORT” mode with CONSULT-II. I “EGR SYSTEM P0400” (If so equipped) I “EGR SYSTEM P1402” (If so equipped) Suggested upshift speeds Shown below are suggested vehicle speeds for shifting into a higher gear. These suggestions relate to fuel economy and vehicle performance. Actual upshift speeds will vary according to road conditions, the weather and individual driving habits. Gear change
ACCEL shift point km/h (MPH)
1st to 2nd
15 (9)
2nd to 3rd
35 (22)
3rd to 4th
50 (31)
4th to 5th
70 (43)
TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)
NCEC0031S04
The following is the information specified in Mode 6 of ISO15031-5. 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. Items for which these data (test value and test limit) are displayed are the same as SRT code items (6 test items). 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. X: Applicable
—: Not applicable
Test limit
Application
Test value (GST display) SRT item
CATALYST
Self-diagnostic test item TID
CID
01H
01H
Max.
X
02H
81H
Min.
X
Three way catalyst function
EC-41
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Emission-related Diagnostic Information (Cont’d) Test value (GST display) SRT item
Self-diagnostic test item
Heated oxygen sensor 1 (front)
HO2S
Heated oxygen sensor 2 (rear)
Heated oxygen sensor 1 (front) heater
Test limit
Application
04H
Max.
X
0AH
84H
Min.
X
0BH
04H
Max.
X
0CH
04H
Max.
X
0DH
04H
Max.
X
19H
86H
Min.
X
1AH
86H
Min.
X
1BH
06H
Max.
X
1CH
06H
Max.
X
29H
08H
Max.
X
2AH
88H
Min.
X
2DH
0AH
Max.
X
2EH
8AH
Min.
X
31H
8CH
Min.
X
32H
8CH
Min.
X
33H
8CH
Min.
X
34H
8CH
Min.
X
35H
0CH
Max.
X
X: Applicable
—: Not applicable
TID
CID
09H
HO2S HTR Heated oxygen sensor 2 (rear) heater
EGR SYSTEM (If so equipped)
EGR function (If so equipped)
EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS DTC*4 Items (CONSULT-II screen terms)
NCEC0031S05
SRT code
Test value/Test limit (GST only)
1st trip DTC*4
Reference page
CONSULT-II GST*2
ECM*1
NO SELF DIAGNOSTIC FAILURE INDICATED
P0000
0000
—
—
—
—
MAF SEN/CIRCUIT
P0100
0100
—
—
X
EC-QG-110
AIR TEMP SEN/CIRC
P0110
0110
—
—
X
EC-QG-116
COOLANT T SEN/CIRC
P0115
0115
—
—
X
EC-QG-120
THRTL POS SEN/CIRC
P0120
0120
—
—
X
EC-QG-125
HO2S1 (B1)*5
P0130
0130
X
X
X*3
EC-QG-132
HO2S1 (B1)*5
P0131
0131
X
X
X*3
EC-QG-139
HO2S1 (B1)*5
P0132
0132
X
X
X*3
EC-QG-145
HO2S1 (B1)*5
P0133
0133
X
X
X*3
EC-QG-151
HO2S1 (B1)*5
P0134
0134
X
X
X*3
EC-QG-160
HO2S1 HTR (B1)*5
P0135
0135
X
X
X*3
EC-QG-166
HO2S2 (B1)*5
P0137
0137
X
X
X*3
EC-QG-171
HO2S2 (B1)*5
P0138
0138
X
X
X*3
EC-QG-180
HO2S2 (B1)*5
P0139
0139
X
X
X*3
EC-QG-188
EC-42
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Emission-related Diagnostic Information (Cont’d) DTC*4 SRT code
Test value/Test limit (GST only)
1st trip DTC*4
Reference page
0140
X
X
X*3
EC-QG-197
P0141
0141
X
X
X*3
EC-QG-203
FUEL SYS LEAN/BK1*5
P0171
0171
—
—
X
EC-QG-208
FUEL SYS RICH/BK1*5
P0172
0172
—
—
X
EC-QG-215
MULTI CYL MISFIRE*5
P0300
0300
—
—
X
EC-QG-222
CYL 1 MISFIRE*5
P0301
0301
—
—
X
EC-QG-222
CYL 2 MISFIRE*5
P0302
0302
—
—
X
EC-QG-222
CYL 3 MISFIRE*5
P0303
0303
—
—
X
EC-QG-222
CYL 4 MISFIRE*5
P0304
0304
—
—
X
EC-QG-222
KNOCK SEN/CIRC-B1
P0325
0325
—
—
—
EC-QG-228
CKP SEN/CIRCUIT *5
P0335
0335
—
—
X
EC-QG-232
CMP SEN/CIRCUIT
P0340
0340
—
—
X
EC-QG-238
EGR SYSTEM*5*6
P0400
0400
X
X
X*3
EC-QG-244
EGR VOL CON/V CIR*5*6
P0403
0403
—
—
X
EC-QG-252
TW CATALYST SYS-B1*5
P0420
0420
X
X
X*3
EC-QG-258
PURG VOLUME CONT/V*5
P0443
0443
—
—
X
EC-QG-262
VEH SPEED SEN/CIRC
P0500
0500
—
—
X
EC-QG-267
IACV/AAC VLV/CIRC*5
P0505
0505
—
—
X
EC-QG-274
ECM
P0605
0605
—
—
X
EC-QG-282
INT/V TIM V/CIR-B1*5
P1111
1111
—
—
X
EC-QG-284
ENG OVER TEMP
P1217
1217
—
—
X
EC-QG-289
EGR TEMP SEN/CIRC*5*6
P1401
1401
—
—
X
EC-QG-300
EGR SYSTEM*5*6
P1402
1402
X
X
X*3
EC-QG-305
P-N POS SW/CIRCUIT*5
P1706
1706
—
—
X
EC-QG-313
Items (CONSULT-II screen terms)
CONSULT-II GST*2
ECM*1
HO2S2 (B1)*5
P0140
HO2S2 HTR (B1)*5
*1: *2: *3: *4: *5: *6:
In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO15031-6. These are not displayed with GST. 1st trip DTC No. is the same as DTC No. Not available for “Eastern Europe model”. If so equipped
EC-43
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Emission-related Diagnostic Information (Cont’d)
HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC (With CONSULT-II)
NCEC0031S06 NCEC0031S0601
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” (engine stopped) again. 2. Touch “ENGINE”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. (The DTC in the ECM will be erased.)
SEF950W
The emission-related diagnostic information can be erased by selecting “ERASE” in the “SELF-DIAG RESULTS” mode with CONSULT-II.
How to Erase DTC (With GST)
NCEC0031S0602
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” (engine stopped) again.
EC-44
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Emission-related Diagnostic Information (Cont’d)
2. Select Mode 4 with GST (Generic Scan Tool). The emission-related diagnostic information can be erased by selecting Mode 4 with GST (Generic Scan Tool).
How to Erase DTC (No Tools)
NCEC0031S0603
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” again. 2. Change the diagnostic test mode from Mode II to Mode I by using the data link connector. (See EC-QG48.) The emission-related diagnostic information can be erased by changing the diagnostic test mode from Diagnostic Test Mode II to Mode I by using the data link connector. (Refer to EC-QG-48.) NOTE: I If the battery is disconnected, the emission-related diagnostic information will be lost after approx. 24 hours. I Erasing the emission-related diagnostic information using CONSULT-II or GST is easier and quicker than switching the mode using the data link connector. I The following data are cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data 4) 1st trip freeze frame data 5) System readiness test (SRT) codes 6) Test values 7) Distance traveled while MI is activated 8) Others 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) NATS (Nissan Anti-Theft System)
SEF543X
I I I
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 “NATS (Nissan Anti-Theft System)” in EL section. 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 with CONSULT-II using NATS program card. Therefore, be sure to receive all keys from vehicle owner. Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.
EC-45
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Malfunction Indicator (MI) (Cont’d)
DESCRIPTION
NCEC0032
SAT652J
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. I If the MI does not light up, refer to EL section (“WARNING LAMPS”) or see EC-QG-354. 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.
On Board Diagnostic System Function
=NCEC0032S01
The on board diagnostic system has the following four functions. Diagnostic Test Mode I 1. BULB CHECK: This function checks the MI bulb for damage (blown, open circuit, etc.). If the MI does not come on, check MI circuit and ECM test mode selector. (See the following page.) 2. 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. I “Misfire (Possible three way catalyst damage)” I Fail-safe mode Diagnostic Test Mode II 3. SELF-DIAGNOSTIC RESULTS: This function allows DTCs and 1st trip DTCs to be read. 4. HEATED OXYGEN SENSOR 1 (FRONT) MONITOR: This function allows the fuel mixture condition (lean or rich), monitored by heated oxygen sensor 1 (front), to be read. MI Flashing without DTC NCEC0032S0101 If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM test mode selector following “HOW TO SWITCH DIAGNOSTIC TEST MODES”. How to switch the diagnostic test (function) modes, and details of the above functions are described later. (Refer to EC-QG-48.)
EC-46
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Malfunction Indicator (MI) (Cont’d) Condition
Diagnostic Test Mode I
Diagnostic Test Mode II
BULB CHECK
SELF-DIAGNOSTIC RESULTS
MALFUNCTION WARNING
HEATED OXYGEN SENSOR 1 (FRONT) MONITOR
Engine stopped Ignition switch in “ON” position Engine running
The following emission-related diagnostic information is cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data 4) 1st trip freeze frame data 5) System readiness test (SRT) codes 6) Test values 7) Distance traveled while MI is activated 8) Others
EC-47
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Malfunction Indicator (MI) (Cont’d)
How to Switch Diagnostic Test Modes
NCEC0032S02
SEF951WA
*1: EC-QG-354 *2: EC-QG-46
*3: EC-QG-354
EC-48
*4: EC-QG-81
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Malfunction Indicator (MI) (Cont’d)
Diagnostic Test Mode I — Bulb Check
NCEC0032S03
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the MI bulb. Refer to EL section (“WARNING LAMPS”) or see EC-QG-354.
Diagnostic Test Mode I — Malfunction Warning MI
I
NCEC0032S04
Condition
ON
When the malfunction is detected or the ECM’s CPU is malfunctioning.
OFF
No malfunction.
These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS).
Diagnostic Test Mode II — Self-diagnostic Results
NCEC0032S05
In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI. 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.
SEF952W
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 1000th-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 latter 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 TROUBLE DIAGNOSIS — INDEX, EC-QG-6.) How to Erase Diagnostic Test Mode II (Self-diagnostic results) NCEC0032S0501 The DTC can be erased from the backup memory in the ECM when the diagnostic test mode is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to “HOW TO SWITCH DIAGNOSTIC TEST MODES”.) I If the battery is disconnected, the DTC will be lost from the backup memory after approx. 24 hours. I Be careful not to erase the stored memory before starting trouble diagnoses.
EC-49
QG16I18DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator (MI) (Cont’d)
Diagnostic Test Mode II — Heated Oxygen Sensor (Front) Monitor
NCEC0032S06
In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated oxygen sensor 1 (front). 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 (front) 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
NCEC0033
RELATIONSHIP BETWEEN MI, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS I I I I
I
NCEC0033S01
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 “Two Trip Detection Logic” on EC-QG-36. The MI will go off after the vehicle is driven 3 times 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 MI (goes off) DTC, Freeze Frame Data (no display) 1st Trip DTC (clear) 1st Trip Freeze Frame Data (clear)
NCEC0033S02
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-QG-52. For details about patterns “A” and “B” under “Except”, see EC-QG-54. *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-50
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
OBD System Operation Chart (Cont’d)
RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE” <EXHAUST QUALITY DETERIORATION>, “FUEL INJECTION SYSTEM”
NCEC0033S03
SEF392S
*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
EC-51
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.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
OBD System Operation Chart (Cont’d)
EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” Driving Pattern B
NCEC0033S04 NCEC0033S0401
Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. I The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. I The B counter will be counted up when driving pattern B is satisfied without any malfunction. I The MI will go off when the B counter reaches 3. (*2 in EC-QG-51)
Driving Pattern C
NCEC0033S0402
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) × (1±0.1) [%] Engine coolant temperature (T) condition: I When the freeze frame data shows lower than 70°C (158°F), “T” should be lower than 70°C (158°F). I 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) I The C counter will be cleared when the malfunction is detected regardless of driving pattern C. I The C counter will be counted up when driving pattern C is satisfied without the same malfunction. I The DTC will not be displayed after C counter reaches 80. I The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC is stored in ECM.
EC-52
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
OBD System Operation Chart (Cont’d)
RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” NCEC0033S05
SEF393S
*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
EC-53
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.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
OBD System Operation Chart (Cont’d)
EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” NCEC0033S06 Driving Pattern A NCEC0033S0601
AEC574
I I I
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
NCEC0033S0602
Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. I The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. I The B counter will be counted up when driving pattern B is satisfied without any malfunctions. I The MI will go off when the B counter reaches 3 (*2 in EC-QG-53).
EC-54
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE CONSULT-II
CONSULT-II CONSULT-II INSPECTION PROCEDURE
=NCEC0034 NCEC0034S01
1. 2.
Turn ignition switch OFF. Connect “CONSULT-II” to data link connector. (Data link connector is located behind the fuse box cover.)
3. 4.
Turn ignition switch ON. Touch “START”.
5.
Touch “ENGINE”.
SEF922W
PBR455D
PEF895K
6.
Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual.
NEF244A
EC-55
QG16I18DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)
ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION NCEC0034S02 DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS
ENGINE CONTROL COMPONENT PARTS
Item
INPUT
WORK SUPPORT
DTC*1
FREEZE FRAME DATA*2
Camshaft position (PHASE) sensor
X
X
Mass air flow sensor
X
Engine coolant temperature sensor
X
Heated oxygen sensor 1 (Front)
DATA MONITOR
DATA MONI- ACTIVE TOR TEST (SPEC)
DTC & SRT CONFIRMATION SRT STATUS
SRT DTC WORK WORK SUPSUPPORT PORT
X
X
X
X
X
X
X
X
X
X
X
X
Heated oxygen sensor 2 (rear)
X
X
X
X
X
X
Vehicle speed sensor or ABS actuator and electric unit (control unit)
X
X
X
Throttle position sensor
X
X
X
EGR temperature sensor (If so equipped)
X
X
X
Intake air temperature sensor
X
X
X
Crankshaft position sensor (POS)
X
X
X
Knock sensor
X
Ignition switch (start signal)
X
X
Closed throttle position switch (throttle position sensor signal)
X
X
Air conditioner switch
X
X
Refrigerant pressure sensor
X
X
X
X
Power steering oil pressure switch
X
X
Electrical load
X
X
Battery voltage
X
X
Park/Neutral position (PNP) switch
X
X
X
X
EC-56
X
QG16I18DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d) DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS WORK SUPPORT
Item
DTC*1
FREEZE FRAME DATA*2
DATA MONITOR
Injectors
ENGINE CONTROL COMPONENT PARTS
Power transistor (Ignition timing) IACV-AAC valve
X
X
X
X
X (Ignition signal)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X
Intake valve timing control solenoid valve EVAP canister purge volume control solenoid valve OUTPUT
X
Air conditioner relay Fuel pump relay
DATA MONI- ACTIVE TOR TEST (SPEC)
X
DTC & SRT CONFIRMATION SRT STATUS
EGR volume control valve (If so equipped)
X
X
X
Heated oxygen sensor heater 1 (front)
X
X
X
X
Heated oxygen sensor heater 2 (rear)
X
X
X
X
Cooling fan
X
X
X
X
X
Calculated load value
X
X
SRT DTC WORK WORK SUPSUPPORT PORT
X
X
X
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-QG-38.
FUNCTION Diagnostic test mode
NCEC0034S03
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.*1
Data monitor
Input/Output data in the ECM can be read.
Data monitor (spec)
Input/Output specifications of the basic fuel schedule, AFM, A/F feedback control value and the other data monitor items 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.
DTC confirmation
The status of system monitoring tests and the self-diagnosis status/result can be confirmed.
ECM part number
ECM part numbers can be read.
*1 The following emission-related diagnostic information is cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data
EC-57
QG16I18DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) 4) 5) 6) 7) 8)
1st trip freeze frame data System readiness test (SRT) codes Test values Distance traveled while MI is activated. Others
WORK SUPPORT MODE WORK ITEM
NCEC0034S04
CONDITION
USAGE
FUEL PRESSURE RELEASE
I FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS.
When releasing fuel pressure from fuel line
TARGET IDLE RPM ADJ*
I IDLE CONDITION
When setting target idle speed
TARGET IGNITION TIMING ADJ*
I IDLE CONDITION
When adjusting target ignition timing After adjustment, confirm target ignition timing with a timing light.
*: This function is not necessary in the usual service procedure.
SELF DIAGNOSTIC MODE DTC and 1st Trip DTC
NCEC0034S05 NCEC0034S0501
Regarding items of “DTC and 1st trip DTC”, refer to “TROUBLE DIAGNOSIS — INDEX”, EC-QG-6.
Freeze Frame Data and 1st Trip Freeze Frame Data NCEC0034S0502 Freeze frame data item*
Description
DIAG TROUBLE CODE [PXXXX]
I Engine Control component part/control system has a trouble code, it is displayed as “PXXXX”. [Refer to “Alphabetical & P No. Index for DTC” (EC-QG-6).]
FUEL SYS DATA
I “Fuel injection system status” at the moment a malfunction is detected is displayed. I One mode in the following is displayed. “MODE 2”: Open loop due to detected system malfunction “MODE 3”: Open loop due to driving conditions (power enrichment, deceleration enrichment) “MODE 4”: Closed loop - using oxygen sensor(s) as feedback for fuel control “MODE 5”: Open loop - has not yet satisfied condition to go to closed loop
CAL/LD VALUE [%]
I The calculated load value at the moment a malfunction is detected is displayed.
COOLANT TEMP [°C] I The engine coolant temperature at the moment a malfunction is detected is displayed. or [°F] S-FUEL TRIM [%]
I “Short-term fuel trim” at the moment a malfunction is detected is displayed. I The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule.
L-FUEL TRIM [%]
I “Long-term fuel trim” at the moment a malfunction is detected is displayed. I The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim.
ENGINE SPEED [rpm]
I The engine speed at the moment a malfunction is detected is displayed.
VHCL SPEED [km/h] or [mph]
I The vehicle speed at the moment a malfunction is detected is displayed.
*: The items are the same as those of 1st trip freeze frame data.
EC-58
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE CONSULT-II (Cont’d)
DATA MONITOR MODE Monitored item [Unit]
ECM input signals
Main signals
Description
NCEC0034S06
Remarks I Accuracy becomes poor if engine speed drops below the idle rpm. I If the signal is interrupted while the engine is running, an abnormal value may be indicated.
ENG SPEED [rpm]
q
q
I Indicates the engine speed computed from the POS signal of the crankshaft position sensor.
MAS A/F SE-B1 [V]
q
q
I The signal voltage of the mass air flow sensor is I When the engine is stopped, a displayed. certain value is indicated. I When the engine coolant temperature sensor is open or short-circuited, ECM enters failsafe mode. The engine coolant temperature determined by the ECM is displayed.
COOLAN TEMP/S [°C] or [°F]
q
q
I The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed.
HO2S1 (B1) [V]
q
q
I The signal voltage of the heated oxygen sensor 1 (front) is displayed.
HO2S2 (B1) [V]
q
I The signal voltage of the heated oxygen sensor 2 (rear) is displayed.
q
I Display of heated oxygen sensor 1 (front) 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]
q
I Display of heated oxygen sensor 2 (rear) signal: RICH ... means the amount of oxygen after I When the engine is stopped, a three way catalyst is relatively small. certain value is indicated. LEAN ... means the amount of oxygen after three way catalyst is relatively large.
VHCL SPEED SE [km/h] or [mph]
q
BATTERY VOLT [V]
q
THRTL POS SEN [V]
q
q
I The throttle position sensor signal voltage is displayed.
EGR TEMP SEN [V] (If so equipped)
q
q
I The signal voltage of the EGR temperature sensor is displayed.
INT/A TEMP SE [°C] or [°F]
q
START SIGNAL [ON/OFF]
q
q
I Indicates [ON/OFF] condition from the starter signal.
CLSD THL POS [ON/OFF]
q
q
I Indicates idle position [ON/OFF] computed by ECM according to the throttle position sensor signal.
HO2S1 MNTR (B1) [RICH/LEAN]
q
I After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. I When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously.
I The vehicle speed computed from the vehicle speed sensor signal or ABS actuator and electric unit (control unit) signal is displayed. I The power supply voltage of ECM is displayed.
I The intake air temperature determined by the signal voltage of the intake air temperature sensor is indicated.
EC-59
I After starting the engine, [OFF] is displayed regardless of the starter signal.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
CONSULT-II (Cont’d) ECM input signals
Main signals
Description
AIR COND SIG [ON/OFF]
q
q
I Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioning signal.
P/N POSI SW [ON/OFF]
q
q
I Indicates [ON/OFF] condition from the PNP switch signal.
PW/ST SIGNAL [ON/OFF]
q
q
I Indicates [ON/OFF] condition of the power steering oil pressure switch determined by the power steering oil pressure switch signal.
q
I Indicates [ON/OFF] condition from the electrical load signal and/or lighting switch. ON ... rear defogger is operating and/or lighting switch is on. OFF ... rear defogger is not operating and lighting switch is not on.
Monitored item [Unit]
LOAD SIGNAL [ON/OFF]
q
IGNITION SW [ON/OFF]
q
I Indicates [ON/OFF] condition from ignition switch.
HEATER FAN SW [ON/OFF]
q
I Indicates [ON/OFF] condition from the heater fan switch.
INJ PULSE-B1 [msec]
q
I Indicates the actual fuel injection pulse width compensated by ECM according to the input signals.
Remarks
I When the engine is stopped, a certain computed value is indicated.
I “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction.
B/FUEL SCHDL [msec] IGN TIMING [BTDC]
q
I Indicates the ignition timing computed by ECM according to the input signals.
IACV-AAC/V [step]
q
I Indicates the IACV-AAC valve control value computed by ECM according to the input signals.
A/F ALPHA-B1 [%]
q
I Indicates the mean value of the air-fuel ratio feedback correction factor per cycle.
AIR COND RLY [ON/OFF]
q
I Indicates the air conditioner relay control condition determined by ECM according to the input signals.
FUEL PUMP RLY [ON/OFF]
q
I Indicates the fuel pump relay control condition determined by ECM according to the input signals.
INT/V SOL-B1 [ON/OFF]
I The control condition of the valve timing solenoid valve (determined by ECM according to the input signal) is indicated. ON ... Intake valve timing control operating OFF ... Intake valve timing control not operating
COOLING FAN [ON/OFF]
I Indicates the control condition of the cooling fan determined by ECM according to the input signals. HI ... High speed operation LOW ... Low speed operation OFF ... Stop
q
EC-60
I When the engine is stopped, a certain value is indicated. I This data also includes the data for the air-fuel ratio learning control.
QG16I18DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d)
Monitored item [Unit]
EGR VOL CON/V [step] (If so equipped)
ECM input signals
Main signals
q
Description
Remarks
I Indicates the EGR volume control valve computed by the ECM according to the input signals. I The opening becomes larger as the value increases.
HO2S1 HTR (B1) [ON/OFF]
I Indicates [ON/OFF] condition of heated oxygen sensor 1 (front) heater determined by ECM according to the input signals.
HO2S2 HTR (B1) [ON/OFF]
I Indicates [ON/OFF] condition of heated oxygen sensor 2 (rear) heater determined by ECM according to the input signals.
PURG VOL C/V [%]
I Indicates the EVAP canister purge volume control solenoid valve computed by the ECM according to the input signals. I The opening becomes larger as the value increases.
CAL/LD VALUE [%]
I “Calculated load value” indicates the value of the current air flow divided by peak air flow.
ABSOL TH.P/S [%]
I “Absolute throttle position sensor” indicates the throttle opening computed by ECM according to the signal voltage of the throttle position sensor.
MASS AIRFLOW [gm/s]
I Indicates the mass air flow computed by ECM according to the signal voltage of the mass air flow sensor.
TRVL AFTER MIL [km] or [Mile]
I Distance travelled while MI is activated
VOLTAGE [V]
I Voltage measured by the voltage probe.
PULSE [msec] or [Hz] or [%]
I Pulse width, frequency or duty cycle measured by the pulse probe.
IDL A/V LEAN
I 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. INCMP ... Idle air volume learning has not been performed successfully.
I Only “#” is displayed if item is unable to be measured. I Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured.
NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
EC-61
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
CONSULT-II (Cont’d)
DATA MONITOR (SPEC) MODE Monitored item [Unit]
MAS A/F SE-B1 [V]
ECM input signals
Main signals
q
q
Description
NLEC1365S07
Remarks
I The signal voltage of the mass air flow sen- I When the engine is running, specifisor specification is displayed. cation range is indicated.
B/FUEL SCHDL [msec]
I “Base fuel schedule” indicates the fuel injecI When the engine is running, specifition pulse width programmed into ECM, cation range is indicated. prior to any learned on board correction.
A/F ALPHA-B1 [%]
I When the engine is running, specifiI Indicates the mean value of the air-fuel ratio cation range is indicated. feedback correction factor per cycle. I This data also includes the data for the air-fuel ratio learning control.
q
NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
ACTIVE TEST MODE TEST ITEM
CONDITION
NCEC0034S07
JUDGEMENT
CHECK ITEM (REMEDY)
I Engine: Return to the original I Harness and connector trouble condition If trouble symptom disappears, see FUEL INJECTION I Fuel injectors I Change the amount of fuel injec- CHECK ITEM. I Heated oxygen sensor 1 (front) tion using CONSULT-II.
IACV-AAC/V OPENING
I Engine: After warming up, idle the engine. I Change the IACV-AAC valve opening steps using CONSULTII.
Engine speed changes according to the opening steps.
ENG COOLANT TEMP
I Engine: Return to the original trouble condition I Change the engine coolant temperature indication using CONSULT-II.
I Harness and connector If trouble symptom disappears, see I Engine coolant temperature senCHECK ITEM. sor I Fuel injectors
I Engine: Return to the original trouble condition IGNITION TIMING I Timing light: Set I Retard the ignition timing using CONSULT-II.
I Harness and connector I IACV-AAC valve
I “Base Idle Air Volume Initializing” (Refer to EC-QG-33.) I Camshaft position sensor If trouble symptom disappears, see (PHASE) CHECK ITEM. I Crankshaft position sensor (POS) I Engine component parts and installing conditions
POWER BALANCE
I Engine: After warming up, idle the engine. I Air conditioner switch “OFF” I Shift lever “N” I Cut off each injector signal one at a time using CONSULT-II.
Engine runs rough or dies.
I I I I I I
COOLING FAN
I Ignition switch: ON I Turn the cooling fan “ON” and “OFF” using CONSULT-II.
Cooling fan moves and stops.
I Harness and connector I Cooling fan motor
FUEL PUMP RELAY
I Ignition switch: ON (Engine stopped) I Turn the fuel pump relay “ON” and “OFF” using CONSULT-II and listen to operating sound.
Fuel pump relay makes the operat- I Harness and connector ing sound. I Fuel pump relay
EC-62
Harness and connector Compression Injectors Power transistor Spark plugs Ignition coils
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE CONSULT-II (Cont’d)
TEST ITEM
CONDITION
JUDGEMENT
CHECK ITEM (REMEDY)
EGR VOL CONT/V (If so equipped)
I Engine: After warming up, idle the engine. Engine speed changes according I Change the EGR volume control to the opening step. valve opening step using CONSULT-II.
VALVE TIMING SOL
I Ignition switch: ON I Turn intake valve timing control solenoid valve “ON” and “OFF” using CONSULT-II and listen for operating sound.
SELF-LEARNING CONT
I In this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by touching “CLEAR” on the screen.
PURG VOL CONT/V
I Engine: After warming up, idle the engine. I Change the EVAP canister purge Engine speed changes according volume control solenoid valve to the opening percent. opening percent using CONSULT-II.
IDLE AIR VOL LEARN
I In this test, the idle air volume that keeps the engine within the specified range is memorised in ECM.
I Harness and connector I EGR volume control valve
I Harness and connector Intake valve timing control solenoid I Intake valve timing control solevalve makes an operating sound. noid valve
I Harness and connector I EVAP canister purge volume control solenoid valve
DTC & SRT CONFIRMATION MODE SRT STATUS Mode
NCEC0034S08 NCEC0034S0801
For details, refer to “SYSTEM READINESS TEST (SRT) CODE”, EC-QG-38.
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
TEST ITEM
CONDITION
NCEC0034S0802
REFERENCE PAGE
HO2S1 (B1) P0130
EC-QG-132
HEATED OXYGEN SEN- HO2S1 (B1) P0131 SOR 1 (FRONT) HO2S1 (B1) P0132
EC-QG-139 EC-QG-145
HO2S1 (B1) P0133
Refer to corresponding trouble diagnosis for DTC.
HO2S2 (B1) P0137 HEATED OXYGEN SENHO2S2 (B1) P0138 SOR 2 (REAR) HO2S2 (B1) P0139 EGR SYSTEM (If so equipped)
EC-QG-151 EC-QG-171 EC-QG-180 EC-QG-188
EGR SYSTEM P0400
EC-QG-244
EGR SYSTEM P1402
EC-QG-305
EC-63
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
CONSULT-II (Cont’d)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA) NCEC0034S10
SEF705Y
SEF707X
CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1) “AUTO TRIG” (Automatic trigger): I 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 left, 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%, “REALTIME DIAG” screen is also displayed. 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): I 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. Use these triggers as follows: 1) “AUTO TRIG” I While trying to detect the DTC/1st trip DTC by performing the “DTC Confirmation Procedure”, be sure to select “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected. I 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 GI section, “Incident Simulation Tests” in “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.) 2) “MANU TRIG” I 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-64
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE CONSULT-II (Cont’d)
SEF720X
EC-65
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Generic Scan Tool (GST)
Generic Scan Tool (GST) DESCRIPTION
=NCEC0035 NCEC0035S01
Generic Scan Tool (OBDII scan tool) complying with ISO15031-4 has 9 different functions explained on the next page. ISO9141 is used as the protocol. The name “GST” or “Generic Scan Tool” is used in this service manual.
SEF139P
GST INSPECTION PROCEDURE 1. 2.
NCEC0035S02
Turn ignition switch OFF. Connect “GST” to data link connector. (Data link connector is located under the fuse box cover.)
SEF922W
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.)
SEF398S
5.
Perform each diagnostic mode according to each service procedure. For further information, see the GST Operation Manual of the tool maker.
SEF416S
EC-66
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
QG16I18DE
Generic Scan Tool (GST) (Cont’d)
FUNCTION Diagnostic test mode
NCEC0035S03
Function
MODE 1
READINESS TESTS
This mode gains access to current emission-related data values, including analog inputs and outputs, digital inputs and outputs, distance traveled while MI is activated and system status information.
MODE 2
(FREEZE DATA)
This mode gains access to emission-related data value which were stored by ECM during the freeze frame. [For details, refer to “Freeze Frame Data” (EC-QG-58).]
MODE 3
DTCs
This mode gains access to emission-related power train trouble codes which were stored by ECM.
MODE 4
CLEAR DIAG INFO
This mode can clear all emission-related diagnostic information. This includes: I Clear number of diagnostic trouble codes (MODE 1) I Clear diagnostic trouble codes (MODE 3) I Clear trouble code for freeze frame data (MODE 1) I Clear freeze frame data (MODE 2) I Reset status of system monitoring test (MODE 1) I Clear on board monitoring test results (MODE 6 and 7)
MODE 6
(ON BOARD TESTS)
This mode accesses the results of on board diagnostic monitoring tests of specific components/systems that are not continuously monitored.
MODE 7
(ON BOARD TESTS)
This mode enables the off board test drive to obtain test results for emission-related powertrain components/systems that are continuously monitored during normal driving conditions.
MODE 8 MODE 9
— (CALIBRATION ID)
This mode is not applicable on this vehicle. This mode enables the off-board (External test equipment) to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs.
EC-67
TROUBLE DIAGNOSIS — INTRODUCTION
QG16I18DE
Introduction
Introduction
MEF036D
SEF233G
NCEC0036
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 problems such as vacuum leaks, fouled spark plugs, or other problems with the engine. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems 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 problems. A road test with CONSULT-II (or GST) or a circuit tester connected should be performed. Follow the “Work Flow” on EC-QG-70. 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 problems, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “Diagnostic Worksheet” like the example on next page should be used. Start your diagnosis by looking for “conventional” problems first. This will help troubleshoot driveability problems on an electronically controlled engine vehicle.
SEF234G
DIAGNOSTIC WORKSHEET KEY POINTS WHAT
üü..... Vehicle & engine model WHEN ..... Date, Frequencies WHERE ..... Road conditions HOW ..... Operating conditions, Weather conditions, Symptoms SEF907L
NCEC0036S01
There are many operating conditions that lead to the malfunction of engine components. A good grasp of such conditions can make trouble-shooting faster and more accurate. In general, each customer feels differently about a problem. 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 malfunction indicator to come on steady or blink and DTC to be detected. Example: Vehicle ran out of fuel, which caused the engine to misfire.
EC-68
TROUBLE DIAGNOSIS — INTRODUCTION
QG16I18DE Introduction (Cont’d)
Worksheet Sample
NCEC0036S0101
MTBL0311
EC-69
TROUBLE DIAGNOSIS — INTRODUCTION
QG16I18DE
Work Flow
Work Flow
NCEC0037
SEF510ZD
*1: If the incident cannot be duplicated, refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. *2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to “TROUBLE DIAGNOSIS FOR POWER SUPPLY”, EC-QG-103.
*3: If time data of “SELF-DIAG RESULTS” is other than “0” or “1t” refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. *4: If the malfunctioning part cannot
EC-70
be found, refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. *5: EC-QG-81 *6: EC-QG-40 *7: EC-QG-98
TROUBLE DIAGNOSIS — INTRODUCTION
QG16I18DE Work Flow (Cont’d)
DESCRIPTION FOR WORK FLOW STEP
NCEC0037S01
DESCRIPTION
STEP I
Get detailed information about the conditions and the environment when the incident/symptom occurred using the “DIAGNOSTIC WORK SHEET”, EC-QG-69.
STEP II
Before confirming the concern, check and write down (print out using CONSULT-II or Generic Scan Tool) the (1st trip) Diagnostic Trouble Code (DTC) and the (1st trip) freeze frame data, then erase the code and the data. (Refer to EC-QG-44.) The (1st trip) DTC and the (1st trip) freeze frame data can be used when duplicating the incident at STEP III & IV. Study the relationship between the cause, specified by (1st trip) DTC, and the symptom described by the customer. (The “Symptom Matrix Chart” will be useful. See EC-QG-82.) Also check related service bulletins for information.
STEP III
Try to confirm the symptom and under what conditions the incident occurs. The “DIAGNOSTIC WORK SHEET” and the freeze frame data are useful to verify the incident. Connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to GI section.) If the malfunction code is detected, skip STEP IV and perform STEP V.
STEP IV
Try to detect the (1st trip) Diagnostic Trouble Code by driving in (or performing) the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE”. Check and read the (1st trip) DTC and (1st trip) freeze frame data by using CONSULT-II or Generic Scan Tool. During the (1st trip) DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to GI section.) In case the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” is not available, perform the “OVERALL FUNCTION CHECK” instead. The (1st trip) DTC cannot be displayed by this check, however, this simplified “check” is an effective alternative. The “NG” result of the “OVERALL FUNCTION CHECK” is the same as the (1st trip) DTC detection.
STEP V
Take the appropriate action based on the results of STEP I through IV. If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC PXXXX. If the normal code is indicated, proceed to the BASIC INSPECTION. (Refer to EC-QG-72.) If CONSULT-II is available, perform “DATA MONITOR (SPEC)” mode with CONSULT-II and proceed to the “TROUBLE DIAGNOSIS-SPECIFICATION VALUE”, EC-QG-98. (If malfunction is detected, proceed to “REPAIR/REPLACE”. Then perform inspections according to the Symptom Matrix Chart. (Refer to EC-QG-82.)
STEP VI
Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) “Harness Layouts”. Gently shake the related connectors, components or wiring harness with CONSULT-II set in “DATA MONITOR (AUTO TRIG)” mode. Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II. Refer to EC-QG-91. The “DIAGNOSTIC PROCEDURE” in EC section contains a description based on open circuit inspection. A short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details, refer to GI section (“HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”, “Circuit Inspection”). Repair or replace the malfunction parts.
STEP VII
Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions and circumstances which resulted in the customer’s initial complaint. Perform the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” and confirm the normal code [Diagnostic trouble code No. P0000 or 0000] is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the previous one. Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) (1st trip) DTC in ECM. (Refer to EC-QG-44.)
EC-71
TROUBLE DIAGNOSIS — BASIC INSPECTION
QG16I18DE
Basic Inspection
Basic Inspection
NCEC0038
Precaution: Perform Basic Inspection without electrical or mechanical loads applied; I Headlamp switch is OFF, On vehicle equipped with daytime light system, set lighting switch to the 1st position to light only small lamps. I Air conditioner switch is OFF, I Rear window defogger switch is OFF, I Steering wheel is in the straight-ahead position, etc. 1
INSPECTION START
1. Check service records for any recent repairs that may indicate a related problem, or a current need for scheduled maintenance. 2. Open engine hood and check the following: I Harness connectors for improper connections I Vacuum hoses for splits, kinks and improper connections I Wiring for improper connections, pinches and cuts I Air cleaner clogging I Hoses and ducts for leaks
SEF983U
©
2
GO TO 2.
CHECK THROTTLE DRUM OPERATION-I
Confirm that throttle drum is in contact with the stopper. OK or NG OK (with CONSULT-II)
©
GO TO 5.
OK (without CONSULTII)
©
GO TO 8.
NG
©
GO TO 3.
3
CHECK ACCELERATOR WIRE INSTALLATION
Check accelerator wire for slack OK or NG OK
©
GO TO 4.
NG
©
Adjust accelerator wire. Refer to FE section, “Adjusting Accelerator Wire”.
EC-72
TROUBLE DIAGNOSIS — BASIC INSPECTION
QG16I18DE Basic Inspection (Cont’d)
4
CHECK THROTTLE VALVE OPERATION
1. Remove intake air ducts. 2. Check throttle valve operation when moving throttle drum by hand. OK or NG OK
©
Retighten the throttle drum fixing nuts.
NG
©
Clean the throttle body and throttle valve.
5 1. 2. 3. 4. 5.
CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Turn ignition switch “ON”. Select “THRTL POS SEN” and “CLSD THL POS” in “DATA MONITOR” mode with CONSULT-II. Make sure that “THRTL POS SEN” indicates 0.35 to 0.65V, and “CLSD THL POS” indicates “ON”. (Accelerator pedal is fully released.)
NEF238A
OK or NG OK
©
GO TO 11.
NG
©
GO TO 6.
6
ADJUST THROTTLE POSITION SENSOR IDLE POSITION
With CONSULT-II 1. Loosen throttle position sensor fixing bolts. 2. Turn throttle position sensor body clockwise or counterclockwise until “THRTL POS SEN” indication becomes 0.35 to 0.65V.
SEF964W
3. Tighten the throttle position sensor fixing bolts. ©
GO TO 7.
EC-73
TROUBLE DIAGNOSIS — BASIC INSPECTION
QG16I18DE
Basic Inspection (Cont’d)
7
RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY
With CONSULT-II NOTE: Always warm up engine to normal operating temperature. If engine is cool, the throttle position sensor idle position memory will not be reset correctly. 1. Start engine and warm it up to normal operating temperature. 2. Select “CLSD THL POS” in “DATA MONITOR” mode with CONSULT-II. 3. Stop engine. (Turn ignition switch “OFF”.) 4. Turn ignition switch “ON” and wait at least 5 seconds.
SEF864V
5. Turn ignition switch “OFF” and wait at least 9 seconds. 6. Repeat steps 4 and 6 until “CLSD THL POS” indication changes to “ON”.
SEF061Y
©
8 1. 2. 3. 4.
GO TO 11.
CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Turn ignition switch “ON”. Check voltage between ECM terminal 92 and ground with accelerator pedal fully released.
NEF239A
Voltage: 0.35 to 0.65V OK
©
GO TO 6.
NG
©
GO TO 9.
EC-74
TROUBLE DIAGNOSIS — BASIC INSPECTION
QG16I18DE Basic Inspection (Cont’d)
9
ADJUST THROTTLE POSITION SENSOR IDLE POSITION
Without CONSULT-II 1. Loosen throttle position sensor fixing bolts. 2. Turn throttle position sensor body clockwise or counterclockwise until the voltage between ECM terminal 92 and ground becomes 0.35 to 0.65V.
SEF964W
3. Tighten the throttle position sensor fixing bolts. ©
10
GO TO 10.
RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY
Without CONSULT-II NOTE: Always warm up engine to normal operating temperature. If engine is cool, the throttle position sensor idle position memory will not be reset correctly. 1. Start engine and warm it up to normal operating temperature. 2. Stop engine. (Turn ignition switch “OFF”.) 3. Turn ignition switch “ON” and wait at least 5 seconds.
SEF864V
4. Turn ignition switch “OFF” and wait at least 9 seconds. 5. Repeat steps 4 and 6, 20 times. ©
11
GO TO 11.
CHECK (1ST TRIP) DTC
1. Start engine and warm it up to normal operating temperature. 2. Rev (2,000 to 3,000 rpm) two or three times. 3. Make sure no (1st trip) DTC is displayed with CONSULT-II GST or Diagnostic Test Mode II (Self-diagnostic Results). OK or NG OK
©
GO TO 13.
NG
©
GO TO 12.
12
REPAIR MALFUNCTION
Repair or replace components as necessary according to corresponding “Diagnostic Procedure”. ©
GO TO 11.
EC-75
TROUBLE DIAGNOSIS — BASIC INSPECTION Basic Inspection (Cont’d)
13
CHECK TARGET IDLE SPEED
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode With CONSULT-II. 3. Check idle speed. 700±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 700±50 rpm OK or NG OK
©
GO TO 22.
NG
©
GO TO 14.
14
PERFORM IDLE AIR VOLUME LEARNING
Refer to “Idle Air Volume Learning”, EC-QG-33. Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT
©
GO TO 15.
INCMP
©
1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 14.
15
CHECK TARGET IDLE SPEED AGAIN
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode With CONSULT-II. 3. Check idle speed. 700±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 700±50 rpm OK or NG OK
©
GO TO 20.
NG
©
GO TO 16.
16
REPLACE IACV-AAC VALVE
Replace IACV-AAC valve. ©
17
GO TO 17.
PERFORM IDLE AIR VOLUME LEARNING
Refer to “Idle Air Volume Learning”, EC-QG-33. Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT
©
GO TO 18.
INCMP
©
1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 14.
EC-76
QG16I18DE
TROUBLE DIAGNOSIS — BASIC INSPECTION
QG16I18DE Basic Inspection (Cont’d)
18
CHECK TARGET IDLE SPEED AGAIN
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode With CONSULT-II. 3. Check idle speed. 700±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 700±50 rpm OK or NG OK
©
GO TO 20.
NG
©
GO TO 19.
19
CHECK ECM FUNCTION
1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of a problem, but this is rarely the case.) 2. Perform initialization of NATS system and registration of NATS ignition key IDs. Refer to “NATS (Nissan Anti-Theft System)”, EC-QG-45. ©
20
GO TO 14.
CHECK IGNITION TIMING
1. Start engine and warm it up to normal operating temperature. 2. Check ignition timing at idle using a timing light.
SEM872F
Ignition timing: 8°±5° BTDC
OK
©
GO TO 28.
NG
©
GO TO 21.
21
CHECK TIMING CHAIN INSTALLATION
Check timing chain installation. Refer to EM section. OK or NG OK
©
GO TO 19.
NG
©
1. Repair the timing chain installation. 2. GO TO 14.
EC-77
TROUBLE DIAGNOSIS — BASIC INSPECTION
QG16I18DE
Basic Inspection (Cont’d)
22
CHECK IGNITION TIMING
1. Start engine and let it idle. 2. Check ignition timing at idle using a timing light.
SEM872F
Ignition timing: 8°±5° BTDC
OK
©
GO TO 28.
NG
©
GO TO 23.
23
PERFORM IDLE AIR VOLUME LEARNING
Refer to “Idle Air Volume Learning”, EC-QG-33. Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT
©
GO TO 24.
INCMP
©
1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 23.
24
CHECK TARGET IDLE SPEED AGAIN
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode With CONSULT-II. 3. Check idle speed. 700±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 700±50 rpm OK or NG OK
©
GO TO 26.
NG
©
GO TO 25.
25
CHECK ECM FUNCTION
1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of a problem, but this is rarely the case.) 2. Perform initialization of NATS system and registration of NATS ignition key IDs. Refer to “NATS (Nissan Anti-Theft System)”, EC-QG-45. ©
GO TO 23.
EC-78
TROUBLE DIAGNOSIS — BASIC INSPECTION
QG16I18DE Basic Inspection (Cont’d)
26
CHECK IGNITION TIMING AGAIN
Check ignition timing again. Refer to Test No. 22.
OK
©
GO TO 28.
NG
©
GO TO 27.
27
CHECK TIMING CHAIN INSTALLATION
Check timing chain installation. Refer to EM section. OK or NG OK
©
GO TO 25.
NG
©
1. Repair the timing chain installation. 2. GO TO 23.
28
ERASE UNNECESSARY DTC
After this inspection, unnecessary DTC No. might be displayed. Erase the stored memory in ECM. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-QG-44. ©
INSPECTION END
EC-79
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
DTC Inspection Priority Chart
DTC Inspection Priority Chart
NCEC0039
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. Priority
Detected items (DTC)
1
I I I I I I I I I I I
P0100 Mass air flow sensor P0110 Intake air temperature sensor P0115 Engine coolant temperature sensor P0120 Throttle position sensor P0325 Knock sensor P0340 Camshaft position sensor (PHASE) circuit P0403 EGR volume control valve* P0500 Vehicle speed sensor P0605 ECM P0335, P1336 Crankshaft position sensor (POS) P1706 Park/Neutral position switch
2
I I I I I I I
P0130 P0135 P0137 P0141 P0443 P1217 P1401
3
I I I I I I
P0171, P0172 Fuel injection system function P0300 - P0304 Misfire P0400, P1402 EGR function* P0420 Three way catalyst function P0505 IACV-AAC valve P1111 Intake valve timing control
- P0134 Heated oxygen sensor 1 (front) Heated oxygen sensor 1 heater (front) - P0140 Heated oxygen sensor 2 (rear) Heated oxygen sensor 2 heater (rear) EVAP canister purge volume control solenoid valve Overheat (cooling system) EGR temperature sensor*
*: If so equipped
EC-80
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE Fail-safe Chart
Fail-safe Chart
=NCEC0040
The ECM enters fail-safe mode if any of the following malfunctions is detected due to the open or short circuit. When the ECM enters the fail-safe mode, the MI illuminates. DTC No. CONSULT-II GST
ECM*1
P0100
0100
Mass air flow sensor circuit
P0115
0115
Engine coolant tempera- Engine coolant temperature will be determined by ECM based on the time ture sensor circuit after turning ignition switch “ON” or “START”. CONSULT-II displays the engine coolant temperature decided by ECM. The radiator fan operates.
Detected items
Engine operating condition in fail-safe mode
Engine speed will not rise more than 2,400 rpm due to the fuel cut.
Condition 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 P0120
0120
Throttle position sensor circuit
When engine is idling When accelerating Unable to access Diagnostic Test Mode II
ECM
40 - 80°C (104 - 176°F) (Depends on the time)
Throttle position will be determined based on the injected fuel amount and the engine speed. Therefore, acceleration will be poor. Condition
Unable to access ECM
Engine coolant temperature decided (CONSULT-II display)
Driving condition Normal Poor acceleration
ECM fail-safe activating condition The computing function of the ECM was judged to be malfunctioning. When the fail-safe system activates (i.e., if the ECM detects a malfunction condition in the CPU of ECM), the MI on the instrument panel lights to warn the driver. However it is not possible to access ECM and DTC cannot be confirmed. Engine control with fail-safe When ECM fail-safe is operating, fuel injection, ignition timing, fuel pump operation and IACV-AAC valve operation are controlled under certain limitations. ECM fail-safe operation Engine speed
Engine speed will not rise more than 3,000 rpm
Fuel injection
Simultaneous multiport fuel injection system
Ignition timing
Ignition timing is fixed at the preset valve
Fuel pump
Fuel pump relay is “ON” when engine is running and “OFF” when engine stalls
IACV-AAC valve
Full open
Replace ECM, if ECM fail-safe condition is confirmed. *: In Diagnostic Test Mode II (Self-diagnostic results)
EC-81
QG16I18DE
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart
Symptom Matrix Chart
NCEC0041
SYSTEM — ENGINE CONTROL SYSTEM
NCEC0041S01
Fuel pump circuit
1
1
2
3
2
Fuel pressure regulator system
3
3
4
4
4
Injector circuit
1
1
2
3
2
Evaporative emission system
3
3
4
4
4
Positive crankcase ventilation system
3
3
4
4
4
Incorrect idle speed adjustment
3
3
IACV-AAC valve circuit
1
1
2
3
3
Incorrect ignition timing adjustment
3
3
1
1
Ignition circuit
1
1
2
2 2
Main power supply and ground circuit Air conditioner circuit
Fuel
Air
Ignition
EGR*
AJ
AK
AL
2
2
4
4
2
2
4
4
4
4
4
1 2
AM HA
3
EC-QG-336
2
EC-QG-319
4
4
EC-QG-25
4
4
4
1
1
1
1
2
2
2
2
1
1
1
1
EC-QG-32
2
2
2
2
2
EC-QG-323
2
3
3
3
EC-QG-252
1
2
3
3
3
EC-QG-244, 252, 305
2
2
3
3
3
2
2
3
3
3
EC-82
3
3
2
2
3
3
3
3
4
2
EC-QG-30
1 - 6: The numbers refer to the order of inspection. (continued on next page) *: If so equipped
4
Reference page
4
EGR volume control valve circuit EGR system
AG AH
BATTERY DEAD (UNDER CHARGE)
AF
EXCESSIVE OIL CONSUMPTION
HIGH IDLE/LOW IDLE
AE
EXCESSIVE FUEL CONSUMPTION
LACK OF POWER/POOR ACCELERATION
AD
OVERHEATS/WATER TEMPERATURE HIGH
SPARK KNOCK/DETONATION
AC
SLOW/NO RETURN TO IDLE
HESITATION/SURGING/FLAT SPOT
AB
IDLING VIBRATION
ENGINE STALL
AA
Warranty symptom code
ROUGH IDLE/HUNTING
HARD/NO START/RESTART (EXCP. HA)
SYMPTOM
3 2 3
1
EC-QG-28 EC-QG-32 2
EC-QG-274
3
2
EC-QG-103
3
2
HA section
QG16I18DE
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)
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
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
Crankshaft position sensor (POS) circuit
2
2
Camshaft position sensor (PHASE) circuit
3
2
Mass air flow sensor circuit
1
1
2
2
2
2
1
2
3
2
1
2
3
2
Throttle position sensor circuit
1
2
Incorrect throttle position sensor adjustment
3
Vehicle speed sensor circuit or ABS actuator and electric unit (control unit) circuit
2
Heated oxygen sensor 1 (front) circuit Engine coolant temperature sensor circuit
1
Knock sensor circuit 2
Start signal circuit
2
2
AM HA
3
EC-QG-238
2
2
EC-QG-110
2
2
2
EC-QG-132
3
2
2
3
2
EC-QG-120
2
2
2
2
2
2
EC-QG-125
1
1
1
1
1
1
1
EC-QG-72
3
3
3
EC-QG-267
3
EC-QG-228
3
EC-QG-282, 81
3
3
3
3
3
3
3
3
EC-QG-332
PNP switch circuit Power steering oil pressure switch circuit
Reference page
EC-QG-232
2
ECM
BATTERY DEAD (UNDER CHARGE)
ENGINE STALL
AA
Warranty symptom code
EXCESSIVE OIL CONSUMPTION
HARD/NO START/RESTART (EXCP. HA)
SYMPTOM
3
3
2
Electrical load signal circuit 1 - 6: The numbers refer to the order of inspection. (continued on next page)
EC-83
3
3
3
EC-QG-313
3
3
EC-QG-342
3
3
EC-QG-351
QG16I18DE
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart (Cont’d)
SYSTEM — ENGINE MECHANICAL & OTHER
NCEC0041S03
Fuel
AG AH
AJ
AK
AL
BATTERY DEAD (UNDER CHARGE)
AF
EXCESSIVE OIL CONSUMPTION
AE
EXCESSIVE FUEL CONSUMPTION
HIGH IDLE/LOW IDLE
AD
OVERHEATS/WATER TEMPERATURE HIGH
LACK OF POWER/POOR ACCELERATION
AC
SLOW/NO RETURN TO IDLE
SPARK KNOCK/DETONATION
AB
IDLING VIBRATION
HESITATION/SURGING/FLAT SPOT
AA
ROUGH IDLE/HUNTING
ENGINE STALL
Warranty symptom code
HARD/NO START/RESTART (EXCP. HA)
SYMPTOM
Reference page
AM HA
Fuel tank
FE section 5
Fuel piping Vapor lock
5
5
5
5
5
5
5
5
5
5
5
5
5
Valve deposit Poor fuel (Heavy weight gasoline, Low octane) Air
5
—
Air duct Air cleaner Air leakage from air duct (Mass air flow sensor — throttle body) Throttle body, Throttle wire
5
5
5
5 5
5
5
5
5 5
FE section
Air leakage from intake manifold/ Collector/Gasket Cranking
—
Battery 1
1
1
1
1
1
1
Alternator circuit
EL section 1
Starter circuit
3
Flywheel
6
EM section
1 - 6: The numbers refer to the order of inspection. (continued on next page)
EC-84
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
Symptom Matrix Chart (Cont’d)
5
5
5
5
5
AG AH
AJ
AK
AL
BATTERY DEAD (UNDER CHARGE)
AF
EXCESSIVE OIL CONSUMPTION
AE
EXCESSIVE FUEL CONSUMPTION
AD
OVERHEATS/WATER TEMPERATURE HIGH
HIGH IDLE/LOW IDLE
AC
SLOW/NO RETURN TO IDLE
LACK OF POWER/POOR ACCELERATION
AB
IDLING VIBRATION
SPARK KNOCK/DETONATION
AA
ROUGH IDLE/HUNTING
HESITATION/SURGING/FLAT SPOT
Engine
ENGINE STALL
Warranty symptom code
HARD/NO START/RESTART (EXCP. HA)
SYMPTOM
Reference page
AM HA
Cylinder head 5
5
5
Cylinder head gasket
4
3
Cylinder block Piston
4 EM section
Piston ring 6
6
6
6
6
6
6
6
5
5
5
5
5
5
5
5
Connecting rod Bearing Crankshaft Valve mechanism
Timing chain Camshaft EM section
Intake valve 3 Exhaust valve Exhaust
Exhaust manifold/Tube/Muffler/ Gasket
5
5
5
5
5
5
5
5
FE section
5
5
5
5
5
5
5
5
MA, EM and LC sections
Three way catalyst Lubrication
Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery Oil level (Low)/Filthy oil
Cooling
Radiator/Hose/Radiator filler cap Thermostat
5
LC section
Water pump Water gallery
5
5
5
5
5
Cooling fan
5
5
4 5
Coolant level (low)/ Contaminated coolant
5 EC-QG-289 MA section
1 - 6: The numbers refer to the order of inspection.
EC-85
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0042
Remarks: I Specification data are reference values. I 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. Specification data might be displayed even when ignition timing is not adjusted to specification. This IGN TIMING monitors the data calculated by the ECM according to the input signals from the camshaft position sensor and other ignition timing related sensors.) I If the real-time diagnosis results are NG, and the on board diagnostic system results are OK, when diagnosing the mass air flow sensor, first check to see if the fuel pump control circuit is normal. MONITOR ITEM
CONDITION
ENG SPEED
I Tachometer: Connect I Run engine and compare tachometer indication with the CONSULT-II value.
MAS A/F SE-B1
I I I I
COOLAN TEMP/S
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
HO2S2 (B1) HO2S2 MNTR (B1)
Almost the same speed as the CONSULT-II value.
Idle
1.0 - 1.7V
2,500 rpm
1.5 - 2.1V
I Engine: After warming up
More than 70°C (158°F) 0 - 0.3V +, 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
SPECIFICATION
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
I Engine: After warming up
Revving engine from idle to 3,000 rpm quickly
0 - 0.3V +, 0.6 - 1.0V LEAN +, RICH
VHCL SPEED SE
I Turn drive wheels and compare speedometer indication with the CONSULT-II value
Almost the same speed as the CONSULT-II value
BATTERY VOLT
I Ignition switch: ON (Engine stopped)
11 - 14V
I Engine: Idle
Throttle valve fully closed
0.35 - 0.65V
I Ignition switch: ON (Engine stopped)
Throttle valve fully opened
3.7 - 4.5V
THRTL POS SEN
EGR TEMP SEN*
I Engine: After warming up
Less than 4.5V
START SIGNAL
I Ignition switch: ON , START , ON
OFF , ON , OFF
I Engine: Idle
Throttle valve: Idle position
ON
I Ignition switch: ON (Engine stopped)
Throttle valve: Slightly open
OFF
A/C switch “OFF”
OFF
A/C switch “ON” (Compressor operates)
ON
Shift lever “N”
ON
Except above
OFF
Steering wheel in neutral position (forward direction)
OFF
The steering wheel is turned
ON
CLSD THL/P SW CLSD THL POS
AIR COND SIG
P/N POSI SW
PW/ST SIGNAL
IGNITION SW
I Engine: After warming up, idle the engine
I Ignition switch: ON
I Engine: After warming up, idle the engine I Ignition switch: ON , OFF
ON , OFF
*: If so equipped
EC-86
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM
INJ PULSE-B1
LOAD SIGNAL
B/FUEL SCHDL
IGN TIMING
IACV-AAC/V
PURG VOL C/V
CONDITION I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
I Engine: running
SPECIFICATION
Idle
2.4 - 3.2 msec
2,000 rpm
1.9 - 3.2 msec
Rear window defogger or headlamp “ON”
ON
Except the above
OFF
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
1.5 - 2.5 msec
2,000 rpm
1.5 - 2.5 msec
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
8° BTDC
2,000 rpm
Approx. 30° BTDC
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
5 - 20 steps
2,000 rpm
—
Idle
0%
Rev engine up from 2,000 to 4,000 rpm.
—
Maintaining engine speed at 2,000 rpm
75 - 125%
I Engine: After warming up I No-load I M/T models: Lift up drive wheels and shift to 1st gear position.
A/F ALPHA-B1
I Engine: After warming up
AIR COND RLY
I Air conditioner switch: OFF , ON
OFF , ON ON
FUEL PUMP RLY
I Ignition switch is turned to ON (Operates for 1 second) I Engine running and cranking I When engine is stopped (stops in 1.5 seconds) I Except as shown above
OFF
COOLING FAN
HO2S1 HTR (B1)
HO2S2 HTR (B1)
I After warming up engine, idle the engine. I Air conditioner switch: OFF
Engine coolant temperature is 99°C (210°F) or less
OFF
Engine coolant temperature is 100°C (212°F) or more
ON
I Engine speed: Below 3,200 rpm
ON
I Engine speed: Above 3,200 rpm
OFF
I Engine speed
Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]
ON
Above 3,600 rpm
OFF
I Ignition switch ON (Engine stopped) Idle INT/V SOL-B1
I Engine: After warming up
EGR VOL CON/V*
I I I I
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load
OFF OFF
Revving engine with full throttle openON ing (Under 4,600 rpm) Idle
0 step
Revving engine up to 3,000 rpm quickly
10 - 55 steps
*: If so equipped
EC-87
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM HEATER FAN SW
CAL/LD VALUE
ABSOL TH⋅P/S
MASS AIRFLOW
IDL A/V LEARN
TRVL AFTER MIL
CONDITION
SPECIFICATION
I Heater fan switch is “ON”
ON
I Heater fan switch is “OFF’
OFF
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
Not used
2,500 rpm
Not used
I Engine: Idle
Throttle valve fully closed
0.0°
I Ignition switch: ON (Engine stopped)
Throttle valve fully opened
Approx. 80°
Idle
1.0 - 4.0 g⋅m/s
2,500 rpm
5.0 - 10.0 g⋅m/s
IDLE AIR VOL LEARN in ACTIVE TEST has not been performed
YET
IDLE AIR VOL LEARN in ACTIVE TEST has already been performed successfully
CMPLT
IDLE AIR VOL LEARN in ACTIVE TEST has not been performed successfully
INCMP
Vehicle has traveled after MI has turned ON.
0 - 65,535 km (0 - 40,722 mile)
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: N No-load
I Ignition switch: ON
I Ignition switch: ON
Major Sensor Reference Graph in Data Monitor Mode
NCEC0043
The following are the major sensor reference graphs in “DATA MONITOR” mode. (Select “HI SPEED” in “DATA MONITOR” with CONSULT-II.)
THRTL POS SEN, ABSOL TH⋅P/S, CLSD THL POS
NCEC0043S01
Below is the data for “THRTL POS SEN”, “ABSOL TH⋅P/S” and “CLSD THL POS” when depressing the accelerator pedal with the ignition switch “ON”. The signal of “THRTL POS SEN” and “ABSOL TH⋅P/S” should rise gradually without any intermittent drop or rise after “CLSD THL POS” is changed from “ON” to “OFF”. CLSD THL POS 10:22 OFF
-00"09 +02"69 ON
ABSOL TH P/S 10:22 % 0
25
50
-00"09 +02"69 75
100
THRTL POS SEN 10:22 x0.1V 0
13
26
-00"09 +02"69 38
51
Full Release
Full Depress SEF580W
ENG SPEED, MAS A/F SE-B1, THRTL POS SEN, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1
NCEC0043S02
Below is the data for “ENG SPEED”, “MAS A/F SE-B1”, “THRTL POS SEN”, “HO2S1 (B1)”, “HO2S2 (B1)” and “INJ PULSE-B1” when revving engine quickly up to 4,800 rpm under no load after warming up engine to normal operating temperature. Each value is for reference, the exact value may vary.
EC-88
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
Major Sensor Reference Graph in Data Monitor Mode (Cont’d)
● “ENG SPEED” should increase gradually while
ENG SPEED
depressing the accelerator pedal and should decrease gradually after releasing the pedal without any intermittent drop.
● “MAS A/F SE-B1” should increase when
MAS A/F SE-B1
depressing the accelerator pedal and should decrease at the moment “THRTL POS SEN” is closed (accelerator pedal is released).
NEF066A
EC-89
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
Major Sensor Reference Graph in Data Monitor Mode (Cont’d)
SEF601Y
SEF170YA
EC-90
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
ECM Terminals and Reference Value
ECM Terminals and Reference Value PREPARATION 1. 2.
NCEC0044 NCEC0044S01
ECM is located behind the center console. For this inspection: Remove the front passenger center console panel. Remove ECM harness protector.
SEF967W
3. I I I
Perform all voltage measurements with the connector connected. Extend tester probe as shown to perform tests easily. Open harness securing clip to make testing easier. Use extreme care not to touch 2 pins at one time. Data is for comparison and may not be exact.
SEF367I
ECM HARNESS CONNECTOR TERMINAL LAYOUTNCEC0044S02
SEF970W
ECM INSPECTION TABLE
NCEC0044S03
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.
EC-91
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
1
3
4
WIRE COLOR
Y/R
W/R
L
ITEM
Intake valve timing control solenoid valve
Heated oxygen sensor 2 heater (rear)
Heated oxygen sensor 1 heater (front)
CONDITION
DATA (DC Voltage)
[Engine is running] I Idle speed
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Lift up drive wheels and shift gear “ON” I Rev engine up from 1,200 to 3,000 rpm
Approximately 0V
[Engine is running] I Engine speed is below 3,600 rpm I After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more
Approximately 0.7V
[Ignition switch “ON”] I Engine stopped I Engine speed is above 3,600 rpm
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Engine speed is below 3,200 rpm
Approximately 0V
[Engine is running] I Engine speed is above 3,200 rpm
BATTERY VOLTAGE (11 - 14V)
6 7 15 16
BR Y/B P OR
IACV-AAC valve
[Engine is running] I Warm-up condition I Idle speed
0.1 - 14V
8* 9* 17* 18*
W/B SB G/R R/Y
EGR volume control valve
[Engine is running] I Warm-up condition I Rev engine up from 2,000 to 4,000 rpm
0 - 14V
[Engine is running] I Cooling fan is not operating
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Cooling fan is operating
Approximately 0V
13
LG/R
Cooling fan relay
5 - 12V
14
P/B
EVAP canister purge volume control valve (ON/OFF duty)
[Engine is running] I Warm-up condition I Accelerator pedal depressed
SEF975W
[Ignition switch “ON”] I For 1 second after turning ignition switch “ON” [Engine is running] 21
B/P
0 - 1V
Fuel pump relay [Ignition switch “ON”] BATTERY VOLTAGE I More than 1 second after turning ignition switch (11 - 14V) “ON”
22
23
OR/L
L/W
Malfunction indicator
Air conditioner relay
[Ignition switch “ON”]
0 - 1V
[Engine is running] I Idle speed
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Both A/C switch and blower switch are “ON”
Approximately 0V
[Engine is running] I A/C switch is “OFF”
BATTERY VOLTAGE (11 - 14V)
*: If so equipped
EC-92
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
31
WIRE COLOR
W/G
ITEM
CONDITION
ECM relay (Self shutoff)
DATA (DC Voltage)
[Ignition switch “OFF”] I For 9 seconds after turning ignition switch “OFF”
0 - 1V
[Ignition switch “OFF”] I 9 seconds passed after turning ignition switch “OFF”
BATTERY VOLTAGE (11 - 14V) 10 - 11V
[Engine is running] I Warm-up condition I Idle speed
SEF973W
32
L/OR
Tachometer 10 - 11V
[Engine is running] I Engine speed is 2,000 rpm
SEF974W
0 - 0.3V
[Engine is running] I Warm-up condition I Idle speed 35 36 37 38
Y/G PU/G L/Y GY/L
Ignition Ignition Ignition Ignition
signal signal signal signal
(No. (No. (No. (No.
1) 2) 3) 4)
SEF971W
0.2 - 0.4V
[Engine is running] I Engine speed is 2,000 rpm
SEF972W
41
42
43
B/Y
G/OR
B/R
[Ignition switch “ON”]
Approximately 0V
[Ignition switch “START”]
9 - 12V
[Ignition switch “ON”] I Gear position is “Neutral position”
Approximately 0V
[Ignition switch “ON”] I Except the above gear position
Approximately 5V
[Ignition switch “OFF”]
0V
[Ignition switch “ON”]
BATTERY VOLTAGE (11 - 14V)
Start signal
PNP switch
Ignition switch
EC-93
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
44
46
48
50
WIRE COLOR
GY
PU/W
B
R
ITEM
Air conditioner switch
Power steering oil pressure switch
ECM ground
Electrical load signal (Headlamp Rear defogger)
CONDITION
DATA (DC Voltage)
[Engine is running] I Both air conditioner switch and blower switch are “ON” (Compressor operates)
Approximately 0V
[Engine is running] I Air conditioner switch is “OFF”
Approximately 5V
[Engine is running] I Steering wheel is fully turned
Approximately 0V
[Engine is running] I Steering wheel is not turned
Approximately 5V
[Engine is running] I Idle speed
Engine ground
[Engine is running] I Headlamp switch or rear defogger switch is “ON”
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Headlamp switch and rear defogger switch are “OFF”
Approximately 0V
51
LG/B
Blower fan SW
[Ignition switch “ON”] I Blower fan switch is “ON”
Approximately 0V
57
B
ECM ground
[Engine is running] I Idle speed
Engine ground
58
B
Sensors’ ground
[Engine is running] I Warm-up condition I Idle speed
Approximately 0V
[Engine is running] I Warm-up condition I Idle speed
1.0 - 1.7V
[Engine is running] I Warm-up condition I Engine speed is 2,500 rpm
1.5 - 2.1V
61
B
Mass air flow sensor
0 - Approximately 0.7V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I Warm-up condition I Engine speed is 2,000 rpm
SEF008W
63
L
Heated oxygen sensor 2 (rear)
[Engine is running] I After warming up to normal operating temperature and engine speed is 3,000 rpm
0 - Approximately 1.0V
64
G
Intake air temperature sensor
[Engine is running]
Approximately 0 - 4.8V Output voltage varies with intake air temperature
EC-94
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
WIRE COLOR
ITEM
CONDITION
DATA (DC Voltage) 2.0 - 3.0V
[Engine is running] I Warm-up condition I Idle speed
66* 75
W W
SEF977W
Camshaft position sensor (PHASE)
2.0 - 3.0V
[Engine is running] I Engine speed is 2,000 rpm
SEF978W
67
W/L
Power supply for ECM (Back-up)
[Ignition switch “OFF”]
BATTERY VOLTAGE (11 - 14V)
70
BR/Y
Engine coolant temperature sensor
[Engine is running]
Approximately 0 - 4.8V Output voltage varies with engine coolant temperature
[Engine is running] I Warm-up condition I Idle speed
Less than 4.5V
[Engine is running] I Warm-up condition I EGR system is operating
0 - 1.0V
[Engine is running] I Warm-up condition I Idle speed
Approximately 0V
[Engine is running] I Air conditioner switch is “ON” (Compressor operates)
More than 1.5V
[Engine is running] I Air conditioner switch is turned from “ON” to “OFF”
Voltage is decreasing gradually
[Engine is running] I Idle speed
1.0 - 4.0V
72*
73
74
81
PU
W
R/L
W
EGR temperature sensor
Mass air flow sensor ground
Refrigerant pressure sensor
Knock sensor
*: If so equipped
EC-95
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
WIRE COLOR
ITEM
CONDITION
DATA (DC Voltage) 3.0 - 4.0V
[Engine is running] I Warm-up condition I Idle speed
85
W
SEF979W
Crankshaft position sensor (POS)
3.0 - 4.0V
[Engine is running] I Engine speed is 2,000 rpm
SEF980W
2.0 - 3.0V
86
OR/W
[Engine is running] Vehicle speed sensor or I Lift up the vehicle ABS actuator and elecI In 2nd gear position tric unit (control unit) I Vehicle speed is 40 km/h (25 MPH) SEF976W
92
93
Y
G/R
Throttle position sensor
Data link connector
[Engine is running] I Accelerator pedal released
0.35 - 0.65V
[Ignition switch “ON”] I Accelerator pedal fully depressed
3.7 - 4.5V
[Engine is running] I Idle speed (CONSULT-II or GST is disconnected)
Approximately 0V BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Warm-up condition I Idle speed 101 103 105 107
R/B Y/B G/B L/B
Injector Injector Injector Injector
No. No. No. No.
1 2 3 4
SEF011W
BATTERY VOLTAGE (11 - 14V) [Engine is running] I Warm-up condition I Engine speed is 2,000 rpm
SEF012W
106 108
B/Y
ECM ground
[Engine is running] I Idle speed
EC-96
Engine ground
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
QG16I18DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
WIRE COLOR
ITEM
CONDITION
DATA (DC Voltage)
110 112
R R
Power supply for ECM
[Ignition switch “ON”]
BATTERY VOLTAGE (11 - 14V)
111
G
Sensors’ power supply
[Ignition switch “ON”]
Approximately 5V
114
G/W
Adjust switch
[Engine is running] I Idle speed
0V
115
BR/W
Data link connector
[Engine is running] I Idle speed (CONSULT-II or GST is disconnected)
0 - 10V
116
Refer to EL section
Immobilizer
[Engine is running] I Idle speed (GST is disconnected)
BATTERY VOLTAGE (11 - 14V)
EC-97
TROUBLE DIAGNOSIS — SPECIFICATION VALUE
QG16I18DE
Description
Description
NLEC1748
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 MIL. The SP value will be displayed for the following three items: I B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction) I A/F ALPHA-B1/B2 (The mean value of air-fuel ratio feedback correction factor per cycle) I MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)
Testing Condition
NLEC1749
I Vehicle driven distance: More than 5,000 km (3,107 miles) I Barometric pressure: 98.3 - 104.3 kPa (0.983 - 1.043 bar, 1.003 - 1.064 kg/cm2, 14.25 - 15.12 psi) I Atmospheric temperature: 20 - 30°C (68 - 86°F) I Engine coolant temperature: 75 - 95°C (167 - 203°F) I Transmission: Warmed-up*1 I Electrical load: Not applied*2 I Engine speed: Idle *1: For after the engine is warmed up to normal operating temperature, drive vehicle until “FLUID TEMP SE” (CVT fluid temperature sensor signal) indicates less than 0.9V. *2: Rear window defogger switch, air conditioner switch, lighting switch are “OFF”. Cooling fans are not operating. Steering wheel is straight ahead.
Inspection Procedure
SEF601Z
NLEC1750
NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform “Basic Inspection”, EC-QG-72. 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1” and “MAS A/F SE-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 “Diagnostic Procedure”, EC-QG-99.
EC-98
TROUBLE DIAGNOSIS — SPECIFICATION VALUE
QG16I18DE Diagnostic Procedure
Diagnostic Procedure
NLEC1751
SEF613ZA
EC-99
TROUBLE DIAGNOSIS — SPECIFICATION VALUE
QG16I18DE
Diagnostic Procedure (Cont’d)
SEF768Z
EC-100
TROUBLE DIAGNOSIS — SPECIFICATION VALUE
QG16I18DE
Diagnostic Procedure (Cont’d)
SEF615Z
EC-101
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT QG16I18DE Description
Description
NCEC0045
Intermittent incidents (I/I) may occur. In many cases, the problem 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 DTC (1st trip) visits. Realize also that the most frequent cause of I/I 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 problem area.
COMMON I/I REPORT SITUATIONS
NCEC0045S01
STEP in Work Flow
Situation
II
The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than “0” or “1t”.
III
The symptom described by the customer does not recur.
IV
(1st trip) DTC data does not appear during the DTC CONFIRMATION PROCEDURE.
VI
The TROUBLE DIAGNOSIS for PXXXX does not indicate the problem area.
Diagnostic Procedure 1
INSPECTION START
Erase (1st trip) DTCs. Refer to “HOW TO ERASE EMISSION-RELATED INFORMATION” (EC-QG-44).
©
2
GO TO 2.
CHECK GROUND TERMINALS
Check ground terminals for corroding or loose connection. Refer to “Circuit Inspection”, “GROUND INSPECTION” in GI section. OK or NG OK
©
GO TO 3.
NG
©
Repair or replace.
3
SEARCH FOR ELECTRICAL INCIDENT
Perform “Incident Simulation Tests” in GI section. OK or NG OK
©
GO TO 4.
NG
©
Repair or replace.
4
CHECK CONNECTOR TERMINALS
Refer to “How to Check Enlarged Contact Spring of Terminal” in GI section. OK or NG OK
©
INSPECTION END
NG
©
Repair or replace connector.
EC-102
NCEC0046
QG16I18DE
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
Main Power Supply and Ground Circuit WIRING DIAGRAM
NCEC0047
BATTERY
Refer to EL-POWER.
ST
OFF
ACC
IGNITION SWITCH
ON
ECM RELAY
FUSE BLOCK (J/B)
To EC-IGN/SG, EC-TP/SW, EC-AAC/V, EC-EGR, EC-EGVC/V
ECM
: Detectable line for DTC : Non-detectable line for DTC
Refer to last page (Foldout page)
YEC770
EC-103
QG16I18DE
TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d)
ECM TERMINALS AND REFERENCE VALUE
NCEC0048
Specification data are reference values and are measured between each terminal and ECM. 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.
31
43
WIRE COLOR
W/G
B/R
ITEM
ECM relay (Self shut-off)
CONDITION
DATA (DC Voltage)
[Ignition switch “OFF”] I For 9 seconds after turning ignition switch “OFF”
0 - 1V
[Ignition switch “OFF”] I 9 seconds passed after turning ignition switch “OFF”
BATTERY VOLTAGE (11 - 14V)
[Ignition switch “OFF”]
0V
[Ignition switch “ON”]
BATTERY VOLTAGE (11 - 14V)
Ignition switch
48
B
ECM ground
[Engine is running] I Idle speed
Engine ground
57
B
ECM ground
[Engine is running] I Idle speed
Engine ground
67
W/L
Power supply for ECM (Back-up)
[Ignition switch “OFF”]
BATTERY VOLTAGE (11 - 14V)
106 108
B/Y B/Y
ECM ground
[Engine is running] I Idle speed
Engine ground
110 112
R R
Power supply for ECM
[Ignition switch “ON”]
BATTERY VOLTAGE (11 - 14V)
DIAGNOSTIC PROCEDURE 1
INSPECTION START
Start engine. Is engine running? Yes or No Yes
©
GO TO 9.
No
©
GO TO 2.
EC-104
NCEC0049
TROUBLE DIAGNOSIS FOR POWER SUPPLY
QG16I18DE
Main Power Supply and Ground Circuit (Cont’d)
2
CHECK POWER SUPPLY-I
1. Turn ignition switch “OFF” and then “ON”. 2. Check voltage between ECM terminal 43 and ground with CONSULT-II or tester.
Voltage: Battery voltage
SEF981W
OK or NG OK
©
GO TO 9.
NG
©
GO TO 3.
3
DETECT MALFUNCTIONING PART
Check the following. I 10A Fuse I 40A fusible link I Harness connectors M50, F104 I Harness for open or short between ECM and fuse block I Harness for open or short between fuse block and ignition switch ©
4
Repair harness or connectors.
CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 48, 57, 106, 108 and engine ground. Refer to WIRING DIAGRAM. Continuity should exist. 4. 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-105
TROUBLE DIAGNOSIS FOR POWER SUPPLY
QG16I18DE
Main Power Supply and Ground Circuit (Cont’d)
5
CHECK POWER SUPPLY-II
1. Disconnect ECM relay.
SEF984W
2. Check voltage between ECM relay terminals 1, 6 and ground with CONSULT-II or tester.
SEF101Y
OK or NG OK
©
GO TO 7.
NG
©
GO TO 6.
6
DETECT MALFUNCTIONING PART
Check the following. I 10A fuse I 15A fuse I Harness for open or short between ECM relay and battery ©
7
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between ECM terminal 31 and ECM relay terminal 2. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK
©
Go to “IGNITION SIGNAL”, EC-QG-323.
NG
©
GO TO 8.
8
DETECT MALFUNCTIONING PART
Check the harness for open or short between ECM relay and ECM. ©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-106
TROUBLE DIAGNOSIS FOR POWER SUPPLY
QG16I18DE
Main Power Supply and Ground Circuit (Cont’d)
9
CHECK POWER SUPPLY-II
1. Stop engine. 2. Check voltage between ECM terminals 67 and ground with CONSULT-II or tester.
SEF982W
Voltage: Battery voltage OK or NG OK
©
GO TO 11.
NG
©
GO TO 10.
10
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I 10A fuse I Harness for open or short between ECM and fuse
©
11
Repair harness or connectors.
CHECK POWER SUPPLY-III
1. Turn ignition switch “ON” and then “OFF”. 2. Check voltage between ECM terminals 110, 112 and ground with CONSULT-II or tester.
SEF983W
Voltage: After turning ignition switch “OFF”, battery voltage will exist for a few seconds, then drop to approximately 0V. OK or NG OK
©
GO TO 17.
NG (Battery voltage does not exist.)
©
GO TO 12.
NG (Battery voltage exists for more than a few seconds.)
©
GO TO 16.
EC-107
TROUBLE DIAGNOSIS FOR POWER SUPPLY
QG16I18DE
Main Power Supply and Ground Circuit (Cont’d)
12
CHECK HARNESS CONTINUITY BETWEEN ECM RELAY AND ECM
1. Disconnect ECM harness connector. 2. Disconnect ECM relay.
SEF984W
3. Check harness continuity between ECM terminals 110, 112 and relay 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 14.
NG
©
GO TO 13.
13
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I Harness for open or short between ECM relay and ECM
©
14
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK VOLTAGE BETWEEN ECM RELAY AND GROUND
Check voltage between relay terminals 1, 3 and ground with CONSULT-II or tester.
SEF985W
Voltage: Battery voltage OK or NG OK
©
GO TO 16.
NG
©
GO TO 15.
15
DETECT MALFUNCTIONING PART
Check the harness for open or short between ECM relay and fuse.
©
Repair harness or connectors.
EC-108
TROUBLE DIAGNOSIS FOR POWER SUPPLY
QG16I18DE
Main Power Supply and Ground Circuit (Cont’d)
16
CHECK ECM RELAY
1. Apply 12V direct current between relay terminals 1 and 2. 2. Check continuity between relay terminals 3 and 5, 6 and 7.
SEC202BC
12V (1 - 2) applied: Continuity exists. No voltage applied: No continuity OK or NG OK
©
GO TO 17.
NG
©
Replace ECM relay.
17
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 48, 57, 106, 108 and engine ground. 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 18.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
18
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-109
QG16I18DE
DTC P0100 MASS AIR FLOW SENSOR (MAFS) Component Description
Component Description
SEF987W
NCEC0050
The mass air flow sensor is placed in the stream of intake air. It measures the intake flow rate by measuring a part of the entire intake flow. It consists of a hot wire that is supplied with electric current from the ECM. The temperature of the hot wire is controlled by the ECM 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 ECM must supply more electric current to maintain the temperature of the hot wire as air flow increases. The ECM detects the air flow by means of this current change.
CONSULT-II Reference Value in Data Monitor Mode
NCEC0051
Specification data are reference values. MONITOR ITEM
MAS A/F SE-B1
CAL/LD VALUE
MASS AIRFLOW
CONDITION I I I I
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load
I I I I
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load
I I I I
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load
SPECIFICATION
Idle
1.0 - 1.7V
2,500 rpm
1.5 - 2.1V
Idle
Not used
2,500 rpm
Not used
Idle
1.0 - 4.0 g⋅m/s
2,500 rpm
5.0 - 10.0 g⋅m/s
ECM Terminals and Reference Value
NCEC0052
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.
61
73
WIRE COLOR
B
ITEM
Mass air flow sensor
Mass air flow sensor ground
W
CONDITION
DATA (DC Voltage)
[Engine is running] I Warm-up condition I Idle speed
1.0 - 1.7V
[Engine is running] I Warm-up condition I Engine speed is 2,500 rpm
1.5 - 2.1V
[Engine is running] I Warm-up condition I Idle speed
Approximately 0V
On Board Diagnosis Logic DTC No. P0100* 0100
Malfunction is detected when ...
Check Items (Possible Cause)
A)
An excessively high voltage from the sensor is sent I Harness or connectors to ECM when engine is not running. (The sensor circuit is open or shorted.) I Mass air flow sensor
B)
An excessively low voltage from the sensor is sent to ECM when engine is running.
I Harness or connectors (The sensor circuit is open or shorted.) I Intake air leaks I Mass air flow sensor
*: When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
EC-110
NCEC0053
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
QG16I18DE
DTC Confirmation Procedure Detected items
Engine operating condition in fail-safe mode
Mass air flow sensor circuit
Engine speed will not rise more than 2,400 rpm due to the fuel cut.
DTC Confirmation Procedure
NCEC0054
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 9 seconds before conducting the next test.
PROCEDURE FOR MALFUNCTION A
NCEC0054S01
With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 2 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-113. With GST Follow the procedure “With CONSULT-II” above. NEF068A
PROCEDURE FOR MALFUNCTION B
NCEC0054S02
With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and wait 2 seconds at most. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-113. With GST Follow the procedure “With CONSULT-II” above. NEF068A
EC-111
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0056
YEC063A
EC-112
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0057
INSPECTION START
Which malfunction (A, or B) is duplicated? Malfunction A or B A
©
GO TO 3.
B
©
GO TO 2.
2
CHECK INTAKE SYSTEM
Check the following for connection. I Air duct I Vacuum hoses I Intake air passage between air duct to collector OK or NG OK
©
GO TO 3.
NG
©
Reconnect the parts.
3
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
SEF994W
©
GO TO 4.
EC-113
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
QG16I18DE
Diagnostic Procedure (Cont’d)
4
CHECK POWER SUPPLY
1. Disconnect mass air flow sensor harness connector.
SEF995W
2. Turn ignition switch “ON”. 3. Check voltage between terminals 2, 4 and ground with CONSULT-II or tester.
SEF996W
Voltage: Battery voltage OK or NG OK
©
GO TO 6.
NG
©
GO TO 5.
5
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I Harness for open or short between ECM relay and mass air flow sensor I Harness for open or short between mass air flow sensor and ECM
©
6
Repair harness or connectors.
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between mass air flow sensor harness connector terminal 3 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 7.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-114
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
QG16I18DE
Diagnostic Procedure (Cont’d)
7
CHECK INPUT SIGNAL CIRCUIT
1. Check harness continuity between mass air flow sensor harness connector terminal 5 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.
8
CHECK MASS AIR FLOW SENSOR
Refer to “Component Inspection”, EC-QG-115. OK or NG OK
©
GO TO 9.
NG
©
Replace mass air flow sensor.
9
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection
NCEC0058
MASS AIR FLOW SENSOR 1. 2. 3.
Conditions Ignition switch “ON” (Engine stopped.) SEF993W
NCEC0058S01
Turn ignition switch “ON”. Start engine and warm it up to normal operating temperature. Check voltage between ECM terminal 61 (Mass air flow sensor signal) and ground. Voltage V Less than 1.2
Idle (Engine is warmed-up to normal operating temperature.)
1.0 - 1.7
2,500 rpm (Engine is warmed-up to normal operating temperature.)
1.7 - 2.1
Idle to about 4,000 rpm*
1.0 - 1.7 to Approx. 4.0
*: Check for linear voltage rise in response to increases to about 4,000 rpm in engine speed.
4.
SEF987W
5.
If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Repeat above check. If NG, remove mass air flow sensor from air duct. Check hot film for damage or dust.
EC-115
DTC P0110 INTAKE AIR TEMPERATURE SENSOR
QG16I18DE
Component Description
Component Description
NCEC0066
The intake air temperature sensor is built into the 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.
SEF987W
Intake air temperature °C (°F)
Voltage* V
Resistance kΩ
20 (68)
3.5
2.2 - 2.6
80 (176)
1.23
0.31 - 0.37
*: These data are reference values and are measured between ECM terminal 64 (Intake air 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. P0110 0110
Malfunction is detected when ... An excessively low or high voltage from the sensor is sent to ECM.
NCEC0067
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Intake air temperature sensor
DTC Confirmation Procedure
NCEC0068
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 5 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-118. With GST Follow the procedure “With CONSULT-II” above. NEF068A
EC-116
DTC P0110 INTAKE AIR TEMPERATURE SENSOR
QG16I18DE Wiring Diagram
Wiring Diagram
INTAKE AIR TEMPERATURE SENSOR
NCEC0069
: Detectable line for DTC : Non-detectable line for DTC
ECM
YEC772
EC-117
DTC P0110 INTAKE AIR TEMPERATURE SENSOR
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect intake air temperature sensor (mass air flow sensor) harness connector.
SEF995W
3. Turn ignition switch “ON”. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.
NEF228A
Voltage: Approximately 5V OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness for open or short between ECM and intake air temperature sensor
©
3
Repair harness or connectors.
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Check harness continuity between intake air temperature sensor (mass air flow sensor) harness connector terminal 3 and ECM terminal 73. 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.
EC-118
DTC P0110 INTAKE AIR TEMPERATURE SENSOR
QG16I18DE
Diagnostic Procedure (Cont’d)
4
DETECT MALFUNCTIONING PART
Check the following. I Harness for open or short between ECM and intake air temperature sensor
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK INTAKE AIR TEMPERATURE SENSOR
Refer to “Component Inspection”, EC-QG-119. OK or NG OK
©
GO TO 6.
NG
©
Replace intake air temperature sensor.
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection
NCEC0071
INTAKE AIR TEMPERATURE SENSOR
NCEC0071S01
Check resistance between mass air flow sensor terminal 1 and 3.
Intake air temperature °C (°F)
Resistance kΩ
20 (68)
2.1 - 2.9
80 (176)
0.27 - 0.38
If NG, replace mass air flow sensor. SEF012P
EC-119
DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR QG16I18DE (ECTS) (CIRCUIT) Component Description
Component Description
NCEC0072
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)
Voltage* V
Resistance kΩ
−10 (14)
4.4
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
SEF012P
*: These data are reference values and are measured between ECM terminal 70 (Engine coolant 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.
CONSULT-II Reference Value in Data Monitor Mode
NCEC0073
MONITOR ITEM COOLAN TEMP/S
CONDITION
SPECIFICATION
I Engine: After warming up
More than 70°C (158°F)
On Board Diagnosis Logic DTC No. P0115 0115
Malfunction is detected when ... I An excessively high or low voltage from the sensor is sent to ECM.*
NCEC0074
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Engine coolant temperature sensor
*: 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 the engine is running.
EC-120
DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR QG16I18DE (ECTS) (CIRCUIT) DTC Confirmation Procedure
DTC Confirmation Procedure
NEF068A
NCEC0075
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 5 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-123. With GST Follow the procedure “With CONSULT-II” above.
EC-121
DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR QG16I18DE (ECTS) (CIRCUIT) Wiring Diagram
Wiring Diagram
NCEC0076
YEC261
EC-122
DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR QG16I18DE (ECTS) (CIRCUIT) Diagnostic Procedure
Diagnostic Procedure 1
NCEC0077
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect engine coolant temperature sensor harness connector.
SEF999W
3. Turn ignition switch “ON”. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.
SEF997W
Voltage: Approximately 5V OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the harness for open or short between ECM and engine coolant temperature sensor.
©
3
Repair harness or connectors.
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Check harness continuity between engine coolant temperature sensor harness connector terminal 1 and engine 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. I Harness for open or short between ECM and engine coolant temperature sensor
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-123
DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR QG16I18DE (ECTS) (CIRCUIT) Diagnostic Procedure (Cont’d)
5
CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to “Component Inspection”, EC-QG-124. OK or NG OK
©
GO TO 6.
NG
©
Replace engine coolant temperature sensor.
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection
NCEC0078
ENGINE COOLANT TEMPERATURE SENSOR Check resistance as shown in the figure.
SEF152P
Temperature °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
EC-124
NCEC0078S01
QG16I18DE
DTC P0120 THROTTLE POSITION SENSOR
Component Description
Component Description
NCEC0079
Throttle position sensor
Output voltage between terminal No. 2 and 3 (V)
The throttle position sensor responds to the accelerator pedal movement. This sensor is a kind of potentiometer which transforms the throttle position into output voltage, and emits the voltage signal to the ECM. In addition, the sensor detects the opening and closing speed of the throttle valve and feeds the voltage signal to the ECM. Idle position of the throttle valve is determined by the ECM receiving the signal from the throttle position sensor. This sensor controls engine operation such as fuel cut. On the other hand, the “Wide open and closed throttle position switch”, which is built into the throttle position sensor unit, is not used for engine control.
Supply voltage: 5V (Applied between terminal No. 1 and 3)
Output voltage between terminal No. 2 and 3)
Throttle valve opening angle (deg) NEF245A
CONSULT-II Reference Value in Data Monitor Mode
NCEC0080
Specification data are reference values. MONITOR ITEM
THRTL POS SEN
ABSOL TH⋅P/S
CONDITION
SPECIFICATION
I Engine: Idle
Throttle valve fully closed
0.35 - 0.65V
I Ignition switch: ON (Engine stopped)
Throttle valve fully opened
3.7 - 4.5V
I Engine: Idle
Throttle valve fully closed
0.0°
I Ignition switch: ON (Engine stopped)
Throttle valve fully opened
Approx. 80°
EC-125
QG16I18DE
DTC P0120 THROTTLE POSITION SENSOR ECM Terminals and Reference Value
ECM Terminals and Reference Value
=NCEC0081
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. 58
92
111
WIRE COLOR
B
Y
G
ITEM
CONDITION
Sensors’ ground
Throttle position sensor
Sensors’ power supply
DATA (DC Voltage)
[Engine is running] I Warm up condition I Idle speed
Approximately 0V
[Engine is running] I Accelerator pedal fully released
0.35 - 0.65V
[Ignition switch “ON”] I Accelerator pedal fully depressed
3.7 - 4.5V
[Ignition switch “ON”]
Approximately 5V
On Board Diagnosis Logic DTC No. P0120* 0120
Malfunction is detected when ... An excessively low or high voltage from the sensor is sent to ECM while driving.
NCEC0082
Check Items (Possible Cause) I Harness or connectors (The throttle position sensor circuit is open or shorted.) I Throttle position sensor
*: 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 Throttle position will be determined based on the injected fuel amount and the engine speed. Therefore, acceleration will be poor.
Throttle position sensor circuit
Condition
Driving condition
When engine is idling
Normal
When accelerating
Poor acceleration
DTC Confirmation Procedure
NCEC0083
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: I Before performing the following procedure, confirm that battery voltage is more than 10V at idle. I This test 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.
EC-126
DTC P0120 THROTTLE POSITION SENSOR
QG16I18DE
DTC Confirmation Procedure (Cont’d)
With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and maintain the following conditions for at least 5 consecutive seconds.
PEF651U
VHCL SPEED SE
More than 4 km/h (2 MPH)
Selector lever
Suitable position except “N” position
3)
If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-129. With GST Follow the procedure “With CONSULT-II” above.
EC-127
DTC P0120 THROTTLE POSITION SENSOR
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0084
YEC064A
EC-128
DTC P0120 THROTTLE POSITION SENSOR
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0085
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
SEF994W
©
2
GO TO 2.
CHECK POWER SUPPLY
1. Disconnect throttle position sensor harness connector. Throttle position sensor harness connector
Throttle body
IACV-AAC valve harness connector NEF246A
2. Turn ignition switch “ON”. 3. Check voltage between terminal 3 and ground with CONSULT-II or tester.
SEF209W
Voltage: Approximately 5V OK or NG OK
©
GO TO 3.
NG
©
Repair harness or connectors.
EC-129
DTC P0120 THROTTLE POSITION SENSOR
QG16I18DE
Diagnostic Procedure (Cont’d)
3
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Check harness continuity between throttle position sensor harness connector terminal 1 and engine 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 harness for open or short between ECM and throttle position sensor.
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 92 and throttle position sensor harness connector 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 6.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
6
CHECK THROTTLE POSITION SENSOR
Refer to “Component Inspection”, EC-QG-131. OK or NG OK
©
GO TO 7.
NG
©
Replace throttle position sensor. To adjust it, perform “Basic Inspection”, EC-QG-72.
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-130
DTC P0120 THROTTLE POSITION SENSOR
QG16I18DE Component Inspection
Component Inspection
NCEC0086
THROTTLE POSITION SENSOR
NEF069A
NCEC0086S01
With CONSULT-II 1) Stop engine (ignition switch OFF). 2) Turn ignition switch ON. 3) Select “DATA MONITOR” mode with CONSULT-II. 4) Check voltage of “THRTL POS SEN” under the following conditions. NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle. Throttle valve conditions Completely closed Partially open Completely open
5)
Voltage (V) 0.35 - 0.65 (a) Between (a) and (b) 3.7 - 4.5 (b)
If NG, adjust throttle position sensor idle position. Refer to “Basic Inspection”, EC-QG-72. If it is impossible to adjust throttle position sensor idle position in “Basic Inspection”, replace throttle position sensor.
Without CONSULT-II Stop engine (ignition switch OFF). Turn ignition switch ON. Check voltage between ECM terminal 92 (Throttle position sensor signal) and ground under the following conditions. NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle. 1) 2) 3)
Throttle valve conditions SEF007X
Completely closed Partially open Completely open
4)
Voltage (V) 0.35 - 0.65 (a) Between (a) and (b) 3.7 - 4.5 (b)
If NG, adjust throttle position sensor idle position. Refer to “Basic Inspection”, EC-QG-72. If it is impossible to adjust throttle position sensor idle position in “Basic Inspection”, replace throttle position sensor.
EC-131
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
QG16I18DE
Component Description
Component Description
NLEC0094
The heated oxygen sensor 1 (front) 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 (front) 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 (front) 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
NLEC0095
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
ECM Terminals and Reference Value
NLEC0096
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. TERMIWIRE NAL NO. COLOR
ITEM
CONDITION
DATA (DC Voltage) 0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W
EC-132
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NLEC0097
Under the condition in which the heated oxygen sensor 1 (front) 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. P0130 0130
Malfunction is detected when ... I The voltage from the sensor is constantly approx. 0.3V.
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front)
DTC Confirmation Procedure
SEF825Y
SEF826
NLEC0098
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 9 seconds before conducting the next test. TESTING CONDITION: I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “HO2S1 (B1) P0130” of “HO2S1 (B1)” in “DTC WORK SUPPORT” mode with CONSULT-II. 3) Touch “START”. 4) Let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 4. 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
1,700 - 3,200 rpm
Vehicle speed
Above 64 km/h (40 MPH)
B/FUEL SCHDL
Above 3.0 msec
Selector lever
Suitable position
SEF645Y
6)
If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG
EC-133
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
QG16I18DE
Overall Function Check
RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG-136.
Overall Function Check
SEF011X
NLEC0099
Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The voltage does not remain in the range of 0.2 - 0.4V. 4) If NG, go to “Diagnostic Procedure”, EC-QG-136.
EC-134
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
QG16I18DE Wiring Diagram
Wiring Diagram
NCEC0100
YEC065A
EC-135
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
NLEC0101
INSPECTION START
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
SEF994W
3. Disconnect heated oxygen sensor 1 (front) harness connector.
SEF012XA
©
2
GO TO 2.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for 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 HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-QG-137. OK or NG OK
©
GO TO 4.
NG
©
Replace heated oxygen sensor 1 (front).
4
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
EC-136
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
QG16I18DE Component Inspection
Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)
SEF646Y
SEF647Y
NLEC0102 NLEC0102S01
With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
SEF648Y
1) 2) 3) I
SEF011X
I I
Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. Check the following with engine speed held at 2,000 rpm constant under no load. Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time.
EC-137
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
QG16I18DE
Component Inspection (Cont’d)
I The voltage never exceeds 1.0V. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
EC-138
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
QG16I18DE
Component Description
Component Description
NLEC0103
The heated oxygen sensor 1 (front) 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 (front) 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 (front) 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
NLEC0104
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
ECM Terminals and Reference Value
NLEC0105
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. TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) 0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W
EC-139
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NLEC0106
To judge the malfunction, the output from the heated oxygen sensor 1 (front) 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. P0131 0131
Malfunction is detected when ... I The maximum and minimum voltages from the sensor are not reached to the specified voltages.
Check Items (Possible Cause) I I I I I
Heated oxygen sensor 1 (front) Heated oxygen sensor 1 heater (front) Fuel pressure Injectors Intake air leaks
DTC Confirmation Procedure
SEF827Y
SEF828Y
NLEC0107
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 (B1) P0131” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 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.)
SEF651Y
EC-140
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
QG16I18DE
DTC Confirmation Procedure (Cont’d) ENG SPEED
1,700 - 2,600 rpm
Vehicle speed
64 - 100 km/h (40 - 62 MPH)
B/FUEL SCHDL
3.0 - 5.2 msec
Selector lever
Suitable position
7)
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 “Diagnostic Procedure”, EC-QG-141.
Overall Function Check
SEF011X
Diagnostic Procedure 1
RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)
1. Turn ignition switch “OFF”. 2. Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) ©
NLEC0108
Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The maximum voltage is over 0.6V at least one time. I The minimum voltage is over 0.1V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-QG-141.
GO TO 2.
EC-141
NLEC0109
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
2
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.
SEF652Y
4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed.
SEF995W
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0171. Refer to EC-QG-208.
No
©
GO TO 3.
3
CHECK FRONT HEATED OXYGEN SENSOR HEATER
Refer to “Component Inspection”, EC-QG-170. OK or NG OK
©
GO TO 4.
NG
©
Replace front heated oxygen sensor.
EC-142
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
4
CHECK HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-QG-143. OK or NG OK
©
GO TO 5.
NG
©
Replace heated oxygen sensor 1 (front).
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. Refer to “Wiring Diagram”, EC-QG-135, for circuit. ©
INSPECTION END
Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)
With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1) 2)
SEF646Y
SEF647Y
NLEC0110 NLEC0110S02
EC-143
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
QG16I18DE
Component Inspection (Cont’d)
SEF648Y
Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator lamp goes on more than five times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1) 2)
SEF011X
EC-144
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
QG16I18DE
Component Description
Component Description
NLEC0111
The heated oxygen sensor 1 (front) 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 (front) 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 (front) 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
NLEC0112
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
ECM Terminals and Reference Value
NLEC0113
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. TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) 0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W
EC-145
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NLEC0114
To judge the malfunction, the output from the heated oxygen sensor 1 (front) is monitored to determine whether the “rich” output is sufficiently high. The “lean” output is sufficiently low. When both the outputs are shifting to the rich side, the malfunction will be detected.
SEF299UA
DTC No. P0132 0132
Malfunction is detected when ... I The maximum and minimum voltages from the sensor are beyond the specified voltages.
Check Items (Possible Cause) I I I I
Heated oxygen sensor 1 (front) Heated oxygen sensor 1 heater (front) Fuel pressure Injectors
DTC Confirmation Procedure
SEF829Y
SEF830Y
NLEC0115
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 (B1) P0132” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 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
1,700 - 2,600 rpm
Vehicle speed
64 - 100 km/h (40 - 62 MPH)
B/FUEL SCHDL
3.0 - 5.2 msec
Selector lever
Suitable position
SEF655Y
EC-146
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
QG16I18DE
DTC Confirmation Procedure (Cont’d)
7)
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 “Diagnostic Procedure”, EC-QG-147.
Overall Function Check
SEF011X
Diagnostic Procedure 1
RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)
1. Turn ignition switch “OFF”. 2. Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) ©
NLEC0116
Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The maximum voltage is below 0.8V at least one time. I The minimum voltage is below 0.3V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-QG-147.
GO TO 2.
EC-147
NLEC0117
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
2
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.
SEF652Y
4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed.
SEF995W
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0172. Refer to EC-QG-215.
No
©
GO TO 3.
3
CHECK HARNESS CONNECTOR
1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector. 3. Check harness connector for water. Water should not exit. OK or NG OK
©
GO TO 4.
NG
©
Repair or replace harness connector.
EC-148
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
4
CHECK HEATED OXYGEN SENSOR 1 HEATER (FRONT)
Refer to “Component Inspection”, EC-QG-170. OK or NG OK
©
GO TO 5.
NG
©
Replace heated oxygen sensor 1 (front).
5
CHECK HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-QG-149. OK or NG OK
©
GO TO 6.
NG
©
Replace heated oxygen sensor 1 (front).
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. Refer to “Wiring Diagram”, EC-QG-135, for circuit. ©
INSPECTION END
Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)
With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1) 2)
SEF646Y
SEF647Y
NLEC0118 NLEC0118S02
EC-149
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
QG16I18DE
Component Inspection (Cont’d)
SEF648Y
Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator lamp goes on more than 5 times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1) 2)
SEF011X
EC-150
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
QG16I18DE
Component Description
Component Description
NLEC0119
The heated oxygen sensor 1 (front) 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 (front) 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 (front) 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
NLEC0120
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
ECM Terminals and Reference Value
NLEC0121
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. TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) 0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W
EC-151
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NLEC0122
To judge the malfunction of heated oxygen sensor 1 (front), this diagnosis measures response time of heated oxygen sensor 1 (front) signal. The time is compensated by engine operating (speed and load), fuel feedback control constant, and heated oxygen sensor 1 (front) temperature index. Judgment is based on whether the compensated time [heated oxygen sensor 1 (front) cycling time index] is inordinately long or not. SEF010V
DTC No. P0133 0133
Malfunction is detected when ...
Check Items (Possible Cause)
I The response of the voltage signal from the sensor takes I Harness or connectors more than the specified time. (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front) I Heated oxygen sensor 1 heater (front) I Fuel pressure I Injectors I Intake air leaks I Exhaust gas leaks I PCV I Mass air flow sensor
DTC Confirmation Procedure
SEF831Y
SEF832Y
NLEC0123
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 (B1) P0133” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 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.) ENG SPEED
2,100 - 3,100 rpm
Vehicle speed
80 - 120 km/h (50 - 75 MPH)
B/FUEL SCHDL
3.8 - 7.6 msec
Selector lever
Suitable position
SEF658Y
EC-152
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
QG16I18DE
Overall Function Check
7)
Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG-155.
Overall Function Check
SAT652J
NLEC0124
Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set ECM in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT)]. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] 4) If NG, go to “Diagnostic Procedure”, EC-QG-155.
EC-153
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0125
YEC065A
EC-154
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NLEC0126
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
SEF994W
©
2
GO TO 2.
RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)
Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) ©
3
GO TO 3.
CHECK EXHAUST AIR LEAK
1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.
SEF099P
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-155
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
5
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.
SEF652Y
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? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed.
JEF105Y
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 or 0172 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0171, P0172. Refer to EC-QG-208, 215.
No
©
GO TO 6.
6
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for 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-156
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
7
CHECK HEATED OXYGEN SENSOR 1 HEATER (FRONT)
Refer to “Component Inspection”, EC-QG-170. OK or NG OK
©
GO TO 8.
NG
©
Replace heated oxygen sensor 1 (front).
8
CHECK HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-QG-158. OK or NG OK
©
GO TO 9.
NG
©
Replace heated oxygen sensor 1 (front).
9
CHECK MASS AIR FLOW SENSOR
Refer to “Component Inspection”, EC-QG-115. OK or NG OK
©
GO TO 10.
NG
©
Replace mass air flow sensor.
10
CHECK PCV VALVE
Refer to “Positive Crankcase Ventilation”, EC-QG-28. OK or NG OK
©
GO TO 11.
NG
©
Repair or replace PCV valve.
11
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
EC-157
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
QG16I18DE
Component Inspection
Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)
SEF646Y
SEF647Y
NLEC0127 NLEC0127S02
With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” five times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
SEF648Y
1) 2) 3) I
SEF011X
I I
Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. Check the following with engine speed held at 2,000 rpm constant under no load. Malfunction indicator lamp goes on more than five times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time.
EC-158
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
QG16I18DE
Component Inspection (Cont’d)
I The voltage never exceeds 1.0V. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
EC-159
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
QG16I18DE
Component Description
Component Description
NLEC0128
The heated oxygen sensor 1 (front) 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 (front) 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 (front) 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
NLEC0129
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
ECM Terminals and Reference Value
NLEC0130
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. TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) 0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W
EC-160
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NLEC0131
To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 (front) output is not inordinately high.
SEF301U
DTC No. P0134 0134
Malfunction is detected when ... I An excessively high voltage from the sensor is sent to ECM.
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front)
DTC Confirmation Procedure
SEF174Y
NLEC0132
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON”. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Restart engine and let it idle for 2 minutes. 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-163. With GST 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Restart engine and let it idle for 2 minutes. 4) Turn ignition switch “OFF” and wait at least 9 seconds. 5) Restart engine and let it idle for 2 minutes. 6) Select “MODE 3” with GST. 7) If DTC is detected, go to “Diagnostic Procedure”, EC-QG-163. I When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is recommended.
EC-161
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0133
YEC065A
EC-162
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NLEC0134
RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)
Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) ©
2
GO TO 2.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector.
SEF012XA
2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for 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 HARNESS CONNECTOR
Check heated oxygen sensor 1 (front) harness connector for water. Water should not exist. OK or NG OK
©
GO TO 4.
NG
©
Repair or replace harness connector.
4
CHECK HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-QG-164. OK or NG OK
©
GO TO 5.
NG
©
Replace heated oxygen sensor 1 (front).
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
EC-163
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
QG16I18DE
Component Inspection
Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)
SEF646Y
SEF647Y
NLEC0135 NLEC0135S01
With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” five times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
SEF648Y
1) 2) 3) I
SEF011X
I I
Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. Check the following with engine speed held at 2,000 rpm constant under no load. Malfunction indicator lamp goes on more than five times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time.
EC-164
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
QG16I18DE
Component Inspection (Cont’d)
I The voltage never exceeds 1.0V. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
EC-165
DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER
QG16I18DE
Description
Description
NLEC0136
SYSTEM DESCRIPTION
NLEC0136S01
Sensor
Input Signal to ECM
Camshaft position sensor (PHASE) Crankshaft position sensor (POS)
Engine speed
ECM function
Actuator
Heated oxygen sensor 1 heater (front) control
Heated oxygen sensor 1 heater (front)
The ECM performs ON/OFF control of the heated oxygen sensor 1 heater (front) corresponding to the engine operating condition.
OPERATION
NLEC0136S02
Engine speed
Heated oxygen sensor 1 heater (front)
Above 3,200 rpm
OFF
Below 3,200 rpm
ON
CONSULT-II Reference Value in Data Monitor Mode
NLEC0137
Specification data are reference values. MONITOR ITEM HO2S1 HTR (B1)
CONDITION
SPECIFICATION
I Engine speed: Below 3,200 rpm
ON
I Engine speed: Above 3,200 rpm
OFF
ECM Terminals and Reference Value
NLEC0138
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.
4
WIRE COLOR
L
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running] Heated oxygen sensor 1 I Engine speed is below 3,200 rpm. heater (front) [Engine is running] I Engine speed is above 3,200 rpm.
Approximately 0V BATTERY VOLTAGE (11 - 14V)
On Board Diagnosis Logic DTC No. P0135 0135
Malfunction is detected when ... I The current amperage in the heated oxygen sensor 1 heater (front) circuit is out of the normal range. [An improper voltage drop signal is sent to ECM through the heated oxygen sensor 1 heater (front).]
EC-166
NLEC0139
Check Items (Possible Cause) I Harness or connectors (The heated oxygen sensor 1 heater (front) circuit is open or shorted.) I Heated oxygen sensor 1 heater (front)
DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER
QG16I18DE
DTC Confirmation Procedure
DTC Confirmation Procedure
NLEC0140
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 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.
1) 2) 3)
SEF058Y
1) 2) 3) 4) 5) I
With CONSULT-II 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 “Diagnostic Procedure”, ECQG-169. With GST Start engine and run it for at least 5 seconds at idle speed. Turn ignition switch “OFF” and wait at least 9 seconds. Start engine and run it for at least 5 seconds at idle speed. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-QG-169. When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is recommended.
EC-167
DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0141
YEC066A
EC-168
DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NLEC0142
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector.
SEF012XA
3. Turn ignition switch “ON”. 4. Check voltage between terminal 3 and ground with CONSULT-II or tester.
SEF025X
Voltage: Battery voltage OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F104, M50 I 10A fuse I Harness for open or short between heated oxygen sensor 1 (front) and fuse ©
3
Repair harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between heated oxygen sensor 1 (front) harness connector terminal 1 and ECM terminal 4. 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-169
DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER
QG16I18DE
Diagnostic Procedure (Cont’d)
4
CHECK HEATED OXYGEN SENSOR 1 HEATER (FRONT)
Refer to “Component Inspection”, EC-QG-170. OK or NG OK
©
GO TO 5.
NG
©
Replace heated oxygen sensor 1 (front).
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
Component Inspection HEATED OXYGEN SENSOR 1 HEATER (FRONT)
SEF935X
NLEC0143 NLEC0143S01
Check resistance between terminals 3 and 1. Resistance: 2.3 - 4.3 Ω at 25°C (77°F) Check continuity between terminals 2 and 1, 3 and 2. Continuity should not exist. If NG, replace the heated oxygen sensor 1 (front). CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
EC-170
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
QG16I18DE Component Description
Component Description
SEF327R
NLEC0144
The heated oxygen sensor 2 (rear), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). 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 (rear) is not used for engine control operation.
CONSULT-II Reference Value in Data Monitor Mode
NLEC0145
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S2 (B1) I Engine: After warming up
HO2S2 MNTR (B1)
Revving engine from idle to 3,000 rpm
LEAN +, RICH
ECM Terminals and Reference Value
NLEC0146
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. 63
WIRE COLOR
L
ITEM
Heated oxygen sensor 2 (rear)
CONDITION
DATA (DC Voltage)
[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and engine speed is 3,000 rpm
On Board Diagnosis Logic
NLEC0147
The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the minimum voltage of the sensor is sufficiently low during various driving conditions such as fuel-cut. SEF258VA
DTC No. P0137 0137
Malfunction is detected when ... I The minimum voltage from the sensor does not reach the specified voltage.
EC-171
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
QG16I18DE
DTC Confirmation Procedure
DTC Confirmation Procedure
SEF682X
SEF684X
NLEC0594
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 9 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. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0137” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) 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 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED
1,500 - 3,600 rpm
Vehicle speed
Above 70 km/h (43 MPH)
B/FUEL SCHDL
Above 2.7 msec
Selector lever
4th gear position
NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG175.
EC-172
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
QG16I18DE Overall Function Check
Overall Function Check
SEF032X
NLEC0595
Use this procedure to check the overall function of the rear heated oxygen sensor circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage when revving engine 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 0.56V at least once during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) 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 0.56V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-QG-175.
EC-173
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
QG16I18DE
Wiring Diagram
Wiring Diagram
EC-174
NCEC0150
YEC067A
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0151
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
SEF994W
©
GO TO 2.
EC-175
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
2
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.
SEF652Y
4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed.
SEF995W
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0172. Refer to EC-QG-215.
No
©
GO TO 3.
EC-176
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
3
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector.
SEF033X
3. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 63 [or heated oxygen sensor 2 (rear) harness connector terminal 2] and ground. Continuity should not exist. 5. 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 harness for open or short between heated oxygen sensor 2 (rear) and ECM. ©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and body ground. 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 HEATED OXYGEN SENSOR 2 (REAR)
Refer to “Component Inspection”, EC-QG-178. OK or NG OK
©
GO TO 7.
NG
©
Replace heated oxygen sensor 2 (rear).
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
EC-177
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
QG16I18DE
Component Inspection
Component Inspection HEATED OXYGEN SENSOR 2 (REAR)
SEF662Y
NLEC0152 NLEC0152S01
With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.56V at least once when the “FUEL INJECTION” is −25%. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
SEF244YA
Without CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) 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. If the voltage is above 0.68V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or 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 0.56V at least once. CAUTION: I 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. 1)
SEF032X
EC-178
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
QG16I18DE
Component Inspection (Cont’d)
I
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
EC-179
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
QG16I18DE
Component Description
Component Description
SEF327R
NLEC0153
The heated oxygen sensor 2 (rear), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). 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 (rear) is not used for engine control operation.
CONSULT-II Reference Value in Data Monitor Mode
NLEC0154
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S2 (B1) I Engine: After warming up
HO2S2 MNTR (B1)
Revving engine from idle to 3,000 rpm
LEAN +, RICH
ECM Terminals and Reference Value
NLEC0155
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. 63
WIRE COLOR
L
ITEM
Heated oxygen sensor 2 (rear)
CONDITION
DATA (DC Voltage)
[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and engine speed is 2,000 rpm
On Board Diagnosis Logic
NLEC0156
The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the maximum voltage of the sensor is sufficiently high during various driving conditions such as fuel-cut. SEF259VA
DTC No. P0138 0138
Malfunction is detected when ... I The maximum voltage from the sensor does not reach the specified voltage.
EC-180
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors I Intake air leaks
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
QG16I18DE
DTC Confirmation Procedure
DTC Confirmation Procedure
SEF685X
SEF687X
NLEC0596
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 9 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. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0138” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) 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 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED
1,500 - 3,600 rpm
Vehicle speed
Above 70 km/h (43 MPH)
B/FUEL SCHDL
Above 2.7 msec
Selector lever
4th gear position
NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG184.
EC-181
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
QG16I18DE
Overall Function Check
Overall Function Check
SEF032X
NLEC0597
Use this procedure to check the overall function of the rear heated oxygen sensor circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage when revving engine 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 4, step 5 is not necessary. 5) 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 above 0.68V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-QG-184.
EC-182
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
QG16I18DE Wiring Diagram
Wiring Diagram
EC-183
NCEC0159
YEC067A
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
NLEC0160
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
SEF994W
©
GO TO 2.
EC-184
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
2
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.
SEF652Y
4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed.
SEF995W
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0171. Refer to EC-QG-208.
No
©
GO TO 3.
EC-185
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
3
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 [or heated oxygen sensor 2 (rear) harness connector terminal 2] and ground. Continuity should not exist. 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
Check the harness for open or short between ECM and heated oxygen sensor 2 (rear). ©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and engine ground. Refer to wiring diagram. Continuity should exist. 2. 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 HEATED OXYGEN SENSOR 2 (REAR)
Refer to “Component Inspection”, EC-QG-186. OK or NG OK
©
GO TO 7.
NG
©
Replace heated oxygen sensor 2 (rear).
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
Component Inspection HEATED OXYGEN SENSOR 2 (REAR) 1) 2) 3) 4) SEF662Y
NLEC0161 NLEC0161S01
With CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes.. Stop vehicle with engine running. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.56V at least once when the “FUEL INJECTION” is −25%.
EC-186
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
QG16I18DE
Component Inspection (Cont’d)
CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
SEF244YA
Without CONSULT-II Start engine and drive vehicle at a speed of 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) 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. If the voltage is above 0.68V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or 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 0.56V at least once. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1)
SEF032X
EC-187
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
QG16I18DE
Component Description
Component Description
SEF327R
NLEC0162
The heated oxygen sensor 2 (rear), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). 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 (rear) is not used for engine control operation.
CONSULT-II Reference Value in Data Monitor Mode
NLEC0163
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S2 (B1) I Engine: After warming up
HO2S2 MNTR (B1)
Revving engine from idle to 3,000 rpm
LEAN +, RICH
ECM Terminals and Reference Value
NLEC0164
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. 63
WIRE COLOR
L
ITEM
CONDITION
Heated oxygen sensor 2 (rear)
DATA (DC Voltage)
[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 2,000 rpm
On Board Diagnosis Logic
NLEC0165
The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the switching response of the sensor’s voltage is faster than specified during various driving conditions such as fuel-cut. SEF302U
DTC No. P0139 0139
Malfunction is detected when ... I It takes more than the specified time for the sensor to respond between rich and lean.
EC-188
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors I Intake air leaks
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
QG16I18DE
DTC Confirmation Procedure
DTC Confirmation Procedure
SEF688X
SEF690X
NLEC0598
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 9 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. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0139” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) 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 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED
1,500 - 3,600 rpm
Vehicle speed
Above 70 km/h (43 MPH)
B/FUEL SCHDL
Above 2.7 msec
COOLAN TEMP/S
70 - 105°C (158 - 221°F)
Selector lever
4th gear position
NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG192.
EC-189
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
QG16I18DE
Overall Function Check
Overall Function Check
SEF032X
NLEC0599
Use this procedure to check the overall function of the rear heated oxygen sensor circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) 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 change at more than 0.06V for 1 second during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) 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 change at more than 0.06V for 1 second during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-QG-192.
EC-190
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
QG16I18DE Wiring Diagram
Wiring Diagram
EC-191
NCEC0168
YEC067A
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0169
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
SEF994W
©
GO TO 2.
EC-192
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
2
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.
SEF652Y
4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed.
SEF995W
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0172. Refer to EC-QG-215.
No
©
GO TO 3.
EC-193
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
QG16I18DE
Diagnostic Procedure (Cont’d)
3
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector.
SEF033X
2. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 [or heated oxygen sensor 2 (rear) harness connector terminal 2] and ground. Continuity should not exist. 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
Check the harness for open or short between heated oxygen sensor 2 (rear) and ECM. ©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and engine ground. Refer to wiring diagram. Continuity should exist. 2. 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 HEATED OXYGEN SENSOR 2 (REAR)
Refer to “Component Inspection”, EC-QG-195. OK or NG OK
©
GO TO 7.
NG
©
Replace heated oxygen sensor 2 (rear).
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
EC-194
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
QG16I18DE Component Inspection
Component Inspection HEATED OXYGEN SENSOR 2 (REAR)
SEF662Y
NLEC0170 NLEC0170S01
With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.56V at least once when the “FUEL INJECTION” is −25%. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.
SEF244YA
Without CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) 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. If the voltage is above 0.68V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or 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 0.56V at least once. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool 1)
SEF032X
EC-195
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING) Component Inspection (Cont’d)
and approved anti-seize lubricant.
EC-196
QG16I18DE
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
QG16I18DE Component Description
Component Description
SEF327R
NLEC0171
The heated oxygen sensor 2 (rear), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). 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 (rear) is not used for engine control operation.
CONSULT-II Reference Value in Data Monitor Mode
NLEC0172
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S2 (B1) I Engine: After warming up
HO2S2 MNTR (B1)
Revving engine from idle to 3,000 rpm
LEAN +, RICH
ECM Terminals and Reference Value
NLEC0173
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. 63
WIRE COLOR
L
ITEM
CONDITION
Heated oxygen sensor 2 (rear)
DATA (DC Voltage)
[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 2,000 rpm
On Board Diagnosis Logic
NLEC0174
The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether or not the voltage is too high during various driving conditions such as fuelcut. SEF305U
DTC No. P0140 0140
Malfunction is detected when ... I An excessively high voltage from the sensor is sent to ECM.
EC-197
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear)
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
QG16I18DE
DTC Confirmation Procedure
DTC Confirmation Procedure
SEF189Y
ENG SPEED
Above 1,500 rpm
VHCL SPEED SE
Above 70 km/h (43 MPH)
B/FUEL SCHDL
Above 2.7 msec
COOLAN TEMP/S
70 - 105°C (158 - 221°F)
Selector lever
Suitable position
6)
If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-200.
Overall Function Check
SEF032X
NLEC0175
NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 3) Stop vehicle with engine running. 4) Let engine idle for 1 minute. 5) Maintain the following conditions for at least 5 consecutive minutes.
NLEC0176
Use this procedure to check the overall function of the heated oxygen sensor 2 (rear) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage after 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 2V during this procedure. 5) If NG, go to “Diagnostic Procedure”, EC-QG-200.
EC-198
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
QG16I18DE Wiring Diagram
Wiring Diagram
EC-199
NCEC0177
YEC067A
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0178
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
SEF994W
©
2
GO TO 2.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector.
SEF033X
2. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 [or heated oxygen sensor 2 (rear) harness connector terminal 2] and ground. Continuity should not 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 harness for open or short between heated oxygen sensor 2 (rear) and ECM. ©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-200
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
QG16I18DE
Diagnostic Procedure (Cont’d)
4
CHECK GROUND CIRCUIT
1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and engine ground. Refer to wiring diagram. Continuity should exist. 2. 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.
5
CHECK HARNESS CONNECTOR
Check heated oxygen sensor 2 (rear) harness connector for water. Water should not exist. OK or NG OK
©
GO TO 6.
NG
©
Repair or replace harness connector.
6
CHECK HEATED OXYGEN SENSOR 2 (REAR)
Refer to “Component Inspection”, EC-QG-201. OK or NG OK
©
GO TO 7.
NG
©
Replace heated oxygen sensor 2 (rear).
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
Component Inspection HEATED OXYGEN SENSOR 2 (REAR)
With CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.56V at least once when the “FUEL INJECTION” is −25%. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1)
SEF662Y
NLEC0179 NLEC0179S01
EC-201
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
QG16I18DE
Component Inspection (Cont’d)
SEF244YA
Without CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) 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. If the voltage is above 0.68V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or 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 0.56V at least once. CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1)
SEF032X
EC-202
DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)
QG16I18DE Description
Description
NLEC0180
SYSTEM DESCRIPTION
NLEC0180S01
Sensor
Input Signal to ECM
Camshaft position sensor (PHASE) Crankshaft position sensor (POS)
ECM function Heated oxygen sensor 2 heater (rear) control
Engine speed
Actuator
Heated oxygen sensor 2 heater (rear)
The ECM performs ON/OFF control of the heated oxygen sensor 2 heater (rear) corresponding to the engine speed.
OPERATION
NLEC0180S02
Engine condition
Heated oxygen sensor 2 heater (rear)
Engine stopped
OFF
Engine is running.
After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more
ON
Engine speed above 3,600 rpm
OFF
CONSULT-II Reference Value in Data Monitor Mode
NLEC0181
Specification data are reference values. MONITOR ITEM
HO2S2 HTR (B1)
CONDITION
I Engine speed
SPECIFICATION
Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]
ON
Above 3,600 rpm
OFF
I Ignition switch ON (Engine stopped)
OFF
ECM Terminals and Reference Value
NLEC0182
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. TERMIWIRE NAL NO. COLOR
3
W/R
ITEM
Heated oxygen sensor 2 heater (rear)
CONDITION
DATA (DC Voltage)
[Engine is running] I Engine speed is below 3,600 rpm [After driving Approximately 0.7V for 2 minutes at a speed of 70 km/h (43 MPH) or more] [Engine is running] I Engine speed is above 3,600 rpm [Ignition switch “ON”] I Engine stopped
EC-203
BATTERY VOLTAGE (11 - 14V)
DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic DTC No. P0141 0141
Malfunction is detected when ... I The current amperage in the heated oxygen sensor 2 heater (rear) circuit is out of the normal range. [An improper voltage drop signal is sent to ECM through the heated oxygen sensor 2 heater (rear).]
Check Items (Possible Cause) I Harness or connectors (The heated oxygen sensor 2 heater (rear) circuit is open or shorted.) I Heated oxygen sensor 2 heater (rear)
DTC Confirmation Procedure
SEF175Y
NLEC0183
NLEC0184
NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is in between 10.5V and 16V at idle. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. Engine speed must be maintained at speeds of 3,600 rpm or less during vehicle operations. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-206. With GST 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. Engine speed must be maintained at speeds of 3,600 rpm or less during vehicle operations. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 4) Select “MODE 3” with GST. 5) If DTC is detected, go to “Diagnostic Procedure”, EC-QG-206. When using GST, “DTC Confirmation Procedure ” should be performed twice as much as when using CONSULT-II because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is recommended.
EC-204
DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)
QG16I18DE Wiring Diagram
Wiring Diagram
EC-205
NCEC0185
YEC068A
DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0186
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 2 (rear) harness connector.
SEF033X
3. Turn ignition switch “ON”. 4. Check voltage between terminal 4 and ground.
SEF047X
Voltage: Battery voltage OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F104, M50 I Harness for open or short between heated oxygen sensor 2 (rear) and fuse I 10A fuse ©
3
Repair harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 1 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 5.
NG
©
GO TO 4.
EC-206
DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)
QG16I18DE
Diagnostic Procedure (Cont’d)
5
CHECK HEATED OXYGEN SENSOR 2 HEATER (REAR)
Refer to “Component Inspection”, EC-QG-207. OK or NG OK
©
GO TO 6.
NG
©
Replace heated oxygen sensor 2 (rear).
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
Component Inspection
NLEC0187
HEATED OXYGEN SENSOR 2 HEATER (REAR)
NLEC0187S01
Check the following. 1. Check resistance between terminals 1 and 4. Resistance: 2.3 - 4.3Ω at 25°C (77°F) 2. Check continuity. Terminal No.
Continuity
2 and 1, 3, 4 No 3 and 1, 2, 4
If NG, replace the heated oxygen sensor 2 (rear). CAUTION: I 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. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. SEF048X
EC-207
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0188
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 (front). 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 (front)
DTC No. P0171 0171
ECM function
Input Signal to ECM
Fuel injection & mixture ratio control
Density of oxygen in exhaust gas (Mixture ratio feedback signal)
Malfunction is detected when ... I Fuel injection system does not operate properly. I The amount of mixture ratio compensation is too large. (The mixture ratio is too lean.)
Actuator
Injectors
Check Items (Possible Cause) I I I I I I I
Intake air leaks Heated oxygen sensor 1 (front) Injectors Exhaust gas leaks Incorrect fuel pressure Lack of fuel Mass air flow sensor
DTC Confirmation Procedure
NCEC0189
NEF068A
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 4) Clear the self-learning control coefficient by touching “CLEAR”. 5) Select “DATA MONITOR” mode with CONSULT-II. 6) 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 “Diagnostic Procedure”, EC-QG211. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-QG-211. If engine does not start, visually check for exhaust and intake air leak.
SEF995W
With GST Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 9 seconds. Disconnect mass air flow sensor harness connector. Then restart and run engine for at least 3 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Select “MODE 7” with GST. Make sure 1st trip DTC P0100 is detected. Select “MODE 4” with GST and erase the 1st trip DTC P0100.
SEF652Y
1) 2) 3) 4) 5) 6)
EC-208
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
QG16I18DE
DTC Confirmation Procedure (Cont’d)
7)
Start engine again and run it for at least 10 minutes at idle speed. 8) Select “MODE 7” with GST. The 1st trip DTC P0171 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-QG-211. 9) If it is difficult to start engine at step 8, the fuel injection system has a malfunction. 10) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-QG-211. If engine does not start, visually check for exhaust and intake air leak.
EC-209
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
QG16I18DE
Wiring Diagram
Wiring Diagram
EC-210
NCEC0190
YEC069A
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0191
CHECK EXHAUST AIR LEAK
1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.
SEF099P
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 mass air flow sensor. OK or NG OK
©
GO TO 3.
NG
©
Repair or replace.
3
CHECK HEATED OXYGEN SENSOR 1 (FRONT) CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect Heated oxygen sensor 1 (front) harness connector and ECM harness connector.
SEF012XA
3. Check harness continuity between ECM terminal 62 and Heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not 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-211
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
QG16I18DE
Diagnostic Procedure (Cont’d)
4
CHECK FUEL PRESSURE
1. Release fuel pressure to zero. Refer to EC-QG-29. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi) OK or NG OK
©
GO TO 6.
NG
©
GO TO 5.
5
DETECT MALFUNCTIONING PART
Check the following. I Fuel pump and circuit Refer to EC-QG-336. I Fuel pressure regulator Refer to EC-QG-30. I Fuel lines Refer to “ENGINE MAINTENANCE” in MA section. I Fuel filter for clogging
©
6
Repair or replace.
CHECK MASS AIR FLOW SENSOR
With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 1.0 - 4.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 1.0 - 5.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec OK or NG OK
©
GO TO 7.
NG
©
Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-QG-110.
EC-212
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
QG16I18DE
Diagnostic Procedure (Cont’d)
7
CHECK FUNCTION OF INJECTORS
With CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.
NEF105A
4. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Listen to each injector operating sound.
MEC703B
Clicking noise should be heard. OK or NG OK
©
GO TO 8.
NG
©
Perform trouble diagnosis for “INJECTORS”, EC-QG-319.
8
REMOVE INJECTOR
1. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 2. Turn ignition switch “OFF”. 3. Remove injector with fuel tube assembly. Refer to EC-QG-30. Keep fuel hose and all injectors connected to injector gallery. The injector harness connectors should remain connected.
©
GO TO 9.
EC-213
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
QG16I18DE
Diagnostic Procedure (Cont’d)
9
CHECK INJECTOR
1. Disconnect all ignition coil harness connectors. 2. Place pans or saucers under each injector. 3. Crank engine for about 3 seconds. Make sure that fuel sprays out from injectors.
SEF595Q
Fuel should be sprayed evenly for each cylinder. OK or NG OK
©
GO TO 10.
NG
©
Replace injectors from which fuel does not spray out. Always replace O-ring with new one.
10
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-214
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0192
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 (front). 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 sensor 1 (front)
DTC No. P0172 0172
ECM function
Input Signal to ECM
Fuel injection & mixture ratio control
Density of oxygen in exhaust gas (Mixture ratio feedback signal)
Malfunction is detected when ... I Fuel injection system does not operate properly. I The amount of mixture ratio compensation is too large. (The mixture ratio is too rich.)
Actuator
Injectors
Check Items (Possible Cause) I I I I I
Heated oxygen sensor 1 (front) Injectors Exhaust gas leaks Incorrect fuel pressure Mass air flow sensor
DTC Confirmation Procedure
NCEC0193
NEF068A
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 4) Clear the self-learning control coefficient by touching “CLEAR”. 5) Select “DATA MONITOR” mode with CONSULT-II. 6) 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 “Diagnostic Procedure”, EC-QG218. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-QG-218. If engine does not start, remove ignition plugs and check for fouling, etc.
SEF995W
With GST Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 9 seconds. Disconnect mass air flow sensor harness connector. Then restart and run engine for at least 3 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Select “MODE 7” with GST. Make sure 1st trip DTC P0100 is detected. Select “MODE 4” with GST and erase the 1st trip DTC P0100.
SEF652Y
1) 2) 3) 4) 5) 6)
EC-215
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
QG16I18DE
DTC Confirmation Procedure (Cont’d)
7)
Start engine again and run it for at least 10 minutes at idle speed. 8) Select “MODE 7” with GST. The 1st trip DTC P0172 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-QG-218. 9) If it is difficult to start engine at step 8, the fuel injection system has a malfunction. 10) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-QG-218. If engine does not start, remove ignition plugs and check for fouling, etc.
EC-216
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
QG16I18DE Wiring Diagram
Wiring Diagram
EC-217
NCEC0194
YEC069A
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0195
CHECK FOR EXHAUST AIR LEAK
1. Start engine and run it at idle. 2. Listen for an exhaust air leak before the three way catalyst.
SEF099P
OK or NG OK
©
GO TO 2.
NG
©
Repair or replace.
2
CHECK HEATED OXYGEN SENSOR 1 (FRONT) CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect Heated oxygen sensor 1 (front) harness connector and ECM harness connector.
SEF012XA
3. Check harness continuity between ECM terminal 62 and Heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not 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.
EC-218
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
QG16I18DE
Diagnostic Procedure (Cont’d)
3
CHECK FUEL PRESSURE
1. Release fuel pressure to zero. Refer to EC-QG-29. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. Approximately 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. Approximately 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi) OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the following. I Fuel pump and circuit (Refer to EC-QG-336.) I Fuel pressure regulator (Refer to EC-QG-30.)
©
5
Repair or replace.
CHECK MASS AIR FLOW SENSOR
With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 1.0 - 4.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 1.0 - 4.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec OK or NG OK
©
GO TO 6.
NG
©
Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-QG-113.
EC-219
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
QG16I18DE
Diagnostic Procedure (Cont’d)
6
CHECK FUNCTION OF INJECTORS
With CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.
NEF105A
4. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Listen to each injector operating sound.
MEC703B
Clicking noise should be heard. OK or NG OK
©
GO TO 7.
NG
©
Perform trouble diagnosis for “INJECTORS”, EC-QG-319319.
7
REMOVE INJECTOR
1. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 2. Turn ignition switch “OFF”. 3. Remove injector assembly. Refer to EC-QG-30. Keep fuel hose and all injectors connected to injector gallery.
©
8 1. 2. 3. 4.
GO TO 8.
CHECK INJECTOR Disconnect all injector harness connectors. Disconnect all ignition coil harness connectors. Prepare pans or saucers under each injectors. Crank engine for about 3 seconds. Make sure fuel does not drip from injector. OK or NG
OK (Does not drip)
©
GO TO 9.
NG (Drips)
©
Replace the injectors from which fuel is dripping. Always replace O-ring with new one.
EC-220
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
QG16I18DE
Diagnostic Procedure (Cont’d)
9
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-221
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0202
When a misfire occurs, the engine speed will fluctuate. If the engine speed fluctuates enough to cause the CKP sensor signal to vary, The ECM can determine that a misfire is occurring. Sensor
Input Signal to ECM
Crankshaft position sensor (POS)
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 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. (After the first trip detection, the MI will light up from engine starting. If a misfire is detected that will cause three way catalyst damage, the MI will start blinking.) 2. Two Trip Detection Logic (Exhaust quality deterioration) For misfire conditions that will not damage the TWC (but will affect 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.
Malfunction is detected when ...
P0300 0300
I Multiple cylinders misfire.
P0301 0301
I No. 1 cylinder misfires.
P0302 0302
I No. 2 cylinder misfires.
P0303 0303
I No. 3 cylinder misfires.
P0304 0304
I No. 4 cylinder misfires.
Check Items (Possible Cause) I I I I I I I I I I
Improper spark plug Insufficient compression Incorrect fuel pressure EGR volume control valve (If so equipped) The injector circuit is open or shorted Injectors Intake air leak Insufficient ignition spark Lack of fuel Heated oxygen sensor 1 (front)
DTC Confirmation Procedure
NEF068A
NCEC0203
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 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”, and select “DATA MONITOR” mode with CONSULT-II.
EC-222
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
QG16I18DE
DTC Confirmation Procedure (Cont’d)
2) 3) 4)
Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 9 seconds. Start engine again and drive at 1,500 - 3,000 rpm for at least 3 minutes. Hold the accelerator pedal as steady as possible. NOTE: Refer to the freeze frame data for the test driving conditions. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-223. With GST Follow the procedure “With CONSULT-II” above.
Diagnostic Procedure 1
CHECK FOR INTAKE AIR LEAK
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.
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 it.
3
CHECK EGR FUNCTION (If so equipped)
Perform DTC Confirmation Procedure for DTC P1402 EGR FUNCTION (OPEN). Refer to EC-QG-305. OK or NG OK
©
GO TO 4.
NG
©
Repair EGR system.
EC-223
NCEC0204
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
QG16I18DE
Diagnostic Procedure (Cont’d)
4
PERFORM POWER BALANCE TEST
With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode.
NEF105A
2. Is there any cylinder which does not produce a momentary engine speed drop? Without CONSULT-II When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop?
SEF055X
Yes or No Yes
©
GO TO 5.
No
©
GO TO 7.
5
CHECK INJECTOR
Does each injector make an operating sound at idle?
MEC703B
Yes or No Yes
©
GO TO 6.
No
©
Check injector(s) and circuit(s). Refer to EC-QG-319.
EC-224
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
QG16I18DE
Diagnostic Procedure (Cont’d)
6 1. 2. 3. 4. 5.
CHECK IGNITION SPARK Turn Ignition switch “OFF”. Disconnect ignition coil assembly from rocker cover. Connect a known good spark plug to the ignition coil assembly. Place end of spark plug against a suitable ground and crank engine. Check for spark.
SEF575Q
OK or NG OK
©
GO TO 7.
NG
©
Check ignition coil, power transistor and their circuits. Refer to EC-QG-323.
7
CHECK SPARK PLUGS
Remove the spark plugs and check for fouling, etc.
SEF156I
OK or NG OK
©
GO TO 8.
NG
©
Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to “ENGINE MAINTENANCE” in MA section.
8
CHECK COMPRESSION PRESSURE
Refer to EM section. I Check compression pressure. Standard: 1,324 kPa (13.24 bar, 13.5 kg/cm2, 192 psi)/350 rpm Minimum: 1,128 kPa (11.28 bar, 11.5 kg/cm2, 164 psi)/350 rpm Difference between each cylinder: 98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)/350 rpm OK or NG OK
©
GO TO 9.
NG
©
Check pistons, piston rings, valves, valve seats and cylinder head gaskets.
EC-225
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
QG16I18DE
Diagnostic Procedure (Cont’d)
9
CHECK FUEL PRESSURE
1. Install any parts removed. 2. Release fuel pressure to zero. Refer to EC-QG-29. 3. Install fuel pressure gauge and check fuel pressure.
SEF925W
At idle: Approx. 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) OK or NG OK
©
GO TO 11.
NG
©
GO TO 10.
10
DETECT MALFUNCTIONING PART
Check the following. I Fuel pump and circuit Refer to EC-QG-336. I Fuel pressure regulator Refer to EC-QG-30. I Fuel lines Refer to “ENGINE MAINTENANCE” in MA section. I Fuel filter for clogging ©
11
Repair or replace.
CHECK IGNITION TIMING
Perform “Basic Inspection”. Refer to EC-QG-72. OK or NG OK
©
GO TO 12.
NG
©
1. Perform “Idle Air Volume Learning”. Refer to EC-QG-33. 2. Check camshaft position sensor (PHASE) (EC-QG-238) and crankshaft position sensor (POS) (EC-QG-232).
12
CHECK HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-QG-231. OK or NG OK
©
GO TO 13.
NG
©
Replace Heated oxygen sensor 1 (front).
EC-226
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
QG16I18DE
Diagnostic Procedure (Cont’d)
13
CHECK MASS AIR FLOW SENSOR
With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 1.0 - 4.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 1.0 - 4.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec OK or NG OK
©
GO TO 15.
NG
©
GO TO 14.
14
CHECK CONNECTORS
Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-QG-110. OK or NG NG
15
©
Repair or replace it.
CHECK SYMPTOM MATRIX CHART
Check items on the rough idle symptom in “Symptom Matrix Chart”, EC-QG-82. 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-QG-44. ©
17
GO TO 17.
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
EC-227
QG16I18DE
DTC P0325 KNOCK SENSOR (KS) Component Description
Component Description
NCEC0206
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. Freeze frame data will not be stored in the ECM for the knock sensor. The MI will not light for knock sensor malfunction. The knock sensor has one trip detection logic. SEF598K
ECM Terminals and Reference Value
NCEC0207
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. 81
WIRE COLOR W
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running] I Idle speed
Knock sensor
1.0 - 4.0V
On Board Diagnosis Logic DTC No. P0325 0325
Malfunction is detected when ... I An excessively low or high voltage from the knock sensor is sent to ECM.
Check Items (Possible Cause) I Harness or connectors (The knock sensor circuit is open or shorted.) I Knock sensor
DTC Confirmation Procedure
NEF068A
NCEC0208
NCEC0209
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 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) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 5 seconds at idle speed. 3) If DTC is detected, go to “Diagnostic Procedure”, EC-QG-230. With GST Follow the procedure “With CONSULT-II” above.
EC-228
DTC P0325 KNOCK SENSOR (KS)
QG16I18DE Wiring Diagram
Wiring Diagram
NCEC0210
ECM
Detectable line for DTC Non-detectable line for DTC
KNOCK SENSOR
EC-229
YEC269
DTC P0325 KNOCK SENSOR (KS)
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0211
RETIGHTEN GROUND SCREWS
Loosen and retighten engine ground screws.
SEF994W
©
2
GO TO 2.
CHECK INPUT SIGNAL CIRCUIT-1
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and knock sensor harness connector. View from the underside of the vehicle Knock sensor harness connector
Oil filter
SEF056X
3. Check harness continuity between knock sensor signal terminal 2 and ECM terminal 81. 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 harness for open or short between knock sensor and ECM.
©
4
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK KNOCK SENSOR
Knock sensor Refer to “Component Inspection”, EC-QG-231. OK or NG OK
©
GO TO 5.
NG
©
Replace knock sensor.
EC-230
DTC P0325 KNOCK SENSOR (KS)
QG16I18DE Diagnostic Procedure (Cont’d)
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection KNOCK SENSOR I 1. 2.
NCEC0212 NCEC0212S01
Use an ohmmeter which can measure more than 10 MΩ. Disconnect knock sensor harness connector. Check resistance between terminal 2 and ground. Resistance: 500 - 620 kΩ [at 25°C (77°F)] CAUTION: Discard any knock sensors that have been dropped or physically damaged. Use only new ones.
SEF057X
EC-231
DTC P0335 CRANKSHAFT POSITION SENSOR (POS)
QG16I18DE
Component Description
Component Description
SEF058X
SEF117X
NCEC0551
The crankshaft position sensor is located on the right rear wall of the cylinder block in relation to the signal plate on the No. 6 counterweight. The crankshaft position sensor is a basic component of the engine control system. It monitors engine speed, piston position, and fluctuation of the engine revolution. These input signals to the engine control system are used to control fuel injection, ignition timing and other functions. The sensor consists of a permanent magnet, core and coil. When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The signal plate is provided with 34 teeth to emit a signal at an interval of 10° during crankshaft operations. However, it is not provided with 2 teeth to emit a signal at an interval of 180°. 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 a voltage signal to provide “time processing” for engine speed, piston position and fluctuation of engine revolutions. This sensor is not used to control the engine system. It is used only for the on board diagnosis.
ECM Terminals and Reference Value
NCEC0552
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 (AC Voltage) 3 - 4V
[Engine is running] I Warm-up condition I Idle speed
85
W
SEF979W
Crankshaft position sensor
3 - 4V
[Engine is running] I Engine speed is 2,000 rpm
SEF980W
EC-232
DTC P0335 CRANKSHAFT POSITION SENSOR (POS)
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic DTC No. P0335 0335
Malfunction is detected when ... I The 10° signal is not entered to ECM for the first few seconds during engine cranking. .......................................................................................................... I The 10° signal is not entered to ECM during engine running. .......................................................................................................... I The 10° signal is not in the normal pattern at each engine revolution.
Check Items (Possible Cause) I Harness or connectors (The crankshaft position sensor (POS) circuit is open or shorted.) I Crankshaft position sensor (POS) I Starter motor (Refer to EL section.) I Starting system circuit (Refer to EL section.) I Dead (Weak) battery
DTC Confirmation Procedure
NEF068A
NCEC0553
NCEC0554
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 2 seconds at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-235. With GST Follow the procedure “With CONSULT-II” above.
EC-233
DTC P0335 CRANKSHAFT POSITION SENSOR (POS)
QG16I18DE
Wiring Diagram
Wiring Diagram
EC-234
NCEC0555
YEC070A
DTC P0335 CRANKSHAFT POSITION SENSOR (POS)
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0556
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
SEF994W
©
2
GO TO 2.
CHECK POWER SUPPLY
1. Disconnect crankshaft position sensor harness connector.
SEF117X
2. Turn ignition switch “ON”. 3. Check voltage between terminal 1 and ground with CONSULT-II or tester.
YEC132A
Voltage: Battery voltage OK or NG OK
©
GO TO 4.
NG
©
GO TO 3.
EC-235
DTC P0335 CRANKSHAFT POSITION SENSOR (POS)
QG16I18DE
Diagnostic Procedure (Cont’d)
3
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I Harness for open or short between crankshaft position sensor and ECM relay I Harness for open or short between crankshaft position sensor and ECM I ECM relay ©
4
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect crankshaft position sensor and ECM harness connectors.
SEF117X
2. Check continuity between ECM terminal 85 and crankshaft position sensor harness connector 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 5.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
5
CHECK GROUND CIRCUIT
1. Reconnect ECM harness connector. 2. Check harness continuity between terminal 3 and engine 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 6.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
6
CHECK CRANKSHAFT POSITION SENSOR
Refer to “Component Inspection”, EC-QG-237. OK or NG OK
©
GO TO 7.
NG
©
Replace crankshaft position sensor.
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-236
DTC P0335 CRANKSHAFT POSITION SENSOR (POS)
QG16I18DE
Component Inspection
Component Inspection
NCEC0557
CRANKSHAFT POSITION SENSOR (POS) 1.
NCEC0557S01
2. 3. 4.
Disconnect crankshaft position sensor (POS) harness connector. Loosen the fixing bolt of the sensor. Remove the sensor. Visually check the sensor for chipping.
5.
Check resistance as shown in the figure.
SEF121X
Terminal No. (Polarity)
Resistance Ω [at 25°C (77°F)]
3 (+) - 1 (−) 2 (+) - 1 (−)
Except 0 or ∞
3 (+) - 2 (−)
If NG, replace crankshaft position sensor. SEF122X
EC-237
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)
QG16I18DE
Component Description
Component Description
SEF058X
NCEC0220
The camshaft position sensor senses the protrusion provided with exhaust valve cam sprocket to identify a particular cylinder. The crankshaft position sensor senses the piston position. When the crankshaft position sensor system becomes inoperative, the camshaft position sensor provides various controls of engine parts instead, utilizing timing of cylinder identification signals. The sensor consists of a permanent magnet, core and coil. 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.
ECM Terminals and Reference Value
NCEC0221
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. TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) 3 - 4V
[Engine is running] I Warm-up condition I Idle speed
SEF977W
66* 75
W
Camshaft position sensor (PHASE)
3 - 4V
[Engine is running] I Engine speed is 2,000 rpm
SEF978W
*: If so equipped
On Board Diagnosis Logic DTC No. P0340 0340
NCEC0222
Malfunction is detected when ...
Check Items (Possible Cause)
I The cylinder No. signal is not entered to ECM for the first few seconds during engine cranking. ................................................................................................. I The cylinder No. signal is not enter to ECM during engine running. ................................................................................................. I The cylinder No. signal is not in the normal pattern during engine running.
I Harness or connectors (The camshaft position sensor (PHASE) circuit is open or shorted.) I Camshaft position sensor (PHASE) I Starter motor (Refer to EL section.) I Starting system circuit (Refer to EL section.)
EC-238
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)
QG16I18DE
DTC Confirmation Procedure
DTC Confirmation Procedure
NCEC0223
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V.
With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-241. With GST Follow the procedure “With CONSULT-II” above. 1) 2) 3) 4)
PEF002P
EC-239
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)
QG16I18DE
Wiring Diagram
Wiring Diagram
EC-240
NCEC0224
YEC071A
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0225
CHECK STARTING SYSTEM
Does the engine turn over? (Does the starter motor operate?) Yes or No Yes
©
GO TO 2.
No
©
Check starting system. (Refer to EL section.)
2
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
SEF994W
©
3
GO TO 3.
CHECK POWER SUPPLY
1. Disconnect camshaft position sensor harness connector.
2. Turn ignition switch “ON”. 3. Check voltage between terminal 1 and ground with CONSULT-II or tester.
Voltage: Battery voltage
SEF060X
SEF061X
OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
EC-241
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)
QG16I18DE
Diagnostic Procedure (Cont’d)
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I Harness for open or short between camshaft position sensor and ECM relay I Harness for open or short between camshaft position sensor and ECM
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between sensor terminal 2 and ECM terminal 75. 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 GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Check harness continuity between sensor terminal 3 and engine 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
©
Repair open circuit or short to ground or short to power in harness or connectors.
7
CHECK CAMSHAFT POSITION SENSOR
Refer to “Component Inspection”, EC-QG-243. OK or NG OK
©
GO TO 8.
NG
©
Replace camshaft position sensor.
8
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-242
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)
QG16I18DE
Component Inspection
Component Inspection
=NCEC0226
CAMSHAFT POSITION SENSOR 1. 2. 3. 4. 5. SEF122X
NCEC0226S01
Disconnect camshaft position sensor (PHASE) harness connector. Loosen the fixing bolt of the sensor. Remove the sensor. Visually check the sensor for chipping. Check resistance as shown in the figure. Terminal No. (Polarity)
Resistance Ω [at 25°C (77°F)]
3 (+) - 1 (−) 2 (+) - 1 (−) 3 (+) - 2 (−)
If NG, replace camshaft position sensor.
EC-243
Except 0 or ∞
DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE Description
Description
NCEC0227
SYSTEM DESCRIPTION Sensor
Input Signal to ECM
Crankshaft position sensor
Engine speed
Mass air flow sensor
Amount of intake air
Engine coolant temperature sensor
Engine coolant temperature
Ignition switch
Start signal
Throttle position sensor
Throttle position
ECM function
EGR control
NCEC0227S01
Actuator
EGR volume control valve
Vehicle speed sensor or ABS actuator and Vehicle speed electric unit (control unit) Battery
Battery voltage
This system controls flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR by-pass passage in the EGR volume control valve changes to control the flow rate. A built-in step motor moves the valve in steps corresponding to the ECM output pulses. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. The EGR volume control valve remains closed under the following conditions. I Low engine coolant temperature I Engine starting I High-speed engine operation I Extremely light load engine operation I Engine idling I Excessively high engine coolant temperature I Wide open throttle I Mass air flow sensor malfunction I Low battery voltage
SEF551W
COMPONENT DESCRIPTION EGR Volume Control Valve
NCEC0227S02 NCEC0227S0201
The EGR volume control valve uses a step motor to control the flow rate of EGR from exhaust manifold. This motor has four winding phases. It operates according to the output pulse signal of the ECM. Two windings are turned ON and OFF in sequence. Each time an ON pulse is issued, the valve opens or closes, changing the flow rate. When no change in the flow rate is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening. SEF552W
EC-244
DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0502
Specification data are reference values. MONITOR ITEM
CONDITION
EGR TEMP SEN
I Engine: After warming up
EGR VOL CON/V
I I I I
SPECIFICATION Less than 4.5V
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load
Idle
0 step
Revving engine up to 3,000 rpm quickly
10 - 55 step
ECM Terminals and Reference Value
NCEC0503
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. TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage)
8 9 17 18
W/B SB G/R R/Y
EGR volume control valve
[Engine is running] I Warm-up condition I Rev engine up from 2,000 to 4,000 rpm
0 - 14V
58
B
Sensor’s ground
[Engine is running] I Warm-up condition I Idle speed
0V
[Engine is running] I Warm-up condition I Idle speed
Less than 4.5V
[Engine is running] I Warm-up condition I EGR system is operating.
0 - 1V
72
PU
EGR temperature sensor
On Board Diagnosis Logic
NCEC0228
If the absence of EGR flow is detected by EGR temperature sensor under the condition that calls for EGR, a low-flow malfunction is diagnosed.
SEF073P
DTC No. P0400 0400
Malfunction is detected when ... I No EGR flow is detected under conditions that call for EGR.
EC-245
Check Items (Possible Cause) I Harness or connectors (The valve circuit is open or shorted.) I EGR valve stuck closed I Dead (Weak) battery I EGR passage I EGR temperature sensor I Exhaust gas leaks
DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE DTC Confirmation Procedure
DTC Confirmation Procedure
NEF107A
NEF108A
PEF785UA
NCEC0229
CAUTION: Always drive vehicle at a safe speed. NOTE: I If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. I P0400 will not be displayed at “SELF-DIAG RESULTS” mode with CONSULT-II even though DTC work support test result is “NG”. TESTING CONDITION: I Before performing the following procedure, confirm battery voltage is more than 10V at idle, then stop engine immediately. I It will be better to perform the test at a temperature above 0°C (32°F). With CONSULT-II 1) Turn ignition switch “ON”. 2) Check “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II and confirm it is within the range listed below. COOLAN TEMP/S: Less than 40°C (104°F) If the value is out of range, park the vehicle in a cool place and allow the engine temperature to stabilize. Do not attempt to lower the coolant temperature with a fan or means other than ambient air. Doing so may produce an inaccurate diagnostic result. 3) Start engine and let it idle monitoring “COOLAN TEMP/S” value. When the “COOLAN TEMP/S” value reaches 70°C (158°F), immediately go to the next step. 4) Select “EGR SYSTEM P0400” of “EGR SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. 5) Touch “START”. 6) Accelerate vehicle to a speed of 40 km/h (25 MPH) once and then stop vehicle with engine running. If “COMPLETED” appears on CONSULT-II screen, go to step 8. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions until “TESTING” changes to “COMPLETED”. (It will take approximately 45 seconds or more.) ENG SPEED
Above 2,400 rpm
Vehicle speed
Above 90 km/h (56 MPH)
B/FUEL SCHDL
4.0 - 8.0 msec
Selector lever
4th or 5th
If “TESTING” is not displayed after 5 minutes, retry from step 2. 8) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG-249. With GST 1) Turn ignition switch “ON”.
EC-246
DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE DTC Confirmation Procedure (Cont’d)
2)
3)
4)
Check engine coolant temperature in MODE 1 with GST. Engine coolant temperature: Less than 40°C (104°F) If the value is out of range, park the vehicle in a cool place and allow the engine temperature to stabilize. Do not attempt to lower the coolant temperature with a fan or means other than ambient air. Doing so may produce an inaccurate diagnostic result. Start engine and let it idle monitoring the value of “COOLAN TEMP/S”. When the engine coolant temperature reaches 70°C (158°F), immediately go to the next step. Maintain the following conditions for at least 1 minute.
Engine speed
Above 2,400 rpm
Vehicle speed
Above 90 km/h (56 MPH)
Selector lever
4th or 5th
5) 6) 7) 8) 9) I
Stop vehicle. Turn ignition switch “OFF” and wait at least 9 seconds, then turn “ON”. Repeat step 2 to 4. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-QG-249. When using GST, “DTC CONFIRMATION PROCEDURE” should be performed twice as much as when using CONSULT-II or ECM (Diagnostic Test Mode II) because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II or ECM (Diagnostic Test Mode II) is recommended.
EC-247
DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE Wiring Diagram
Wiring Diagram
EC-248
NCEC0231
YEC072A
DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0232
CHECK EXHAUST SYSTEM
1. Start engine. 2. Check exhaust pipes and muffler for leaks.
SEF099P
OK or NG OK (With CONSULT-II)
©
GO TO 2.
OK (Without CONSULT-II)
©
GO TO 3.
NG
©
Repair or replace exhaust system.
2
CHECK POWER SUPPLY
1. Disconnect EGR volume control valve harness connector. 2. Turn ignition switch “ON”. 3. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.
DISCONNECT
SEF556WA
Voltage: Battery voltage OK or NG OK
©
GO TO 3.
NG
©
Check the following. I Harness or connectors E90, F73 I Harness for open or short between EGR volume control valve and engine control module relay If NG, repair harness or connectors.
EC-249
DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE Diagnostic Procedure (Cont’d)
3
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 8 and EGR volume control valve terminal 1, ECM terminal 9 and EGR volume control valve terminal 4, ECM terminal 17 and EGR volume control valve terminal 3, ECM terminal 18 and EGR volume control valve terminal 6. Refer to wiring diagram. Continuity should exist. If OK, check harness for short to ground and short to power. OK or NG OK
©
GO TO 4.
NG
©
Repair open circuit, short to ground or short to power in harness connectors.
4
CHECK EGR PASSAGE
Check EGR passage for clogging and cracks. OK or NG OK
©
GO TO 5.
NG
©
Repair or replace EGR passage.
5
CHECK EGR TEMPERATURE SENSOR
Refer to “TROUBLE DIAGNOSIS FOR DTC P1401”, EC-QG-300. OK or NG OK
©
GO TO 6.
NG
©
Replace EGR temperature sensor.
6
CHECK EGR VOLUME CONTROL VALVE
Refer to “Component Inspection”, EC-QG-251. OK or NG OK
©
GO TO 7.
NG
©
Replace EGR volume control valve.
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-250
DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE Component Inspection
Component Inspection
NCEC0233
EGR VOLUME CONTROL VALVE
NCEC0233S01
With CONSULT-II 1) Disconnect EGR volume control valve harness connector. 2) Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6
SEF069X
3) 4)
5) 6)
1) 2)
SEF558W
3)
Temperature °C (°F)
Resistance Ω
20 (68)
20 - 24
Reconnect EGR volume control valve harness connector. Remove EGR volume control valve from cylinder head. (The EGR volume control valve harness connector should remain connected.) Turn ignition switch “ON”. Perform “EGR VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that EGR volume control valve shaft moves smoothly forward and backward according to the valve opening. If NG, replace the EGR volume control valve. Without CONSULT-II Disconnect EGR volume control valve harness connector. Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6 Temperature °C (°F)
Resistance Ω
20 (68)
20 - 24
Turn ignition switch “ON” and “OFF”. Check that EGR volume control valve shaft moves smoothly forward and backward according to the ignition switch position. If NG, replace the EGR volume control valve.
NEF109A
SEF560W
EC-251
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) Description
Description
NCEC0504
SYSTEM DESCRIPTION Sensor
Input Signal to ECM
Crankshaft position sensor
Engine speed
Mass air flow sensor
Amount of intake air
Engine coolant temperature sensor
Engine coolant temperature
Ignition switch
Start signal
Throttle position sensor
Throttle position
ECM function
EGR control
NCEC0504S01
Actuator
EGR volume control valve
Vehicle speed sensor or ABS actuator and Vehicle speed electric unit (control unit) Battery
Battery voltage
This system controls flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR by-pass passage in the EGR volume control valve changes to control the flow rate. A built-in step motor moves the valve in steps corresponding to the ECM output pulses. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. The EGR volume control valve remains closed under the following conditions. I Low engine coolant temperature I Engine starting I High-speed engine operation I Extremely light load engine operation I Engine idling I Excessively high engine coolant temperature I Wide open throttle I Mass air flow sensor malfunction I Low battery voltage
SEF551W
COMPONENT DESCRIPTION
NCEC0504S02
The EGR volume control valve uses a step motor to control the flow rate of EGR from exhaust manifold. This motor has four winding phases. It operates according to the output pulse signal of the ECM. Two windings are turned ON and OFF in sequence. Each time an ON pulse is issued, the valve opens or closes, changing the flow rate. When no change in the flow rate is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening. SEF552W
EC-252
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0506
Specification data are reference values. MONITOR ITEM
EGR VOL CON/V
CONDITION I Engine: After warming up I Shift lever: “N” I No-load
SPECIFICATION
Idle
0 step
Revving engine up to 3,000 rpm quickly
10 - 55 step
ECM Terminals and Reference Value
NCEC0507
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. TERMIWIRE NAL COLOR NO. 8 9 17 18
W/B SB G/R R/Y
ITEM
EGR volume control valve
CONDITION
DATA (DC Voltage)
[Engine is running] I Warm-up condition I Rev engine up from 2,000 to 4,000 rpm
0 - 14V
On Board Diagnosis Logic DTC No. P0403 0403
Malfunction is detected when ... I An improper voltage signal is sent to ECM through the valve.
Check Items (Possible Cause) I Harness or connectors (The EGR volume control valve circuit is open or shorted.) I EGR volume control valve
DTC Confirmation Procedure
NEF110A
NCEC0508
NCEC0509
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and warm it up to normal operating temperature. 4) Rev engine from idle to 2,000 rpm 20 times.
EC-253
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) DTC Confirmation Procedure (Cont’d)
If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-256. With GST Follow the procedure “With CONSULT-II” above.
EC-254
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) Wiring Diagram
Wiring Diagram
NCEC0510
BATTERY : Detectable line for DTC Refer to EL-POWER.
: Non-detectable line for DTC
EGR VOLUME CONTROL VALVE
ECM RELAY
ECM
EC-255
YEC782
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) Diagnostic Procedure
Diagnostic Procedure 1
NCEC0511
CHECK POWER SUPPLY
1. Disconnect EGR volume control valve harness connector. 2. Turn ignition switch “ON”. 3. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.
SEF556W
Voltage: Battery voltage OK or NG OK
©
GO TO 2.
NG
©
Check the following. I Harness or connectors E90, F73 I Harness for open or short between EGR volume control valve and engine control module relay If NG, repair harness or connectors.
2
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 8 and EGR volume control valve terminal 1, ECM terminal 9 and EGR volume control valve terminal 4, ECM terminal 17 and EGR volume control valve terminal 3, ECM terminal 18 and EGR volume control valve terminal 6. Refer to wiring diagram. Continuity should exist. If OK, check harness for short to ground and short to power. OK or NG OK
©
GO TO 3.
NG
©
Repair open circuit, short to ground or short to power in harness connectors.
3
CHECK EGR VOLUME CONTROL VALVE
Refer to “Component Inspection”, EC-QG-257. OK or NG OK
©
GO TO 4.
NG
©
Replace EGR volume control valve.
4
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-256
DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) Component Inspection
Component Inspection
NCEC0512
EGR VOLUME CONTROL VALVE
NCEC0512S01
With CONSULT-II 1) Disconnect EGR volume control valve harness connector. 2) Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6
SEF069X
3) 4)
5) 6)
1) 2)
SEF558W
3)
Temperature °C (°F)
Resistance Ω
20 (68)
20 - 24
Reconnect EGR volume control valve harness connector. Remove EGR volume control valve from cylinder head. (The EGR volume control valve harness connector should remain connected.) Turn ignition switch “ON”. Perform “EGR VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that EGR volume control valve shaft moves smoothly forward and backward according to the valve opening. If NG, replace the EGR volume control valve. Without CONSULT-II Disconnect EGR volume control valve harness connector. Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6 Temperature °C (°F)
Resistance Ω
20 (68)
20 - 24
Turn ignition switch “ON” and “OFF”. Check that EGR volume control valve shaft moves smoothly forward and backward according to the ignition switch position. If NG, replace the EGR volume control valve.
NEF109A
SEF560W
EC-257
DTC P0420 THREE WAY CATALYST FUNCTION
QG16I18DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NLEC0240
The ECM monitors the switching frequency ratio of heated oxygen sensors 1 (front) and 2 (rear). A three way catalyst with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2 (rear). As oxygen storage capacity decreases, the heated oxygen sensor 2 (rear) switching frequency will increase. When the frequency ratio of heated oxygen sensors 1 (front) and 2 (rear) approaches a specified limit value, the three way catalyst malfunction is diagnosed. SEF184UD
DTC No. P0420 0420
Malfunction is detected when ... I Three way catalyst does not operate properly. I Three way catalyst does not have enough oxygen storage capacity.
Check Items (Possible Cause) I I I I I I I
Three way catalyst Exhaust tube Intake air leaks Injectors Injector leaks Spark plug Improper ignition timing
DTC Confirmation Procedure
SEF847Y
SEF848Y
NLEC0241
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 9 seconds before conducting the next test. With CONSULT-II TESTING CONDITION: I Open engine hood before conducting following procedure. I Do not hold engine speed more than specified minutes below. 1) Turn ignition switch “ON”. 2) Select “DTC & SRT CONFIRMATION” then “SRT WORK SUPPORT” mode with CONSULT-II. 3) Start engine. 4) Rev engine up to 3,000±500 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely. If “COMPLETED” appears on the CONSULT-II screen, go to step 7. 5) Wait 5 seconds at idle. 6) Rev engine up to 2,500±500 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. 7) Select “SELF-DIAG RESULTS” mode with CONSULT-II. 8) Confirm that the 1st trip DTC is not detected. If the 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-259.
SEF560X
EC-258
DTC P0420 THREE WAY CATALYST FUNCTION
QG16I18DE Overall Function Check
Overall Function Check
SEF074X
Diagnostic Procedure 1
NCEC0242
Use this procedure to check the overall function of the three way catalyst. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeters probes between ECM terminals 62 (HO2S1 signal), 63 (HO2S2 signal) and engine ground. 4) Keep engine speed at 2,000 rpm constant under no load. 5) Make sure that the voltage switching frequency (high & low) between ECM terminal 63 and engine ground is much less than that of ECM terminal 62 and engine ground. Switching frequency ratio = A/B A: Heated oxygen sensor 2 (rear) voltage switching frequency B: Heated oxygen sensor 1 (front) 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. NOTE: If the voltage at terminal 62 does not switch periodically more than 5 times within 10 seconds at step 4, perform trouble diagnosis for DTC P0133 first. (See EC-QG-155.)
NCEC0243
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 AIR LEAK
1. Start engine and run it at idle. 2. Listen for an exhaust air leak before the three way catalyst.
SEF099P
OK or NG OK
©
GO TO 3.
NG
©
Repair or replace.
EC-259
DTC P0420 THREE WAY CATALYST FUNCTION
QG16I18DE
Diagnostic Procedure (Cont’d)
3
CHECK INTAKE AIR LEAK
Listen for an intake air leak after the mass air flow sensor. OK or NG OK
©
GO TO 4.
NG
©
Repair or replace.
4
CHECK IGNITION TIMING
Check for ignition timing. Refer to TROUBLE DIAGNOSIS — “BASIC INSPECTION”, EC-QG-72. OK or NG OK
©
GO TO 5.
NG
©
Check camshaft position sensor (PHASE) (EC-QG-238) and crankshaft position sensor (POS) (EC-QG-232).
5
CHECK INJECTORS
1. Refer to Wiring Diagram for Injectors, EC-QG-319. 2. Stop engine and then turn ignition switch “ON”. 3. Check voltage between ECM terminals 101, 103, 105 and 107 and ground with CONSULT-II or tester.
SEF075X
Battery voltage should exist. OK or NG OK
©
GO TO 6.
NG
©
Perform “Diagnostic Procedure” INJECTOR, EC-QG-320.
EC-260
DTC P0420 THREE WAY CATALYST FUNCTION
QG16I18DE
Diagnostic Procedure (Cont’d)
6 1. 2. 3. 4.
CHECK IGNITION SPARK Disconnect ignition coil assembly from rocker cover. Connect a known good spark plug to the ignition coil assembly. Place end of spark plug against a suitable ground and crank engine. Check for spark.
SEF575Q
OK or NG OK
©
GO TO 7.
NG
©
Check ignition coil, power transistor and their circuits. Refer to EC-QG-323.
7
CHECK INJECTOR
1. Turn ignition switch “OFF”. 2. Remove injector assembly. Refer to EC-QG-30. Keep fuel hose and all injectors connected to injector gallery. 3. Disconnect camshaft position sensor harness connector. 4. Turn ignition switch “ON”. Make sure fuel does not drip from injector. OK or NG OK (Does not drip)
©
GO TO 8.
NG (Drips)
©
Replace the injector(s) from which fuel is dripping.
8
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
Trouble is fixed
©
INSPECTION END
Trouble is not fixed
©
Replace three way catalyst.
EC-261
DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL QG16I18DE SOLENOID VALVE (CIRCUIT) Description
Description
NCEC0248
SYSTEM DESCRIPTION Sensor
Input Signal to ECM
Crankshaft position sensor (POS)
Engine speed
Mass air flow sensor
Amount of intake air
Engine coolant temperature sensor
Engine coolant temperature
Battery
Battery voltage
Ignition switch
Start signal
Throttle position sensor
Throttle position
Heated oxygen 1 sensor
Density of oxygen in exhaust gas (Mixture ratio feedback signal)
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
NCEC0248S01
ECM function
EVAP canister purge control
Actuator
EVAP canister purge volume control solenoid valve
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
NCEC0248S02
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
NCEC0249
MONITOR ITEM
PURG VOL C/V
CONDITION I Engine: After warming up I No-load I Lift up drive wheels and shift to 1st gear position. I Air conditioner switch “OFF”
SPECIFICATION
Idle
0%
More than 2,000 rpm
—
EC-262
DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL QG16I18DE SOLENOID VALVE (CIRCUIT) ECM Terminals and Reference Value
ECM Terminals and Reference Value
NCEC0250
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. TERWIRE MINAL COLOR NO.
14
P/B
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running] I Warm-up condition I Idle speed
BATTERY VOLTAGE (11 - 14V)
EVAP canister purge volume control solenoid valve [Vehicle is running] I Warm-up condition I 2,000 rpm
5 - 12V
On Board Diagnosis Logic DTC No. P0443 0443
Malfunction is detected when ... I An improper voltage signal is sent to ECM through the valve.
NCEC0251
Check Items (Possible Cause) I Harness or connectors (The valve circuit is open or shorted.) I EVAP canister purge volume control solenoid valve
DTC Confirmation Procedure
NCEC0252
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V. With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-265. With GST Follow the procedure “With CONSULT-II” above. 1) 2) 3) 4)
NEF068A
EC-263
DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL QG16I18DE SOLENOID VALVE (CIRCUIT) Wiring Diagram
Wiring Diagram
NCEC0253
: Detectable line for DTC
IGNITION SWITCH ON or START
: Non-detectable line for DTC FUSE BLOCK (J/B)
Refer to EL-POWER.
EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
ECM
Refer to last page (Foldout page)
EC-264
YEC783
DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL QG16I18DE SOLENOID VALVE (CIRCUIT) Diagnostic Procedure
Diagnostic Procedure 1
NCEC0254
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector.
SEF076X
3. Turn ignition switch “ON”. 4. Check voltage between terminals 2 and engine ground with CONSULT-II or tester.
SEF077X
Voltage: Battery voltage OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104 I 10A fuse I Harness for open or short between EVAP canister purge volume control valve and fuse
©
3
Repair harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 14 and 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.
EC-265
DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL QG16I18DE SOLENOID VALVE (CIRCUIT) Diagnostic Procedure (Cont’d)
4
CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to “Component Inspection” EC-QG-266. OK or NG OK
©
GO TO 5.
NG
©
Replace EVAP canister purge volume control solenoid valve.
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection
NCEC0255
EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
NEF111A
NCEC0255S01
With CONSULT-II 1) Start engine. 2) Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. If OK, inspection end. If NG, go to following step. 3) Check air passage continuity. Condition PURG VOL CONT/V value
Air passage continuity between A and B
100.0%
Yes
0.0%
No
If NG, replace the EVAP canister purge volume control solenoid valve. Without CONSULT-II Check air passage continuity. SEF079X
Condition
Air passage continuity between A and B
12V direct current supply between terminals
Yes
No supply
No
If NG or operation takes more than 1 second, replace solenoid valve.
EC-266
QG16I18DE
DTC P0500 VEHICLE SPEED SENSOR (VSS)
Component Description
Component Description
NCEC0272
MODELS WITH VEHICLE SPEED SENSOR The vehicle speed sensor is installed in the transaxle. It contains a pulse generator which provides a vehicle speed signal to the speedometer. The speedometer then sends a signal to the ECM.
MODELS WITHOUT VEHICLE SPEED SENSOR The ABS actuator and electric unit (control unit) provides a vehicle speed signal to the speedometer. The speedometer then sends a signal to the ECM. SEF080X
ECM Terminals and Reference Value
NCEC0273
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) 2.0 - 3.0 V
86
OR/W
[Engine is running] Vehicle speed sensor or I Lift up the vehicle ABS actuator and elecI In 2nd gear position tric unit (control unit) I Vehicle speed is 40 km/h (25 MPH) SEF976W
On Board Diagnosis Logic DTC No. P0500 0500
Malfunction is detected when ... I The almost 0 km/h (0 MPH) signal from vehicle speed sensor or ABS actuator and electric unit (control unit) is sent to ECM even when vehicle is being driven.
NCEC0274
Check Items (Possible Cause) Models with vehicle speed sensor I Harness or connector (The vehicle speed sensor circuit is open or shorted.) I Vehicle speed sensor Models without vehicle speed sensor I Harness or connector (The ABS actuator and electric unit (control unit) is open or shorted.) I ABS actuator and electric unit (control unit)
DTC Confirmation Procedure
NCEC0275
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 9 seconds before conducting the next test. TESTING CONDITION: This procedure 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.
EC-267
DTC P0500 VEHICLE SPEED SENSOR (VSS)
QG16I18DE
DTC Confirmation Procedure (Cont’d)
1) 2)
3)
NEF112A
4) 5) 6)
With CONSULT-II Start engine Read vehicle speed sensor signal in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULT-II should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. If NG, go to “Diagnostic Procedure”, EC-QG-271. 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 10 consecutive seconds.
ENG SPEED
2,600 - 4,000 rpm
COOLAN TEMP/S
More than 70°C (158°F)
B/FUEL SCHDL
6.0 - 11.7 msec
Selector lever
Suitable position
PW/ST SIGNAL
OFF
7)
If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-271. With GST Follow the procedure “With CONSULT-II” above.
EC-268
DTC P0500 VEHICLE SPEED SENSOR (VSS)
QG16I18DE Wiring Diagram
Wiring Diagram
NCEC0277
MODELS BEFORE VIN - P11U0548750 IGNITION SWITCH ON or START
BATTERY
: Detectable line for DTC FUSE BLOCK (J/B)
: Non-detectable line for DTC
Refer to EL-POWER.
COMBINATION METER (SPEEDOMETER)
VEHICLE SPEED SENSOR
ECM
Refer to last page (Foldout page)
YEC784
EC-269
DTC P0500 VEHICLE SPEED SENSOR (VSS)
QG16I18DE
Wiring Diagram (Cont’d)
MODELS AFTER VIN - P11U0548750
YEC073A
EC-270
DTC P0500 VEHICLE SPEED SENSOR (VSS)
QG16I18DE Diagnostic Procedure
Diagnostic Procedure
NCEC0278
MODELS BEFORE VIN - P11U0548750 1
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 9. 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
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F104, M50 I Harness for open or short between ECM and combination meter
©
3
Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power. Refer to EL section.
CHECK SPEEDOMETER FUNCTION
Make sure that speedometer functions properly. OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104 and M52, F103 I Harness for open or short between combination meter and vehicle speed sensor
©
5
Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL section.
CHECK INTERMITTENT INCIDENT
Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-271
DTC P0500 VEHICLE SPEED SENSOR (VSS)
QG16I18DE
Diagnostic Procedure (Cont’d)
MODELS WITH VSS AFTER VIN - P11U0548750 1
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 4. 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
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F104, M50 I Harness for open or short between ECM and combination meter
©
3
Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power. Refer to EL section.
CHECK SPEEDOMETER FUNCTION
Make sure that speedometer functions properly. OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104, F73, E90 and M52, F103 I Harness for open or short between combination meter and vehicle speed sensor
©
5
Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL section.
CHECK INTERMITTENT INCIDENT
Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-272
DTC P0500 VEHICLE SPEED SENSOR (VSS)
QG16I18DE
Diagnostic Procedure (Cont’d)
MODELS WITHOUT VSS AFTER VIN - P11U0548750 1
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 4. 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
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F104, M50 I Harness for open or short between ECM and combination meter
©
3
Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power. Refer to EL section.
CHECK SPEEDOMETER FUNCTION
Make sure that speedometer functions properly. OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the following. I Harness for open or short between combination meter and ABS actuator and electric unit (control unit)
©
5
Repair harness or connectors. Check ABS actuator and electric unit (control unit) and its circuit. Refer to EL section.
CHECK INTERMITTENT INCIDENT
Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-273
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
QG16I18DE
Description
Description
NCEC0279
SYSTEM DESCRIPTION Sensor
Input Signal to ECM
Crankshaft position sensor (POS)
Engine speed
Engine coolant temperature sensor
Engine coolant temperature
Ignition switch
Start signal
Throttle position sensor
Throttle position
PNP switch
Park/Neutral position
Air conditioner switch
Air conditioner operation
Power steering oil pressure switch
Power steering load signal
Battery
Battery voltage
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Cooling fan
Cooling fan operation
Electrical load
Electrical load signal
NCEC0279S01
ECM function
Actuator
Idle air conIACV-AAC valve trol
This system automatically controls engine idle speed to a specified level. Idle speed is controlled through fine adjustment of the amount of air which by-passes the throttle valve via IACV-AAC valve. The IACV-AAC valve changes the opening of the air by-pass passage to control the amount of auxiliary air. This valve is actuated by a step motor built into the valve, which moves the valve in the axial direction in steps corresponding to the ECM output signals. One step of IACV-AAC valve movement causes the respective opening of the air by-pass passage. (i.e. when the step advances, the opening is enlarged.) The opening of the valve is varied to allow for optimum control of the engine idling speed. The crankshaft position sensor (POS) detects the actual engine speed and sends a signal to the ECM. The ECM then controls the step position of the IACV-AAC valve so that engine speed coincides with the target value memorized in ECM. The target engine speed is the lowest speed at which the engine can operate steadily. The optimum value stored in the ECM is determined by taking into consideration various engine conditions, such as during warm up, deceleration, and engine load (air conditioner, power steering, cooling fan operation and electrical load).
COMPONENT DESCRIPTION
NCEC0279S02
The IACV-AAC valve is operated by a step motor for centralized control of auxiliary air supply. This motor has four winding phases and is actuated by the output signals of ECM which turns ON and OFF two windings each in sequence. Each time the IACV-AAC valve opens or closes to change the auxiliary air quantity, the ECM sends a pulse signal to the step motor. When no change in the auxiliary air quantity is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening. SEF937W
EC-274
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
QG16I18DE
CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0280
MONITOR ITEM
CONDITION I I I I
IACV-AAC/V
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
SPECIFICATION
Idle
5 - 20 steps
2,000 rpm
—
ECM Terminals and Reference Value
NCEC0281
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 7 15 16
WIRE COLOR BR Y/B P OR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running] I Warm-up condition I Idle speed
IACV-AAC valve
0.1 - 14V
On Board Diagnosis Logic DTC No. P0505 0505
Malfunction is detected when ... I An improper voltage signal is sent to ECM through the valve.
Check Items (Possible Cause) I Harness or connectors (The IACV-AAC valve circuit is open.) I IACV-AAC valve
DTC Confirmation Procedure
NEF085A
NCEC0282
NCEC0283
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. If the target idle speed is out of the specified value, perform “Idle Air Volume Learning”, EC-QG-33, before conducting “DTC Confirmation Procedure”. For the target idle speed, refer to “Service Data and Specifications (SDS)”, EC-QG-355. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and warm it up to normal operating temperature. 4) Rev engine from idle to more than 2,000 rpm 20 times. If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-277. With GST Follow the procedure “With CONSULT-II” above.
EC-275
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0284
BATTERY : Detectable line for DTC : Non-detectable line for DTC
Refer to EL-POWER.
IACV-AAC VALVE ECM RELAY
ECM
YEC785
EC-276
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0285
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect IACV-AAC valve harness connector. Throttle body
Throttle position sensor harness connector
IACV-AAC valve harness connector NEF246A
3. Turn ignition switch “ON”. 4. Check voltage between terminal 2, 5 and ground with CONSULT-II or tester.
Voltage: Battery voltage
SEF352QA
OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I 10A fuse I Harness for open or short between IACV-AAC valve and battery ©
3
Repair harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 6 and IACV-AAC valve terminal 1, ECM terminal 7 and IACV-AAC valve terminal 4, ECM terminal 15 and IACV-AAC valve terminal 3, ECM terminal 16 and IACV-AAC valve 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 4.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-277
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
QG16I18DE
Diagnostic Procedure (Cont’d)
4 1. 2. 3. 4.
CHECK AIR CONTROL VALVE (POWER STEERING) OPERATION-I Reconnect the ECM harness connector and IACV-AAC valve harness connector. Disconnect the vacuum hose connected to the air control valve (Power steering) at the intake air duct. Start engine and let it idle. Check vacuum hose for vacuum existence.
SEF162Z
Vacuum does not exist or slightly exist. OK or NG OK
©
GO TO 5.
NG
©
Replace air control valve (Power steering).
5
CHECK AIR CONTROL VALVE (POWER STEERING) OPERATION-II
Check the vacuum hose for vacuum existence when steering wheel is turned.
SEF162Z
Vacuum should exist. OK or NG OK
©
GO TO 8.
NG
©
GO TO 6.
EC-278
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
QG16I18DE
Diagnostic Procedure (Cont’d)
6 1. 2. 3. 4.
CHECK VACUUM PORT Stop engine. Disconnect the vacuum hose connected to the air control valve (Power steering) at the vacuum port. Blow air into vacuum port. Check that air flows freely.
SEF924Y
OK or NG OK
©
GO TO 7.
NG
©
Repair or clean vacuum port.
7
CHECK VACUUM HOSES AND TUBES
1. Disconnect vacuum hoses between the air control valve (Power steering) and vacuum port, air control valve (Power steering) and air duct. 2. Check hoses and tubes for cracks, clogging, improper connection or disconnection.
SEF109L
OK or NG OK
©
GO TO 8.
NG
©
Repair hoses or tubes.
8
CHECK IACV-AAC VALVE
Refer to “Component Inspection”, EC-QG-281. OK or NG OK
©
GO TO 10.
NG
©
GO TO 9.
EC-279
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE Diagnostic Procedure (Cont’d)
9
REPLACE IACV-AAC VALVE
1. Replace IACV-AAC valve assembly. 2. Perform “Idle Air Volume Learning”, EC-QG-33. Is the result CMPLT or INCMP? CMPLT or INCMP CMPLT
©
INSPECTION END
INCMP
©
Follow the instruction of “Idle Air Volume Learning”.
10
CHECK TARGET IDLE SPEED
1. Turn ignition switch “OFF”. 2. Reconnect all harness connectors and vacuum hoses. 3. Start engine and warm it up to normal operating temperature. 4. Also warm up transmission to normal operating temperature. I Drive vehicle for 10 minutes. 5. Stop vehicle with engine running. 6. Check target idle speed. 700±50 rpm OK or NG OK
©
GO TO 11.
NG
©
Perform “Idle Air Volume Learning”, EC-QG-33.
11
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
EC-280
QG16I18DE
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
QG16I18DE Component Inspection
Component Inspection
NCEC0286
IACV-AAC VALVE 1) 2)
NCEC0286S01
Disconnect IACV-AAC valve harness connector. Check IACV-AAC valve resistance. Condition
Resistance
Terminal 2 and terminals 1, 3 20 - 24Ω [at 20°C (68°F)] Terminal 5 and terminals 4, 6
3) 4)
5)
Reconnect IACV-AAC valve harness connector. Remove idle air adjusting unit assembly (IACV-AAC valve is built-in) from engine. (The IACV-AAC valve harness connector should remain connected.) Turn ignition switch “ON” and “OFF”, and ensure the IACVAAC valve shaft smoothly moves forward and backward, according to the ignition switch position. If NG, replace the IACV-AAC valve.
SEF353QA
SEF089X
EC-281
QG16I18DE
DTC P0605 ECM Component Description
Component Description
NCEC0295
The ECM consists of a microcomputer, diagnostic test mode selector, and connectors for signal input and output and for power supply. The ECM controls the engine.
SEF093X
DTC No. P0605 0605
On Board Diagnosis Logic
Malfunction is detected when ... I ECM calculation function is malfunctioning.
Check Items (Possible Cause) I ECM
DTC Confirmation Procedure
NEF068A
NCEC0297
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine. 4) Run engine for at least 1 second at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-282. With GST Follow the procedure “With CONSULT-II” above.
Diagnostic Procedure 1
NCEC0296
INSPECTION START
With CONSULT-II Turn ignition switch “ON”. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See previous page. 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4.
With GST Turn ignition switch “ON”. Select MODE 4 with GST. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See previous page. 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4.
Yes or No Yes
©
GO TO 2.
No
©
INSPECTION END
EC-282
=NCEC0298
DTC P0605 ECM
QG16I18DE Diagnostic Procedure (Cont’d)
2
REPLACE ECM
1. Replace ECM. 2. Perform initialization of NATS (NISSAN ANTI-THEFT SYSTEM) system and registration of all NATS ignition key IDs. Refer to “NATS (NISSAN ANTI-THEFT SYSTEM)”, EC-QG-45. 3. Perform “Idle Air Volume Learning”, EC-QG-33. Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT
©
INSPECTION END
INCMP
©
Follow the construction of “Idle Air Volume Learning”.
EC-283
DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE
QG16I18DE
Component Description
Component Description
NCEC0513
The valve timing control system is utilized to control intake valve opening and closing timing. Engine coolant temperature signals, engine speed and throttle position are used to determine intake valve timing. The intake camshaft sprocket position is regulated by oil pressure controlled by the intake valve timing control. When ECM sends ON signal to intake valve timing control solenoid valve, oil pressure is transmitted to camshaft sprocket. Then, intake side camshaft is advanced. SEF095X
Operation
NCEC0514
Engine operating condition Engine coolant temperature
Engine speed
20°C (68°F) 70°C (158°F)
B/FUEL SCHDL
Intake valve opening and closing time
Valve overlap
Neutral switch
Intake valve timing control solenoid valve
OFF
ON
Advance
Increased
OFF
Normal
Normal
Above 3 msec 1,150 - 4,600 rpm
Above 70°C (158°F)
Above 7 msec Conditions other than those above
CONSULT-II Reference Value in Data Monitor Mode
NCEC0515
MONITOR ITEM
INT/V SOL-B1
CONDITION
I Engine: After warming up
SPECIFICATION
Idle
OFF
Revving engine with full throttle opening (Under 4,600 rpm)
ON
ECM Terminals and Reference Value
NCEC0516
Specification data are reference values and are measured between each terminal and engine 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. TERWIRE MINAL COLOR NO. 1
Y/R
ITEM Intake valve timing control solenoid valve
CONDITION
DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)
Ignition “ON”
On Board Diagnosis Logic DTC No. P1111 1111
Malfunction is detected when ... I An improper voltage signal is entered to ECM through intake valve timing control solenoid valve.
EC-284
NCEC0517
Check Items (Possible Cause) I Harness or connectors (The intake valve timing control solenoid valve circuit is open or shorted.) I Intake valve timing control solenoid valve
DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE
QG16I18DE
DTC Confirmation Procedure
DTC Confirmation Procedure
NEF121A
NCEC0518
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 5 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-287. Without CONSULT-II Follow the procedure “With CONSULT-II” above.
EC-285
DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0519
IGNITION SWITCH ON or START
: Detectable line for DTC : Non-detectable line for DTC FUSE BLOCK (J/B)
Refer to EL-POWER.
INTAKE VALVE TIMING CONTROL SOLENOID VALVE
.
IVC ECM
Refer to last page (Foldout page)
EC-286
YEC787
DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0520
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect intake valve timing control solenoid valve harness connector.
SEF149X
3. Turn ignition switch “ON”. 4. Check voltage between terminal 2 and engine ground with CONSULT-II or tester.
SEF097X
Voltage: Battery voltage OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connector F104, M50 I 10A fuse I Harness for open or short between intake valve timing control solenoid valve and fuse
©
3
Repair harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 1 and intake valve timing control solenoid valve harness connector 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 to short to power or connectors.
EC-287
DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE
QG16I18DE
Diagnostic Procedure (Cont’d)
4
CHECK VALVE TIMING CONTROL SOLENOID VALVE
Refer to “Component Inspection”, EC-QG-288. OK or NG OK
©
GO TO 5.
NG
©
Replace valve timing control solenoid valve.
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Intake valve timing control solenoid valve
Component Inspection
NCEC0521
INTAKE VALVE TIMING CONTROL SOLENOID VALVE NCEC0521S01 1. 2. 3.
Check oil passage visually for any metal debris. Supply intake valve timing control solenoid valve terminals with battery voltage. Make sure that inside plunger protrudes. If NG, replace intake valve timing control solenoid valve.
Plunger FUSE SEF524T
EC-288
QG16I18DE
DTC P1217 OVERHEAT (COOLING SYSTEM)
System Description
System Description
NCEC0433
COOLING FAN CONTROL
NCEC0433S01
Sensor
ECM function
Input Signal to ECM
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Engine coolant temperature sensor
Engine coolant temperature
Air conditioner switch
Air conditioner “ON” signal
Ignition switch
Start signal
Refrigerant pressure sensor
Refrigerant pressure
Actuator
Cooling fan Cooling fan relay(s) control
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 ON-OFF control. The refrigerant pressure sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The transducer is installed in the liquid tank of the air conditioner system.
SEF099X
OPERATION
NCEC0433S02
Engine coolant temperatures at which the cooling fan turns “ON” are indicated in the Table below. Vehicle speed km/h (MPH) Air conditioner switch
ON
High pressure of refrigerant kPa (bar, kg/cm2, psi)
Less than 20 (12)
20 - 80 (12 - 50)
More than 80 (50)
More than 1,760 (17.6, 17.95, 255)
Always
Always
More than 95°C (203°F)
Less than 1,760 (17.6, 17.95, 255)
Always
More than 95°C (203°F)
More than 95°C (203°F)
More than 100°C (212°F)
More than 95°C (203°F)
More than 95°C (203°F)
OFF
CONSULT-II Reference Value in Data Monitor Mode
NCEC0486
Specification data are reference values. MONITOR ITEM
AIR COND SIG
COOLING FAN
CONDITION I Engine: After warming up, idle the engine
I After warming up engine, idle the engine. I Air conditioner switch: OFF
SPECIFICATION
Air conditioner switch: OFF
OFF
Air conditioner switch: ON (Compressor operates)
ON
Engine coolant temperature is less OFF than 99°C (210°F) Engine coolant temperature is 100°C (212°F) or more
EC-289
ON
QG16I18DE
DTC P1217 OVERHEAT (COOLING SYSTEM) ECM Terminals and Reference Value
ECM Terminals and Reference Value
=NCEC0487
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. TERWIRE MINAL COLOR NO.
13
23
LG/R
L/W
ITEM
Cooling fan relay
Air conditioner switch
CONDITION
DATA (DC Voltage)
[Engine is running] I Cooling fan is not operating
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Cooling fan is operating
Approximately 0V
[Engine is running] I Both air conditioner switch and blower switch are “ON” (Compressor operates)
Approximately 0V
[Engine is running] I Air conditioner switch is “OFF”
BATTERY VOLTAGE (11 - 14V)
On Board Diagnosis Logic
NCE0488
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. Diagnostic Trouble Code No. P1217 1217
Malfunction is detected when ...
Check Items (Possible Cause)
I Cooling fan does not operate properly (Overheat). I Harness or connectors I Cooling fan system does not operate properly (Overheat). (The cooling fan circuit is open or shorted). I Engine coolant was not added to the system using the I Cooling fan proper filling method. I Radiator hose I Radiator I Radiator cap I Water pump I Thermostat For more information, refer to “MAIN 12 CAUSES OF OVERHEATING”, EC-QG-298.
CAUTION: When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Also, replace the 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 section (“Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED FLUIDS AND LUBRICANTS”). 2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.
EC-290
DTC P1217 OVERHEAT (COOLING SYSTEM)
QG16I18DE Overall Function Check
Overall Function Check
SEF621WA
SEF111X
SEC163BA
NCEC0489
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 when the engine is hot. Serious burns could be caused by high pressure fluid escaping from 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) 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 “Diagnostic Procedure”, EC-QG-294. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-QG-294. 3) Turn ignition switch “ON”. 4) Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. 5) If the results are NG, go to “Diagnostic Procedure”, EC-QG294. Without CONSULT-II 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 “Diagnostic Procedure”, EC-QG-294. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-QG-294. 3) Start engine. Be careful not to overheat engine. 4) Set temperature control lever 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. Be careful not to overheat engine. 8) Make sure that cooling fan operates. If NG, go to “Diagnostic Procedure”, EC-QG-294.
EC-291
DTC P1217 OVERHEAT (COOLING SYSTEM)
QG16I18DE
Wiring Diagram
Wiring Diagram IGNITION SWITCH ON or START
NCEC0490
BATTERY : Detectable line for DTC FUSE BLOCK (J/B)
: Non-detectable line for DTC Refer to EL-POWER.
COOLING FAN RELAY
COOLING FAN MOTOR-1
COOLING FAN MOTOR-2
Refer to last page (Foldout page)
EC-292
YEC789
DTC P1217 OVERHEAT (COOLING SYSTEM)
QG16I18DE Wiring Diagram (Cont’d)
REFRIGERANT SENSOR
: Detectable line for DTC : Non-detectable line for DTC
ECM
YEC790
EC-293
DTC P1217 OVERHEAT (COOLING SYSTEM)
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1 1. 2. 3. 4. 5.
NCEC0491
CHECK COOLING FAN OPERATION Start engine and let it idle. Set temperature lever at full cold position. Turn air conditioner switch “ON”. Turn blower fan switch “ON”. Make sure that cooling fans-1 and -2 operate.
SEC163BA
OK or NG OK
©
GO TO 11.
NG
©
GO TO 2.
2
CHECK AIR CONDITIONER OPERATION
Is air conditioner operating? (Check operation of compressor and blower motor.) OK or NG OK
©
GO TO 3.
NG
©
Check for failure of air conditioner to operate. Refer to HA section.
3 1. 2. 3. 4.
CHECK POWER SUPPLY Turn ignition switch “OFF”. Disconnect cooling fan relay. Turn ignition switch “ON”. Check voltage between terminals 2, 3 and ground with CONSULT-II or tester.
SEF112X
Voltage: Battery voltage OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
EC-294
DTC P1217 OVERHEAT (COOLING SYSTEM)
QG16I18DE
Diagnostic Procedure (Cont’d)
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M70, E125 I 10A fuse I 40A fusible link I Harness for open or short between cooling fan relay and fuse I Harness for open or short between cooling fan relay and battery
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect cooling fan motor-1 harness connector and cooling fan motor-2 harness connector.
SEF113X
3. Check harness continuity between relay terminal 5 and motor-1 terminal 1, motor-1 terminal 2 and body ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. 5. Check harness continuity between relay terminal 5 and motor-2 terminal 1, motor-2 terminal 2 and body ground. Refer to wiring diagram. Continuity should exist. 6. 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 OUTPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 13 and relay 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 8.
NG
©
GO TO 7.
7
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E42, F4 I Harness for open or short between cooling fan relay and ECM
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-295
DTC P1217 OVERHEAT (COOLING SYSTEM)
QG16I18DE
Diagnostic Procedure (Cont’d)
8
CHECK COOLING FAN RELAY
Refer to “Component Inspection”, EC-QG-299. OK or NG OK
©
GO TO 9.
NG
©
Replace cooling fan relay.
9
CHECK COOLING FAN MOTORS-1 AND -2
Refer to “Component Inspection”, EC-QG-299. OK or NG OK
©
GO TO 10.
NG
©
Replace cooling fan motors.
10
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
11
INSPECTION END
CHECK COOLING SYSTEM FOR LEAK
Apply pressure to the cooling system with a tester, and check if the pressure drops. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage.
SLC754A
Pressure should not drop. OK or NG OK
©
GO TO 12.
NG
©
Check the following for leak I Hose I Radiator I Water pump Refer to LC section (“Water Pump”).
EC-296
DTC P1217 OVERHEAT (COOLING SYSTEM)
QG16I18DE
Diagnostic Procedure (Cont’d)
12
CHECK RADIATOR CAP
Apply pressure to cap with a tester.
SLC755A
Radiator cap relief pressure: 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi) OK or NG OK
©
GO TO 13.
NG
©
Replace radiator cap.
13
CHECK THERMOSTAT
1. Check valve seating condition at normal room temperatures. It should seat tightly. 2. Check valve opening temperature and valve lift.
Valve opening temperature: 76.5°C (170°F) [standard] Valve lift: More than 8 mm/90°C (0.31 in/194°F) 3. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to LC section (“Thermostat”). OK or NG OK
©
GO TO 14.
NG
©
Replace thermostat
14
CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to “Component Inspection”, EC-QG-124. OK or NG OK
©
GO TO 15.
NG
©
Replace engine coolant temperature sensor.
15
CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-QG-298. ©
INSPECTION END
EC-297
SLC343
DTC P1217 OVERHEAT (COOLING SYSTEM)
QG16I18DE
Main 12 Causes of Overheating
Main 12 Causes of Overheating Engine
Step
Inspection item
OFF
1
I I I I
2
Equipment
Standard
NCEC0492
Reference page
I Visual
No blocking
I Coolant mixture
I Coolant tester
50 - 50% coolant mixture
See “RECOMMENDED FLUIDS AND LUBRICANTS” in MA section.
3
I Coolant level
I Visual
Coolant up to MAX level in reservoir tank and radiator filler neck
See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA section.
4
I Radiator cap
I Pressure tester
59 - 98 kPa See “System Check”, (0.59 - 0.98 bar, 0.6 - 1.0 “ENGINE COOLING kg/cm2, 9 - 14 psi) (Limit) SYSTEM” in LC section.
ON*2
5
I Coolant leaks
I Visual
No leaks
ON*2
6
I Thermostat
I Touch the upper and lower radiator hoses
Both hoses should be hot See “Thermostat” and “Radiator”, “ENGINE COOLING SYSTEM” in LC section.
ON*1
7
I Cooling fan
I CONSULT-II
Operating
OFF
8
I Combustion gas leak
I Color checker chemical Negative tester 4 Gas analyzer
—
ON*3
9
I Coolant temperature gauge
I Visual
Gauge less than 3/4 when driving
—
I Coolant overflow to reservoir tank
I Visual
No overflow during driving and idling
See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA section.
Blocked Blocked Blocked Blocked
radiator condenser radiator grille bumper
—
See “System Check”, “ENGINE COOLING SYSTEM” in LC section.
See “TROUBLE DIAGNOSIS FOR OVERHEAT” (EC-QG-289).
OFF*4
10
I Coolant return from reservoir tank to radiator
I Visual
Should be initial level in reservoir tank
See “ENGINE MAINTENANCE” in MA section.
OFF
11
I Cylinder head
I Straight gauge feeler gauge
0.1 mm (0.004 in) Maximum distortion (warping)
See “Inspection”, “CYLINDER HEAD” in EM section.
12
I Cylinder block and pis- I Visual tons
No scuffing on cylinder walls or piston
See “Inspection”, “CYLINDER BLOCK” in EM section.
*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. For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.
EC-298
QG16I18DE
DTC P1217 OVERHEAT (COOLING SYSTEM)
Component Inspection
Component Inspection
NCEC0493
COOLING FAN RELAYS
NCEC0493S01
Check continuity between terminals 3 and 5. Conditions
SEF511P
Continuity
12V direct current supply between terminals 1 and 2
Yes
No current supply
No
If NG, replace relay.
COOLING FAN MOTORS-1 AND -2 1. 2.
NCEC0493S02
Disconnect cooling fan motor harness connectors. Supply cooling fan motor terminals with battery voltage and check operation. Terminals
Cooling fan motor SEF721Q
(+)
(−)
1
2
Cooling fan motor should operate. If NG, replace cooling fan motor.
REFRIGERANT PRESSURE SENSOR
NCEC0493S03
With the refrigerant pressure sensor installed on the vehicle, start the engine and while idling, read the voltage at refrigerant pressure sensor terminals 1 and 2. (Refer to wiring diagram.) Air conditioner condition
Voltage V
OFF
More than approx. 0.3V
ON
More than approx. 1.5V
ON to OFF
Decreasing gradually
If results are NG, check for 5V between refrigerant sensor terminal 3 and ground. If there is 5V, replace sensor.
EC-299
DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED)
QG16I18DE
Component Description
Component Description
NCEC0342
The EGR temperature sensor detects temperature changes in the EGR passageway. When the EGR volume control valve opens, hot exhaust gases flow, and the temperature in the passageway changes. The EGR temperature sensor is a thermistor that modifies a voltage signal sent from the ECM. This modified signal then returns to the ECM as an input signal. As the temperature increases, EGR temperature sensor resistance decreases. This sensor is not used to control the engine system. It is used only for the on board diagnosis. SEF599K
EGR temperature °C (°F)
Voltage* V
Resistance MΩ
0 (32)
4.56
0.62 - 1.05
50 (122)
2.25
0.065 - 0.094
100 (212)
0.59
0.011 - 0.015
*: These data are reference values and are measured between ECM terminal 72 (EGR temperature sensor) and ground. When EGR system is operating. Voltage: 0 - 1.5V
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.
SEF068X
On Board Diagnosis Logic DTC No. P1401 1401
Malfunction is detected when ...
NCEC0343
Check Items (Possible Cause)
A)
An excessively low voltage from the EGR temperature sensor is sent to ECM even when engine coolant temperature is low.
I Harness or connectors (The EGR temperature sensor circuit is shorted.) I EGR temperature sensor I Malfunction of EGR function
B)
An excessively high voltage from the EGR temperature sensor is sent to ECM even when engine coolant temperature is high.
I Harness or connectors (The EGR temperature sensor circuit is open.) I EGR temperature sensor I Malfunction of EGR function
DTC Confirmation Procedure
NCEC0344
Perform “PROCEDURE FOR MALFUNCTION A” first. If 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test.
EC-300
DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED)
QG16I18DE
DTC Confirmation Procedure (Cont’d)
PROCEDURE FOR MALFUNCTION A
NEF113A
PROCEDURE FOR MALFUNCTION B
NEF114A
=NCEC0344S01
With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Verify that engine coolant temperature is less than 50°C (122°F). If the engine coolant temperature is above the range, cool the engine down. 4) Start engine and let it idle for at least 5 seconds. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-303. With GST Follow the procedure “With CONSULT-II” above.
NCEC0344S02
CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: Always perform the test at a temperature above −10°C (14°F). With CONSULT-II 1) Start engine and warm it up to above 80°C (176°F). 2) Select “EGR VOL CONT/V” in “ACTIVE TEST” mode with CONSULT. 3) Hold engine speed at 1,500 rpm. 4) Touch “Qu” and set the EGR volume control valve opening to 50 step and check EGR TEMP SEN. EGR TEMP SEN should decrease to less than 1.0V. If the check result is NG, go to “Diagnostic Procedure”, ECQG-303. If the check result is OK, go to the following step. 5) Turn ignition switch “OFF” and wait at least 9 seconds. 6) Start engine and maintain the following conditions for at least 5 consecutive seconds. ENG SPEED
Above 2,400 rpm
VHCL SPEED SE
Above 90 km/h (56 MPH) or more
B/FUEL SCHDL
4.0 - 4.8 msec
Selector lever
4th or 5th
7)
If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-303. With GST Follow the procedure “With CONSULT-II” above.
EC-301
DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED)
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0346
YEC074A
EC-302
DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED)
QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0347
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect EGR temperature sensor harness connector.
SEF127X
3. Turn ignition switch “ON”. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.
SEF128X
Voltage: Approximately 5V OK or NG OK
©
GO TO 2.
NG
©
Repair harness or connectors.
2
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Check harness continuity between EGR temperature sensor harness terminal 1 and engine 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 4.
NG
©
GO TO 3.
3
DETECT MALFUNCTIONING PART
Check the harness for open or short between EGR temperature sensor and ECM.
©
4
Repair open circuit or short to ground or short to power in harness or connector.
CHECK EGR TEMPERATURE SENSOR
Refer to “Component Inspection”, EC-QG-304. OK or NG OK
©
GO TO 5.
NG
©
Replace EGR temperature sensor.
EC-303
DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED)
QG16I18DE
Diagnostic Procedure (Cont’d)
5
CHECK EGR VOLUME CONTROL VALVE
Refer to “Component Inspection”, EC-QG-251. OK or NG OK
©
GO TO 6.
NG
©
Replace EGR volume control valve.
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection EGR TEMPERATURE SENSOR
NCEC0348 NCEC0348S01
Check resistance change and resistance value.
SEF643Q
EGR temperature °C (°F)
Voltage V
Resistance MΩ
0 (32)
4.56
0.62 - 1.05
50 (122)
2.25
0.065 - 0.094
100 (212)
0.59
0.011 - 0.015
If NG, replace EGR temperature sensor.
SEF068X
EC-304
DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE Description
Description
NCEC0349
SYSTEM DESCRIPTION Sensor
Input Signal to ECM
Crankshaft position sensor (POS)
Engine speed
Mass air flow sensor
Amount of intake air
Engine coolant temperature sensor
Engine coolant temperature
Ignition switch
Start signal
Throttle position sensor
Throttle position
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Battery
Battery voltage
NCEC0349S01
ECM function
Actuator
EGR control EGR volume control valve
This system controls flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR by-pass passage in the EGR volume control valve changes to control the flow rate. A built-in step motor moves the valve in steps corresponding to the ECM output pulses. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. The EGR volume control valve remains close under the following conditions. I Extremely light load engine operation I Mass air flow sensor malfunction I Engine idling I Low engine coolant temperature I Excessively high engine coolant temperature I High-speed engine operation I Wide open throttle I Low battery voltage I Engine starting
SEF551W
COMPONENT DESCRIPTION EGR Volume Control Valve
NCEC0349S02 NCEC0349S0201
The EGR volume control valve uses a step motor to control the flow rate of EGR from exhaust manifold. This motor has four winding phases. It operates according to the output pulse signal of the ECM. Two windings are turned ON and OFF in sequence. Each time an ON pulse is issued, the valve opens or closes, changing the flow rate. When no change in the flow rate is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening. SEF552W
EC-305
DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0539
Specification data are reference values. MONITOR ITEM
CONDITION
EGR TEMP SEN
I Engine: After warming up
EGR VOL CON/V
I I I I
SPECIFICATION Less than 4.5V
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load
Idle
0 step
Revving engine up to 3,000 rpm quickly
10 - 55 step
ECM Terminals and Reference Value
NCEC0540
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. TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage)
8 9 17 18
W/B SB G/R R/Y
EGR volume control valve
[Engine is running.] I Warm-up condition I Rev engine up from 2,000 to 4,000 rpm.
0 - 14V
58
B
Sensor’s ground
[Engine is running.] I Warm-up condition I Idle speed
0V
[Engine is running.] I Warm-up condition I Idle speed
Less than 4.5V
[Engine is running.] I Warm-up condition I EGR system is operating.
0 - 1.0V
72
PU
EGR temperature sensor
On Board Diagnosis Logic
NCEC0350
If EGR temperature sensor detects EGR flow under the condition that does not call for EGR, a high-flow malfunction is diagnosed.
SEF073P
DTC No. P1402 1402
Malfunction is detected when ...
Check Items (Possible Cause)
I EGR flow is detected under conditions that do not call for I Harness or connectors EGR. (The valve circuit is open or shorted.) I EGR volume control valve leaking or stuck open I EGR temperature sensor
EC-306
DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE DTC Confirmation Procedure
DTC Confirmation Procedure
PEF347U
NCEC0351
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Engine coolant temperature and EGR temperature must be verified in “DATA MONITOR” mode with CONSULT-II before starting DTC WORK SUPPORT test. If it is out of range below, the test cannot be conducted. COOLAN TEMP/S: −10 to 40°C (14 to 104°F)* EGR TEMP SEN: Less than 4.8V If the values are out of the ranges indicated above, park the vehicle in a cool place and allow the engine temperature to stabilize. Do not attempt to reduce the engine coolant or EGR temperature with a fan or means other than ambient air. Doing so may produce an inaccurate diagnostic result. *: Although CONSULT-II screen displays “−10 to 40°C (14 to 104°F)” as a range of engine coolant temperature, ignore it.
SEF127X
EC-307
DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE DTC Confirmation Procedure (Cont’d)
1) 2) 3) 4)
NEF115A
5)
1) 2) 3) NEF116A
4) 5) 6) 7) 8)
With CONSULT-II Turn ignition switch “OFF” and wait at least 9 seconds, then turn ignition switch “ON”. Select “EGR SYSTEM P1402” of “EGR SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Follow instructions of CONSULT-II. Start engine and let it idle until “TESTING” on CONSULT-II screen is turned to “COMPLETED”. (It will take 45 seconds or more.) If “TESTING” is not displayed after 5 minutes, turn ignition “OFF” and cool the engine coolant temperature to the range of −10 to 40°C (14 to 104°F). Retry from step 1. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG-310. With GST Turn ignition switch “ON” and select “MODE 1” with GST. Check that engine coolant temperature is within the range of −10 to 40°C (14 to 104°F). Check that voltage between ECM terminal 72 (EGR temperature sensor signal) and ground is less than 4.8V. Start engine and let it idle for at least 45 seconds. Stop engine. Perform from step 1 to 4. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-QG-310.
PEF897U
EC-308
DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE Wiring Diagram
Wiring Diagram
EC-309
NCEC0352
YEC072A
DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0353
CHECK POWER SUPPLY
1. Disconnect EGR volume control valve harness connector. 2. Turn ignition switch “ON”. 3. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.
SEF556W
Voltage: Battery voltage OK or NG OK
©
GO TO 2.
NG
©
Check the following. I Harness or connectors E90, F73 I Harness for open or short between EGR volume control valve and engine control module relay If NG, repair harness or connectors.
2
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 8 and EGR volume control valve terminal 1, ECM terminal 9 and EGR volume control valve terminal 4, ECM terminal 17 and EGR volume control valve terminal 3, ECM terminal 18 and EGR volume control valve terminal 6. Refer to wiring diagram. Continuity should exist. If OK, check harness for short to ground and short to power. OK or NG OK
©
GO TO 3.
NG
©
Repair open circuit, short to ground or short to power in harness connectors.
3
CHECK EGR TEMPERATURE SENSOR
Refer to “Component Inspection”, EC-QG-304. OK or NG OK
©
GO TO 4.
NG
©
Replace EGR temperature sensor.
4
CHECK EGR VOLUME CONTROL VALVE
Refer to “Component Inspection”, EC-QG-251. OK or NG OK
©
GO TO 5.
NG
©
Replace EGR volume control valve.
EC-310
DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE Diagnostic Procedure (Cont’d)
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection EGR TEMPERATURE SENSOR
NCEC0354 NCEC0354S01
Check resistance change and resistance value. EGR temperature °C (°F)
Voltage V
Resistance MΩ
0 (32)
4.56
0.62 - 1.05
50 (122)
2.25
0.065 - 0.094
100 (212)
0.59
0.011 - 0.015
SEF643Q
If NG, replace EGR temperature sensor.
SEF068X
EC-311
DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE Component Inspection (Cont’d)
EGR VOLUME CONTROL VALVE
NCEC0354S04
With CONSULT-II 1) Disconnect EGR volume control valve harness connector. 2) Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6 Temperature °C (°F)
Resistance Ω
20 (68)
20 - 24
SEF069X
3) 4)
5) 6)
1) 2)
3) SEF558W
Reconnect EGR volume control valve harness connector. Remove EGR volume control valve from cylinder head. (The EGR volume control valve harness connector should remain connected.) Turn ignition switch “ON”. Perform “EGR VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that EGR volume control valve shaft moves smoothly forward and backward according to the valve opening If NG, replace the EGR volume control valve. Without CONSULT-II Disconnect EGR volume control valve harness connector. Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6 Temperature °C (°F)
Resistance Ω
20 (68)
20 - 24
Turn ignition switch “ON” and “OFF”. Check that EGR volume control valve shaft moves smoothly forward and backward according to the ignition switch position. If NG, replace the EGR volume control valve.
NEF122A
SEF560W
EC-312
DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH QG16I18DE Component Description
Component Description
NCEC0424
When the gear position is “N”, park/neutral position (PNP) switch is “ON”. ECM detects the park/neutral position when continuity with ground exists.
SEF740W
CONSULT-II Reference Value in Data Monitor Mode
NCEC0425
Specification data are reference values. MONITOR ITEM
CONDITION I Ignition switch: ON
P/N POSI SW
SPECIFICATION
Shift lever: “N”
ON
Except above
OFF
ECM Terminals and Reference Value
NCEC0426
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.
42
WIRE COLOR
G/OR
ITEM
PNP switch
CONDITION
DATA (DC Voltage)
[Ignition switch “ON”] I Gear position is “Neutral position”
Approximately 0V
[Ignition switch “ON”] I Except the above gear position
Approximately 5V
On Board Diagnosis Logic DTC No. P1706 1706
Malfunction is detected when ... I The signal of the PNP switch is not changed in the process of engine starting and driving.
NCEC0427
Check Items (Possible Cause) I Harness or connectors (The PNP switch circuit is open or shorted.) I PNP switch
DTC Confirmation Procedure
NCEC0428
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 9 seconds before conducting the next test.
EC-313
DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH QG16I18DE DTC Confirmation Procedure (Cont’d)
1) 2) 3) 4)
NEF118A
With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Maintain the following conditions for at least 50 consecutive seconds.
ENG SPEED
1,550 - 3,800 rpm
COOLAN TEMP/S
More than 70°C (158°F)
B/FUEL SCHDL
3.0 msec or more
VHCL SPEED SE
70 - 100 km/h (43 - 62 MPH)
Selector lever
Suitable position (Except “N” position)
5)
If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-316.
Overall Function Check
NCEC0429
Use this procedure to check the overall function of the park/neutral position switch circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Turn ignition switch “ON”. 2) Check voltage between ECM terminal 42 (PNP switch signal) and body ground under the following conditions. Condition (Gear position)
SEF137X
Voltage (V) (Known good data)
“N” position
Approx. 0
Except the above position
Approx. 5
3)
If NG, go to “Diagnostic Procedure”, EC-QG-316.
EC-314
DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH QG16I18DE Wiring Diagram
Wiring Diagram
NCEC0430
: Detectable line for DTC : Non-detectable line for DTC
PARK/NEUTRAL POSITION (PNP) SWITCH
EC-315
YEC791
DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH QG16I18DE Diagnostic Procedure For M/T Models
Diagnostic Procedure For M/T Models 1
NCEC0431
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect PNP switch harness connector.
SEF740W
3. Check harness continuity between PNP switch harness connector terminal 2 and body ground. 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
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the harness for open or short between PNP switch and body ground.
©
3
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 42 and PNP switch harness connector 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 5.
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the harness for open or short between ECM and PNP switch.
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK PNP SWITCH
Refer to MT section. OK or NG OK
©
GO TO 6.
NG
©
Replace PNP switch.
EC-316
DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH QG16I18DE Diagnostic Procedure For M/T Models (Cont’d)
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-317
QG16I18DE
INJECTOR Component Description
Component Description
NCEC0435
The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the injector circuit, the coil in the injector is energized. The energized coil pulls the needle valve back and allows fuel to flow through the injector into the intake manifold. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the injector remains open. The ECM controls the injection pulse duration based on engine fuel needs. SEF138X
CONSULT-II Reference Value in Data Monitor Mode
NCEC0436
MONITOR ITEM
INJ PULSE - B1
B/FUEL SCHDL
CONDITION
SPECIFICATION
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
2.4 - 3.2 msec
2,000 rpm
1.9 - 3.2 msec
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
1.5 - 2.5 msec
2,000 rpm
1.5 - 2.5 msec
ECM Terminals and Reference Value
NCEC0437
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. TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Warm-up condition I Idle speed
101 103 105 107
R/B Y/B G/B L/B
Injector Injector Injector Injector
No. No. No. No.
1 2 3 4
SEF011W
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Warm-up condition I Engine speed is 2,000 rpm
SEF012W
EC-318
QG16I18DE
INJECTOR
Wiring Diagram
Wiring Diagram
NCEC0434
IGNITION SWITCH ON or START : Detectable line for DTC FUSE BLOCK (J/B)
INJECTOR No.1
: Non-detectable line for DTC Refer to EL-POWER.
INJECTOR No.2
INJECTOR No.3
INJECTOR No.4
ECM
Refer to last page (Foldout page)
EC-319
YEC792
INJECTOR
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0438
CHECK OVERALL FUNCTION
With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.
NEF105A
3. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Start engine. 2. Listen to each injector operating sound.
MEC703B
Clicking noise should be heard. OK or NG OK
©
INSPECTION END
NG
©
GO TO 2.
EC-320
QG16I18DE
INJECTOR
Diagnostic Procedure (Cont’d)
2 1. 2. 3. 4.
CHECK POWER SUPPLY Stop engine. Disconnect injector harness connector. Turn ignition switch “ON”. Check voltage between terminal 2 and ground with CONSULT-II or tester.
SEF986W
Voltage: Battery voltage OK or NG OK
©
GO TO 4.
NG
©
GO TO 3.
3
DETECT MALFUNCTIONING PART
Check the following. I 10A fuse I Harness connectors M50, F104 I Harness for open or short between injector and fuse
©
4
Repair harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between injector harness connector terminal 1 and ECM terminals 101, 103, 105, 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 harness for open or short between ECM and injector.
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-321
INJECTOR
QG16I18DE
Diagnostic Procedure (Cont’d)
6
CHECK INJECTOR
Refer to “Component Inspection”, EC-QG-322. OK or NG OK
©
GO TO 7.
NG
©
Replace injector.
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection INJECTOR 1. 2.
NCEC0439 NCEC0439S01
Disconnect injector harness connector. Check resistance between terminals as shown in the figure. Resistance: 13.5 - 17.5Ω [at 25°C (77°F)] If NG, replace injector.
SEF139X
EC-322
QG16I18DE
IGNITION SIGNAL
Component Description
Component Description
NCEC0542
IGNITION COIL AND POWER TRANSISTOR
NCEC0542S01
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.
CONSULT-II Reference Value in Data Monitor Mode
NCEC0543
Specification data are reference values. MONITOR ITEM IGNITION SW
CONDITION
SPECIFICATION
I Ignition switch: ON , OFF , ON
ON , OFF , ON
ECM Terminals and Reference Value
NCEC0544
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. TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) 0 - 0.3V
[Engine is running] I Warm-up condition I Idle speed 35 36 37 38
Y/R PU/G L/Y GY/L
Ignition Ignition Ignition Ignition
signal signal signal signal
(No. (No. (No. (No.
1) 2) 3) 4)
SEF971W
0.2 - 0.4V
[Engine is running] I Engine speed is 2,000 rpm
SEF972W
EC-323
IGNITION SIGNAL
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0545
BATTERY : Detectable line for DTC Refer to EL-POWER. : Non-detectable line for DTC
ENGINE CONTROL MODULE RELAY
Next page
CONDENSER
Next page
EC-324
YEC793
QG16I18DE
IGNITION SIGNAL
Wiring Diagram (Cont’d)
Preceding page
IGNITION COIL No. 2 (WITH POWER TRANSISTOR)
IGNITION COIL No. 4 (WITH POWER TRANSISTOR)
SPARK PLUG
SPARK PLUG
IGNITION COIL No. 1 (WITH POWER TRANSISTOR)
IGNITION COIL No. 3 (WITH POWER TRANSISTOR)
SPARK PLUG
SPARK PLUG
Preceding page
: Detectable line for DTC : Non-detectable line for DTC
YEC794
EC-325
IGNITION SIGNAL
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0546
INSPECTION 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 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 2. Make sure that all circuits do not produce a momentary engine speed drop.
SEF190Y
OK or NG OK
©
INSPECTION END
NG
©
GO TO 13.
3
CHECK OVERALL FUNCTION
Without CONSULT-II 1. Let engine idle. 2. Read the voltage signal between ECM terminals 35, 36, 37, 38 and ground with an oscilloscope. 3. Verify that the oscilloscope screen shows the signal wave as shown below.
NEF236A
OK or NG OK
©
INSPECTION END
NG
©
GO TO 13.
EC-326
QG16I18DE
IGNITION SIGNAL
Diagnostic Procedure (Cont’d)
4
CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I
1. Turn ignition switch ON. 2. Check voltage between ECM terminals 110, 112 and ground with CONSULT-II or tester.
SEF366X
OK or NG OK
©
GO TO 5.
NG
©
Go to TROUBLE DIAGNOSIS FOR POWER SUPPLY, EC-QG-103.
5 1. 2. 3. 4.
CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II 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.
SEF367X
OK or NG OK
©
GO TO 11.
NG
©
GO TO 6.
EC-327
IGNITION SIGNAL
QG16I18DE
Diagnostic Procedure (Cont’d)
6
CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III
1. Turn ignition switch OFF. 2. Disconnect ECM relay.
SEF984W
3. Check harness continuity between ECM relay terminal 7 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 8.
NG
©
GO TO 7.
7
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F73, E90 I Harness for open or short between ECM relay and condenser ©
8
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV
1. Check voltage between ECM relay terminal 6 and ground with CONSULT-II or tester.
SEF368X
OK or NG OK
©
GO TO 10.
NG
©
GO TO 9.
9
DETECT MALFUNCTIONING PART
Check the following. I 15A fuses I Harness for open and short between ECM relay and fuse ©
Repair or replace harness or connectors.
EC-328
IGNITION SIGNAL
QG16I18DE Diagnostic Procedure (Cont’d)
10
CHECK ECM RELAY
1. Apply 12V direct current between ECM relay terminals 1 and 2. 2. Check continuity between ECM relay terminals 3 and 5, 6 and 7.
SEF296X
OK or NG OK
©
GO TO 18.
NG
©
Replace ECM relay.
11
CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF. 2. Check harness continuity between condenser terminal 2 and engine 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 12.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
12
CHECK CONDENSER
Refer to “Component Inspection”, EC-QG-331.
SEF369X
OK or NG OK
©
GO TO 13.
NG
©
Replace condenser.
EC-329
IGNITION SIGNAL
QG16I18DE
Diagnostic Procedure (Cont’d)
13 1. 2. 3. 4. 5.
CHECK IGNITION COIL POWER SUPPLY CIRCUIT-V Turn ignition switch OFF. Reconnect harness connectors disconnected. Disconnect ignition coil harness connector. Turn ignition switch ON. Check voltage between ignition coil terminal 1 and ground with CONSULT-II or tester.
NEF237A
Voltage: Battery voltage OK or NG OK
©
GO TO 15.
NG
©
GO TO 14.
14
DETECT MALFUNCTIONING PART
Check the harness for open or short ignition coil harness connector F73. ©
15
Repair or replace harness or connectors.
CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF. 2. Check harness continuity between ignition coil terminal 2 and engine 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 16.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
16
CHECK OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminals 35, 36, 37, 38 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 17.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
17
CHECK IGNITION COIL WITH POWER TRANSISTOR
Refer to “Component Inspection”, EC-QG-331331. OK or NG OK
©
GO TO 18.
NG
©
Replace ignition coil with power transistor.
EC-330
QG16I18DE
IGNITION SIGNAL
Diagnostic Procedure (Cont’d)
18
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection
NCEC0547
IGNITION COIL WITH POWER TRANSISTOR 1. 2.
NCEC0547S01
Disconnect ignition coil with power transistor harness connector. Check ignition coil with power transistor for resistance as show in the figure. Terminal No. (Polarity)
Resistance Ω [at 25°C (77°F)]
3 (+) - 2 (−)
Except 0 or ∞
SEF371Q
1 (+) - 3 (−) Except 0 1 (+) - 2 (−)
If NG, replace ignition coil with power transistor assembly.
CONDENSER 1. 2.
NCEC0547S02
Disconnect condenser harness connector. Check condenser continuity between terminals 1 and 2. Resistance: Above 1 MΩ at 25°C (77°F)
SEF059X
EC-331
QG16I18DE
START SIGNAL CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0441
Specification data are reference values. MONITOR ITEM START SIGNAL
CONDITION
SPECIFICATION
I Ignition switch: ON , START , ON
OFF , ON , OFF
ECM Terminals and Reference Value
NCEC0442
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
WIRE COLOR
B/Y
ITEM
CONDITION
DATA (DC Voltage)
[Ignition switch “ON”]
Approximately 0V
[Ignition switch “START”]
9 - 12V
Start signal
EC-332
START SIGNAL
QG16I18DE Wiring Diagram
Wiring Diagram
NCEC0440
BATTERY
Refer to EL-POWER.
: Detectable line for DTC : Non-detectable line for DTC
OFF
ST
IGNITION SWITCH
ACC ON
FUSE BLOCK (J/B)
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
EC-333
YEC282
START SIGNAL
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
=NCEC0443
INSPECTION START
Do you have CONSULT-II? Yes or No Yes
©
GO TO 2.
No
©
GO TO 3.
2
CHECK OVERALL FUNCTION
With CONSULT-II 1. Turn ignition switch “ON”. 2. Check “START SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.
PEF111P
Condition
“START SIGNAL”
IGN “ON”
OFF
IGN “START”
ON OK or NG
OK
©
INSPECTION END
NG
©
GO TO 4.
EC-334
MTBL0140
START SIGNAL
QG16I18DE Diagnostic Procedure (Cont’d)
3
CHECK OVERALL FUNCTION
Without CONSULT-II 1. Turn ignition switch to “START”. 2. Check voltage between ECM terminal 41 and ground under the following conditions.
SEF142X
Condition
Voltage
Ignition switch “START” Except above
Battery voltage Approximately 0V MTBL0143
OK or NG OK
©
INSPECTION END
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104 I 10A fuse I Harness for open or short between ECM and ignition switch 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
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
EC-335
QG16I18DE
FUEL PUMP System Description
System Description Sensor
Input Signal to ECM
Camshaft position sensor (PHASE)
Engine speed
Ignition switch
Start signal
NCEC0444
ECM function Fuel pump control
Actuator
Fuel pump relay
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 180° signal from the camshaft position sensor, it knows that the engine is rotating, and causes the pump to perform. If the 180° 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 (Signal is not sent from camshaft position sensor.)
Stops in 1.5 seconds
Except as shown above
Stops
Component Description
NCEC0501
A turbine type design fuel pump is used in the fuel tank.
AEC801
CONSULT-II Reference Value in Data Monitor Mode
NCEC0445
MONITOR ITEM
FUEL PUMP RLY
CONDITION
SPECIFICATION
I Ignition switch is turned to ON (Operates for 1 second) I Engine running and cranking I When engine is stopped (stops in 1.5 seconds)
ON
I Except as shown above
OFF
EC-336
QG16I18DE
FUEL PUMP
ECM Terminals and Reference Value
ECM Terminals and Reference Value
NCEC0446
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.
21
WIRE COLOR
B/P
ITEM
CONDITION
DATA (DC Voltage)
[Ignition switch “ON”] I For 1 second after turning ignition switch “ON” [Engine is running]
0 - 1V
[Ignition switch “ON”] I More than 1 second after turning ignition switch “ON”
BATTERY VOLTAGE (11 - 14V)
Fuel pump relay
EC-337
FUEL PUMP
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0447
YEC280
EC-338
QG16I18DE
FUEL PUMP
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0448
CHECK OVERALL FUNCTION
1. Turn ignition switch “ON”. 2. Pinch fuel feed hose with fingers.
SEF143X
Fuel pressure pulsation should be felt on the fuel feed hose for 1 second after ignition switch is turned “ON”. OK or NG OK
©
INSPECTION END
NG
©
GO TO 2.
2
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect fuel pump relay.
SEF071X
3. Turn ignition switch “ON”. 4. Check voltage between terminals 1, 3 and ground with CONSULT-II or tester.
SEF144X
Voltage: Battery voltage OK or NG OK
©
GO TO 4.
NG
©
GO TO 3.
EC-339
FUEL PUMP
QG16I18DE
Diagnostic Procedure (Cont’d)
3
DETECT MALFUNCTIONING PART
Check the following. I 15A fuse I Harness for open or short between fuse and fuel pump relay ©
4
Repair harness or connectors.
CHECK POWER GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect fuel pump harness connector.
SEF299W
3. Check harness continuity between fuel pump harness connector terminal 2 and body ground, terminal 1 and fuel pump relay connector terminal 9J. 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. I Harness for open or short between fuel pump and body ground I Harness for open or short between fuel pump and fuel pump relay ©
6
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 21 and fuel pump relay connector terminal 19C. 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 8.
NG
©
GO TO 7.
7
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104 I Harness for open or short between ECM and fuel pump relay
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-340
QG16I18DE
FUEL PUMP
Diagnostic Procedure (Cont’d)
8
CHECK FUEL PUMP RELAY
Refer to “Component Inspection”, EC-QG-341. OK or NG OK
©
GO TO 9.
NG
©
Replace fuel pump relay.
9
CHECK FUEL PUMP
Refer to “Component Inspection”, EC-QG-341. OK or NG OK
©
GO TO 10.
NG
©
Replace fuel pump.
10
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection
NCEC0449
FUEL PUMP RELAY
NCEC0449S01
Check continuity between terminals 3 and 5. Conditions
Continuity
12V direct current supply between terminals 1 and 2
Yes
No current supply
No
If NG, replace relay. SEF145X
FUEL PUMP 1. 2.
Disconnect fuel pump harness connector. Check resistance between terminals 1 and 2. Resistance: 0.2 - 5.0Ω [at 25°C (77°F)] If NG, replace fuel pump.
SEF326W
EC-341
NCEC0449S02
QG16I18DE
POWER STEERING OIL PRESSURE SWITCH Component Description
Component Description
Power steering oil pressure switch
NCEC0451
The power steering oil pressure switch is attached to the power steering high-pressure tube and detects a power steering load. When a power steering load is detected, it signals the ECM. The ECM adjusts the IACV-AAC valve to increase the idle speed and adjust for the increased load.
NEF124A
CONSULT-II Reference Value in Data Monitor Mode
NCEC0452
Specification data are reference values. MONITOR ITEM
PW/ST SIGNAL
CONDITION I Engine: After warming up, idle the engine
SPECIFICATION
Steering wheel in neutral position (forward direction)
OFF
The steering wheel is fully turned
ON
ECM Terminals and Reference Value
NCEC0453
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.
46
WIRE COLOR
PU/W
ITEM
CONDITION
[Engine is Power steering oil pressure I Steering switch [Engine is I Steering
DATA (DC Voltage)
running] wheel is fully turned
Approximately 0V
running] wheel is not turned
Approximately 5V
EC-342
POWER STEERING OIL PRESSURE SWITCH
QG16I18DE Wiring Diagram
Wiring Diagram
NCEC0450
YEC254
EC-343
POWER STEERING OIL PRESSURE SWITCH
QG16I18DE
Diagnostic Procedure
Diagnostic Procedure 1
=NCEC0454
INSPECTION START
Do you have CONSULT-II? Yes or No Yes
©
GO TO 2.
No
©
GO TO 3.
2
CHECK OVERALL FUNCTION
With CONSULT-II 1. Start engine. 2. Check “PW/ST SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.
PEF591I
Steering is in neutral position
OFF
Steering is turned
ON MTBL0141
OK or NG OK
©
INSPECTION END
NG
©
GO TO 4.
EC-344
POWER STEERING OIL PRESSURE SWITCH
QG16I18DE
Diagnostic Procedure (Cont’d)
3
CHECK OVERALL FUNCTION
Without CONSULT-II 1. Start engine. 2. Check voltage between ECM terminal 46 and ground under the following conditions.
SEF148X
Condition
Voltage
When steering wheel is turned quickly
Approximately 0V
Except above
Approximately 5V MTBL0142
OK or NG OK
©
INSPECTION END
NG
©
GO TO 4.
4
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect power steering oil pressure switch harness connector. 3. Check harness continuity between power steering oil pressure switch harness terminal 2 and engine ground. 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 INPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 46 and power steering oil pressure switch harness 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 7.
NG
©
GO TO 6.
6
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F4, E42 I Harness for open or short between ECM and power steering oil pressure switch
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-345
POWER STEERING OIL PRESSURE SWITCH
QG16I18DE
Diagnostic Procedure (Cont’d)
7
CHECK POWER STEERING OIL PRESSURE SWITCH
Refer to “Component Inspection”, EC-QG-346. OK or NG OK
©
GO TO 8.
NG
©
Replace power steering oil pressure switch.
8
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.
©
INSPECTION END
Component Inspection
NCEC0455
POWER STEERING OIL PRESSURE SWITCH 1. 2.
NCEC0455S01
Disconnect power steering oil pressure switch harness connector then start engine. Check continuity between terminals 1 and 2. Refer to wiring diagram. Conditions
Continuity
Steering wheel is being turned.
Yes
Steering wheel is not being turned.
No
If NG, replace power steering oil pressure switch.
EC-346
QG16I18DE
REFRIGERANT PRESSURE SENSOR
Description
Description
NLEC0580
The refrigerant pressure sensor is installed at the liquid tank 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.
JEF147Y
SEF099X
ECM Terminals and Reference Value
NLEC0581
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)
58
B
Sensor’s ground
[Engine is running] I Warm-up condition I Idle speed
Approximately 0V
74
R/L
Refrigerant pressure sensor
[Engine is running] I Warm-up condition I Both A/C switch and blower switch are “ON” (Compressor operates.)
1.0 - 4.0V
111
G
Sensor’s power supply
[Ignition switch “ON”]
Approximately 5V
EC-347
REFRIGERANT PRESSURE SENSOR
QG16I18DE
Wiring Diagram
Wiring Diagram REFRIGERANT SENSOR
: Detectable line for DTC : Non-detectable line for DTC
ECM
EC-348
YEC790
QG16I18DE
REFRIGERANT PRESSURE SENSOR
Diagnostic Procedure
Diagnostic Procedure 1
NLEC0590
CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION
1. Start engine and warm it up to normal operating temperature. 2. Turn A/C switch and blower switch “ON”. 3. Check voltage between ECM terminal 74 and ground with CONSULT-II or tester.
SEF952XA
OK or NG OK
©
INSPECTION END
NG
©
GO TO 2.
2
CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT
1. Turn A/C switch and blower switch “OFF”. 2. Stop engine. 3. Disconnect refrigerant pressure sensor harness connector.
JEF147Y
4. Turn ignition switch “ON”. 5. Check voltage between refrigerant pressure sensor terminal 1 and ground with CONSULT-II or tester.
NEF243A
OK or NG OK
©
GO TO 4.
NG
©
GO TO 3.
EC-349
REFRIGERANT PRESSURE SENSOR
QG16I18DE
Diagnostic Procedure (Cont’d)
3
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I Harness for open or short between ECM and refrigerant pressure sensor ©
4
Repair harness or connectors.
CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Check harness continuity between refrigerant pressure sensor terminal 3 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK
©
GO TO 6.
NG
©
GO TO 5.
5
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E42, F4 I Harness for open or short between ECM and refrigerant pressure sensor ©
6
Repair open circuit or short to power in harness or connectors.
CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 74 and refrigerant pressure 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 8.
NG
©
GO TO 7.
7
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E42, F4 I Harness for open or short between ECM and refrigerant pressure sensor ©
8
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK REFRIGERANT PRESSURE SENSOR
Refer to HA section, “Refrigerant pressure sensor”. OK or NG OK
©
GO TO 9.
NG
©
Replace refrigerant pressure sensor.
9
CHECK INTERMITTENT INCIDENT
Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©
INSPECTION END
EC-350
QG16I18DE
ELECTRICAL LOAD SIGNAL
CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0548
Specification data are reference values. MONITOR ITEM
CONDITION
I Ignition switch: ON
LOAD SIGNAL
HEATER FAN SW
I Ignition switch: ON
SPECIFICATION
Rear window defogger is operating ON and/or lighting switch is on. Rear window defogger is not operOFF ating and lighting switch is not on. Blower fan motor is operating
ON
Blower fan motor is not operating
OFF
ECM Terminals and Reference Value
NCEC0549
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. TERWIRE MINAL COLOR NO.
50
51
R
LG/B
ITEM
Electric load signal (Load switch)
Blower fan motor switch
CONDITION
DATA (DC Voltage)
[Engine is running] I Rear window defogger is operating and/or lighting switch is on
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Rear window defogger is not operating and lighting switch is not on
Approximately 0V
[Engine is running] I Blower fan motor is operating
Approximately 0V
[Engine is running] I Blower fan motor is not operating
Approximately 5V
EC-351
ELECTRICAL LOAD SIGNAL
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0550
YEC255
EC-352
ELECTRICAL LOAD SIGNAL
QG16I18DE Wiring Diagram (Cont’d)
YEC077A
EC-353
MI & DATA LINK CONNECTORS
QG16I18DE
Wiring Diagram
Wiring Diagram
NCEC0466
YEC078A
EC-354
SERVICE DATA AND SPECIFICATIONS (SDS) Fuel Pressure Regulator
Fuel Pressure Regulator Fuel pressure at idling kPa (bar, kg/cm2, psi)
NCEC0467
Vacuum hose is connected
Approximately 235 (2.35, 2.4, 34)
Vacuum hose is disconnected
Approximately 294 (2.94, 3.0, 43)
Idle Speed and Ignition Timing Target idle speed* Air conditioner: ON
rpm
NCEC0468
700±50
rpm
825 or more
Ignition timing
8°±5° BTDC
Throttle position sensor idle position
V
0.35 - 0.65
*: Under the following conditions: I Air conditioner switch: OFF I Electrical load: OFF (Lights, heater fan & rear window defogger) I Steering wheel: Kept in straight-ahead position
Mass Air Flow Sensor
NCEC0470
Supply voltage (Heater)
V
Battery voltage (11 - 14)
Supply voltage (Sensor)
V
Approximately 5
Output voltage
V
1.0 - 1.7*
Mass air flow (Using CONSULT-II or GST)
1.0 - 4.0 at idle* 5.0 - 10.0 at 2,500 rpm*
g⋅m/sec
*: Engine is warmed up to normal operating temperature and idling under no-load.
Intake Air Temperature Sensor Temperature
°C (°F)
Resistance
NCEC0480
kΩ
20 (68)
2.1 - 2.9
80 (176)
0.27 - 0.38
Engine Coolant Temperature Sensor Temperature
°C (°F)
Resistance
kΩ
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
Throttle Position Sensor Throttle valve conditions
NCEC0471
NCEC0477
Resistance [at 25°C (77°F)]
Completely closed
Approximately 0.6 kΩ (a)
Partially open
Between (a) and (b)
Completely open
Approximately 4.0 kΩ (b)
Heated Oxygen Sensor 1 Heater (Front) Resistance [at 25°C (77°F)] Ω
NCEC0478
2.3 - 4.3
Heated Oxygen Sensor 2 Heater (Rear) Resistance [at 25°C (77°F)] Ω
2.3 - 4.3
EC-355
NCEC0483
SERVICE DATA AND SPECIFICATIONS (SDS) Crankshaft Position Sensor (POS)
Crankshaft Position Sensor (POS)
NCEC0558
Resistance Ω [at 25°C (77°F)]
Terminal No. (Polarity) 3 (+) - 1 (−)
Except 0 or ∞
2 (+) - 1 (−) 3 (+) - 2 (−)
Camshaft Position Sensor (PHASE)
NCEC0559
Resistance Ω [at 25°C (77°F)]
Terminal No. (Polarity) 3 (+) - 1 (−)
Except 0 or ∞
2 (+) - 1 (−) 3 (+) - 2 (−)
EGR Volume Control Valve (If so equipped)
NCEC0560
Resistance Ω [at 20°C (68°F)]
Terminal No. 1-2 2-3
20 - 24 4-5 5-6
EGR Temperature Sensor (If so equipped) EGR temperature °C (°F)
Voltage V
Resistance MΩ
0 (32)
4.56
0.62 - 1.05
50 (122)
2.25
0.065 - 0.094
100 (212)
0.59
0.011 - 0.015
EVAP Canister Purge Volume Control Valve Resistance [at 20°C (68°F)] Ω
NCEC0472
NCEC0481
31 - 35
IACV-AAC Valve
NCEC0474
Resistance Ω [at 20°C (68°F)]
Terminal No. 1-2 2-3
20 - 24 4-5 5-6
Injector Resistance [at 25°C (77°F)] Ω
NCEC0475
13.5 - 17.5
EC-356
SERVICE DATA AND SPECIFICATIONS (SDS) Ignition Coil with Power Transistor
Ignition Coil with Power Transistor Terminal No. (Polarity)
Resistance Ω [at 25°C (77°F)]
3 (+) - 2 (−)
Except 0 or ∞
NCEC0561
1 (+) - 3 (−) Except 0 1 (+) - 2 (−)
Fuel Pump Resistance [at 25°C (77°F)] Ω
NCEC0473
0.2 - 5.0
EC-357
SERVICE DATA AND SPECIFICATIONS (SDS) NOTE
EC-358
ENGINE CONTROL SYSTEM SECTION
EC EC
CONTENTS SR20DE TROUBLE DIAGNOSIS - INDEX ....................................6 Alphabetical & P No. Index for DTC ...........................6 PRECAUTIONS .............................................................10 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″.............10 Precautions for On Board Diagnostic (OBD) System of Engine and CVT.......................................10 Engine Fuel & Emission Control System ..................11 Precautions ................................................................12 Wiring Diagrams and Trouble Diagnosis...................13 PREPARATION .............................................................14 Special Service Tools ................................................14 Commercial Service Tool...........................................14 ENGINE AND EMISSION CONTROL OVERALL SYSTEM.........................................................................15 Engine Control Component Parts Location...............15 Circuit Diagram ..........................................................19 System Diagram ........................................................20 Vacuum Hose Drawing ..............................................21 System Chart .............................................................22 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ...............................................23 Multiport Fuel Injection (MFI) System .......................23 Distributor Ignition (DI) System .................................25 Air Conditioning Cut Control......................................26 Fuel Cut Control (at no load & high engine speed) ........................................................................27 Evaporative Emission System ...................................27 Positive Crankcase Ventilation ..................................30 BASIC SERVICE PROCEDURE ...................................31 Fuel Pressure Release ..............................................31 Fuel Pressure Check .................................................31 Fuel Pressure Regulator Check ................................32 Injector .......................................................................32 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment .................................................................34
Idle Air Volume Learning ...........................................46 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................48 Introduction ................................................................48 Two Trip Detection Logic ...........................................48 Emission-related Diagnostic Information ...................49 Malfunction Indicator (MI) ..........................................58 OBD System Operation Chart ...................................63 CONSULT-II ...............................................................68 Generic Scan Tool (GST) ..........................................78 TROUBLE DIAGNOSIS - INTRODUCTION..................80 Introduction ................................................................80 Work Flow..................................................................82 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........84 Basic Inspection.........................................................84 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................92 DTC Inspection Priority Chart....................................92 Fail-safe Chart ...........................................................93 Symptom Matrix Chart...............................................94 CONSULT-II Reference Value in Data Monitor Mode ..........................................................................98 Major Sensor Reference Graph in Data Monitor Mode ........................................................................100 ECM Terminals and Reference Value .....................103 TROUBLE DIAGNOSIS - SPECIFICATION VALUE ..110 Description ...............................................................110 Testing Condition .....................................................110 Inspection Procedure...............................................110 Diagnostic Procedure .............................................. 111 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.....................................................................114 Description ...............................................................114 Diagnostic Procedure ..............................................114 TROUBLE DIAGNOSIS FOR POWER SUPPLY........115 Main Power Supply and Ground Circuit..................115
CONTENTS DTC P0100 MASS AIR FLOW SENSOR (MAFS)......120 Component Description ...........................................120 CONSULT-II Reference Value in Data Monitor Mode ........................................................................120 ECM Terminals and Reference Value .....................120 On Board Diagnosis Logic.......................................120 DTC Confirmation Procedure ..................................121 Wiring Diagram ........................................................122 Diagnostic Procedure ..............................................123 Component Inspection.............................................126 DTC P0110 INTAKE AIR TEMPERATURE SENSOR ......................................................................127 Component Description ...........................................127 On Board Diagnosis Logic.......................................127 DTC Confirmation Procedure ..................................127 Wiring Diagram ........................................................128 Diagnostic Procedure ..............................................129 Component Inspection.............................................131 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT) .......................................132 Component Description ...........................................132 CONSULT-II Reference Value in Data Monitor Mode ........................................................................132 On Board Diagnosis Logic.......................................132 DTC Confirmation Procedure ..................................133 Wiring Diagram ........................................................134 Diagnostic Procedure ..............................................135 Component Inspection.............................................136 DTC P0120 THROTTLE POSITION SENSOR ...........137 Component Description ...........................................137 CONSULT-II Reference Value in Data Monitor Mode ........................................................................137 ECM Terminals and Reference Value .....................138 On Board Diagnosis Logic.......................................138 DTC Confirmation Procedure ..................................138 Wiring Diagram ........................................................140 Diagnostic Procedure ..............................................141 Component Inspection.............................................142 DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT).....................................................144 Component Description ...........................................144 CONSULT-II Reference Value in Data Monitor Mode ........................................................................144 ECM Terminals and Reference Value .....................144 On Board Diagnosis Logic.......................................145 DTC Confirmation Procedure ..................................145 Overall Function Check ...........................................146 Wiring Diagram ........................................................147 Diagnostic Procedure ..............................................148 Component Inspection.............................................149
(Cont’d)
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING) .....................150 Component Description ...........................................150 CONSULT-II Reference Value in Data Monitor Mode ........................................................................150 ECM Terminals and Reference Value .....................150 On Board Diagnosis Logic.......................................151 DTC Confirmation Procedure ..................................151 Overall Function Check ...........................................152 Diagnostic Procedure ..............................................153 Component Inspection.............................................154 DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING) ......................156 Component Description ...........................................156 CONSULT-II Reference Value in Data Monitor Mode ........................................................................156 ECM Terminals and Reference Value .....................156 On Board Diagnosis Logic.......................................157 DTC Confirmation Procedure ..................................157 Overall Function Check ...........................................158 Diagnostic Procedure ..............................................159 Component Inspection.............................................160 DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING).......................162 Component Description ...........................................162 CONSULT-II Reference Value in Data Monitor Mode ........................................................................162 ECM Terminals and Reference Value .....................162 On Board Diagnosis Logic.......................................163 DTC Confirmation Procedure ..................................163 Overall Function Check ...........................................164 Wiring Diagram ........................................................165 Diagnostic Procedure ..............................................166 Component Inspection.............................................169 DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)........................................170 Component Description ...........................................170 CONSULT-II Reference Value in Data Monitor Mode ........................................................................170 ECM Terminals and Reference Value .....................170 On Board Diagnosis Logic.......................................171 DTC Confirmation Procedure ..................................171 Wiring Diagram ........................................................172 Diagnostic Procedure ..............................................173 Component Inspection.............................................174 DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER.......................................................175 Description ...............................................................175 CONSULT-II Reference Value in Data Monitor Mode ........................................................................175 ECM Terminals and Reference Value .....................175 On Board Diagnosis Logic.......................................175
EC-2
CONTENTS DTC Confirmation Procedure ..................................175 Wiring Diagram ........................................................177 Diagnostic Procedure ..............................................178 Component Inspection.............................................179 DTC P0137 HEATED OXYGEN SENSOR 2(REAR) (MIN. VOLTAGE MONITORING).................................180 Component Description ...........................................180 CONSULT-II Reference Value in Data Monitor Mode ........................................................................180 ECM Terminals and Reference Value .....................180 On Board Diagnosis Logic.......................................180 DTC Confirmation Procedure ..................................181 Overall Function Check ...........................................182 Wiring Diagram ........................................................183 Diagnostic Procedure ..............................................184 Component Inspection.............................................186 DTC P0138 HEATED OXYGEN SENSOR 2(REAR) (MAX. VOLTAGE MONITORING) ...............................187 Component Description ...........................................187 CONSULT-II Reference Value in Data Monitor Mode ........................................................................187 ECM Terminals and Reference Value .....................187 On Board Diagnosis Logic.......................................187 DTC Confirmation Procedure ..................................188 Overall Function Check ...........................................189 Wiring Diagram ........................................................190 Diagnostic Procedure ..............................................191 Component Inspection.............................................193 DTC P0139 HEATED OXYGEN SENSOR 2(REAR) (RESPONSE MONITORING).......................................194 Component Description ...........................................194 CONSULT-II Reference Value in Data Monitor Mode ........................................................................194 ECM Terminals and Reference Value .....................194 On Board Diagnosis Logic.......................................194 DTC Confirmation Procedure ..................................195 Overall Function Check ...........................................196 Wiring Diagram ........................................................197 Diagnostic Procedure ..............................................198 Component Inspection.............................................200 DTC P0140 HEATED OXYGEN SENSOR 2(REAR) (HIGH VOLTAGE)........................................................201 Component Description ...........................................201 CONSULT-II Reference Value in Data Monitor Mode ........................................................................201 ECM Terminals and Reference Value .....................201 On Board Diagnosis Logic.......................................201 DTC Confirmation Procedure ..................................202 Overall Function Check ...........................................202 Wiring Diagram ........................................................203 Diagnostic Procedure ..............................................204 Component Inspection.............................................205
(Cont’d)
DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER .........................................................207 Description ...............................................................207 CONSULT-II Reference Value in Data Monitor Mode ........................................................................207 ECM Terminals and Reference Value .....................207 On Board Diagnosis Logic.......................................207 DTC Confirmation Procedure ..................................208 Wiring Diagram ........................................................209 Diagnostic Procedure ..............................................210 Component Inspection.............................................211 DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE) ............................................212 On Board Diagnosis Logic.......................................212 DTC Confirmation Procedure ..................................212 Wiring Diagram ........................................................213 Diagnostic Procedure ..............................................214 DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE) .............................................218 On Board Diagnosis Logic.......................................218 DTC Confirmation Procedure ..................................218 Wiring Diagram ........................................................220 Diagnostic Procedure ..............................................221 DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE ...............224 On Board Diagnosis Logic.......................................224 DTC Confirmation Procedure ..................................224 Diagnostic Procedure ..............................................225 Component Inspection.............................................229 DTC P0325 KNOCK SENSOR (KS) ...........................230 Component Description ...........................................230 ECM Terminals and Reference Value .....................230 On Board Diagnosis Logic.......................................230 DTC Confirmation Procedure ..................................230 Wiring Diagram ........................................................231 Diagnostic Procedure ..............................................232 Component Inspection.............................................233 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD)..............................................................234 Component Description ...........................................234 ECM Terminals and Reference Value .....................234 On Board Diagnosis Logic.......................................234 DTC Confirmation Procedure ..................................235 Wiring Diagram ........................................................236 Diagnostic Procedure ..............................................237 Component Inspection.............................................238 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS).........................................................................239 Component Description ...........................................239 ECM Terminals and Reference Value .....................239 On Board Diagnosis Logic.......................................240 DTC Confirmation Procedure ..................................240
EC-3
CONTENTS Wiring Diagram ........................................................242 Diagnostic Procedure ..............................................243 Component Inspection.............................................245 DTC P0420 THREE WAY CATALYST FUNCTION ...246 On Board Diagnosis Logic.......................................246 DTC Confirmation Procedure ..................................246 Overall Function Check ...........................................247 Diagnostic Procedure ..............................................247 DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT).................250 Description ...............................................................250 CONSULT-II Reference Value in Data Monitor Mode ........................................................................250 ECM Terminals and Reference Value .....................251 On Board Diagnosis Logic.......................................251 DTC Confirmation Procedure ..................................251 Wiring Diagram ........................................................252 Diagnostic Procedure ..............................................253 Component Inspection.............................................254 DTC P0500 VEHICLE SPEED SENSOR (VSS) .........255 Component Description ...........................................255 ECM Terminals and Reference Value .....................255 On Board Diagnosis Logic.......................................255 DTC Confirmation Procedure ..................................255 Wiring Diagram ........................................................257 Diagnostic Procedure ..............................................260 DTC P0505 IDLE AIR CONTROL VALVE (IACV) AUXILIARY AIR CONTROL (AAC) VALVE ...............263 Description ...............................................................263 CONSULT-II Reference Value in Data Monitor Mode ........................................................................264 ECM Terminals and Reference Value .....................264 On Board Diagnosis Logic.......................................264 DTC Confirmation Procedure ..................................264 Wiring Diagram ........................................................265 Diagnostic Procedure ..............................................266 Component Inspection.............................................270 DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED) ......................................271 Component Description ...........................................271 CONSULT-II Reference Value in Data Monitor Mode ........................................................................271 ECM Terminals and Reference Value .....................271 On Board Diagnosis Logic.......................................271 DTC Confirmation Procedure ..................................272 Overall Function Check ...........................................272 Wiring Diagram ........................................................273 Diagnostic Procedure ..............................................274 Component Inspection.............................................276 DTC P0605 ECM .........................................................277 Component Description ...........................................277 On Board Diagnosis Logic.......................................277
(Cont’d)
DTC Confirmation Procedure ..................................277 Diagnostic Procedure ..............................................278 DTC P1217 OVERHEAT (COOLING SYSTEM) .........279 System Description..................................................279 CONSULT-II Reference Value in Data Monitor Mode ........................................................................280 ECM Terminals and Reference Value .....................280 On Board Diagnosis Logic.......................................280 Overall Function Check ...........................................281 Wiring Diagram ........................................................282 Diagnostic Procedure ..............................................284 Main 12 Causes of Overheating..............................288 Component Inspection.............................................289 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)..................................................290 Component Description ...........................................290 ECM Terminals and Reference Value .....................290 On Board Diagnosis Logic.......................................290 DTC Confirmation Procedure ..................................291 Wiring Diagram ........................................................292 Diagnostic Procedure ..............................................293 Component Inspection.............................................294 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE .............................................................................295 System Description..................................................295 ECM Terminals and Reference Value .....................295 On Board Diagnosis Logic.......................................295 DTC Confirmation Procedure ..................................295 Wiring Diagram ........................................................296 Diagnostic Procedure ..............................................297 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH .......................................................................298 Component Description ...........................................298 CONSULT-II Reference Value in Data Monitor Mode ........................................................................298 ECM Terminals and Reference Value .....................298 On Board Diagnosis Logic.......................................298 DTC Confirmation Procedure ..................................298 Overall Function Check ...........................................299 Wiring Diagram ........................................................300 Diagnostic Procedure ..............................................301 INJECTOR ...................................................................302 Component Description ...........................................302 CONSULT-II Reference Value in Data Monitor Mode ........................................................................302 ECM Terminals and Reference Value .....................302 Wiring Diagram ........................................................303 Diagnostic Procedure ..............................................304 Component Inspection.............................................305 IGNITION SIGNAL.......................................................306 Component Description ...........................................306
EC-4
CONTENTS CONSULT-II Reference Value in Data Monitor Mode ........................................................................306 ECM Terminals and Reference Value .....................306 Wiring Diagram ........................................................308 Diagnostic Procedure ..............................................309 Component Inspection.............................................310 START SIGNAL...........................................................312 CONSULT-II Reference Value in Data Monitor Mode ........................................................................312 ECM Terminals and Reference Value .....................312 Wiring Diagram ........................................................313 Diagnostic Procedure ..............................................314 FUEL PUMP.................................................................316 System Description..................................................316 Component Description ...........................................316 CONSULT-II Reference Value in Data Monitor Mode ........................................................................316 ECM Terminals and Reference Value .....................316 Wiring Diagram ........................................................317 Diagnostic Procedure ..............................................318 Component Inspection.............................................320 POWER STEERING OIL PRESSURE SWITCH.........321 Component Description ...........................................321 CONSULT-II Reference Value in Data Monitor Mode ........................................................................321 ECM Terminals and Reference Value .....................321 Wiring Diagram ........................................................322
(Cont’d)
Diagnostic Procedure ..............................................323 Component Inspection.............................................324 ELECTRICAL LOAD SIGNAL.....................................325 CONSULT-II Reference Value in Data Monitor Mode ........................................................................325 ECM Terminals and Reference Value .....................325 Wiring Diagram ........................................................326 MI & DATA LINK CONNECTORS ..............................329 Wiring Diagram ........................................................329
SERVICE DATA AND SPECIFICATIONS (SDS) .......330 Fuel Pressure Regulator..........................................330 Idle Speed and Ignition Timing................................330 Ignition Coil ..............................................................330 Mass Air Flow Sensor..............................................330 Engine Coolant Temperature Sensor ......................330 Fuel Pump ...............................................................330 IACV-AAC Valve ......................................................330 Injector .....................................................................330 Throttle Position Sensor ..........................................331 Heated Oxygen Sensor 1 (Front) Heater ................331 Intake Air Temperature Sensor................................331 EVAP Canister Purge Volume Control Valve ..........331 Heated Oxygen Sensor 1 (Rear) Heater.................331 Crankshaft Position Sensor (OBD)..........................331
EC-5
SR20DE
TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC
Alphabetical & P No. Index for DTC
NCEC0001
ALPHABETICAL INDEX FOR DTC
NCEC0001S01
DTC*6 Items (CONSULT-II screen terms)
Reference page
CONSULT-II GST*2
ECM*1
—
—
EC-SR-93
AIR TEMP SEN/CIRC *7
P0110
0110
EC-SR-127
A/T DIAG COMM LINE *7
P1605
1605
EC-SR-295
ATF TEMP SEN/CIRC *7
P0710
0710
Refer to AT section.
CAM POS SEN/CIRC
P0340
0340
EC-SR-239
CLOSED TP SW/CIRC *7
P0510
0510
EC-SR-271
COOLANT T SEN/CIRC
P0115
0115
EC-SR-132
CPS/CIRC (OBD) COG *7
P1336
1336
EC-SR-290
CPS/CIRCUIT (OBD) *7
P0335
0335
EC-SR-234
CYL 1 MISFIRE *7
P0301
0301
EC-SR-224
CYL 2 MISFIRE *7
P0302
0302
EC-SR-224
CYL 3 MISFIRE *7
P0303
0303
EC-SR-224
CYL 4 MISFIRE *7
P0304
0304
EC-SR-224
ECM *7
P0605
0605
EC-SR-277
ENGINE SPEED SIG *7
P0725
0725
Refer to AT section.
LINE PRESS SE *7
P1791
1791
Refer to AT section.
HO2S1 HTR (B1)
P0135
0135
EC-SR-175
HO2S1 (B1)
P0130
0130
EC-SR-144
HO2S1 (B1) *7
P0131
0131
EC-SR-150
HO2S1 (B1) *7
P0132
0132
EC-SR-156
HO2S1 (B1) *7
P0133
0133
EC-SR-162
HO2S1 (B1) *7
P0134
0134
EC-SR-170
FUEL SYS -LEAN/BK1 *7
P0171
0171
EC-SR-212
FUEL SYS -RICH/BK1 *7
P0172
0172
EC-SR-218
IACV/AAC VLV/CIRC *7
P0505
0505
EC-SR-263
IN PY SPD SEN/CIRC *7
P0715
0715
Refer to AT section.
KNOCK SEN/CIRC -B1
P0325
0325
EC-SR-230
L/PRESS SOL/CIRC *7
P0745
0745
Refer to AT section.
MAF SEN/CIRCUIT *3
P0100
0100
EC-SR-120
MULTI CYL MISFIRE *7
P0300
0300
EC-SR-224
P1610 - P1615
1610 - 1615
Refer to EL section.
NO SELF DIAGNOSTIC FAILURE INDICATED
P0000
0000
—
NO SELF DIAGNOSTIC FAILURE INDICATED
No DTC
Flashing*5
EC-SR-59
ENG OVER TEMP
P1217
1217
EC-SR-279
P-N POS SW/CIRCUIT *7
P1706
1706
EC-SR-298
Unable to access ECM
NATS MALFUNCTION
EC-6
TROUBLE DIAGNOSIS — INDEX
SR20DE
Alphabetical & P No. Index for DTC (Cont’d) DTC*6 Items (CONSULT-II screen terms)
Reference page
CONSULT-II GST*2
ECM*1
PNP SW/CIRC *7
P0705
0705
Refer to AT section.
PURG VOLUME CONT/V *7
P0443
0443
EC-SR-250
HO2S2 (B1) *7
P0137
0137
EC-SR-180
HO2S2 (B1) *7
P0138
0138
EC-SR-187
HO2S2 (B1) *7
P0139
0139
EC-SR-194
HO2S2 (B1) *7
P0140
0140
EC-SR-201
HO2S2 HTR (B1) *7
P0141
0141
EC-SR-207
STEP MOTOR CIRC -B1 *7
P1777
1777
Refer to AT section.
STEP MOTOR FNC *7
P1778
1778
Refer to AT section.
TCC SOLENOID/CIRC *7
P0740
0740
Refer to AT section.
THRTL POS SEN/CIRC *3
P0120
0120
EC-SR-137
TP SEN/CIRC A/T *7
P1705
1705
Refer to AT section.
TW CATALYST SYSTEM *7
P0420
0420
EC-SR-246
VEH SPD SEN/CIR AT *4 *7
P0720
0720
Refer to AT section.
VEH SPEED SEN/CIRC *4
P0500
0500
EC-SR-255
*1: *2: *3: *4:
In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO 15031-6. When the fail-safe operation occurs, the MI illuminates. The MI illuminates when the “Secondary speed sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. *5: While engine is running. *6: 1st trip DTC No. is the same as DTC No. *7: Not available for “Eastern Europe models”.
P NO. INDEX FOR DTC
NCEC0001S02
DTC*6 CONSULT-II GST*2
ECM*1
—
—
No DTC
Items (CONSULT-II screen terms)
Reference page
Unable to access ECM
EC-SR-93
Flashing*5
NO SELF DIAGNOSTIC FAILURE INDICATED
EC-SR-59
P0000
0000
NO SELF DIAGNOSTIC FAILURE INDICATED
—
P0100
0100
MAF SEN/CIRCUIT*3
EC-SR-120
P0110
0110
AIR TEMP SEN/CIRC *7
EC-SR-127
P0115
0115
COOLANT T SEN/CIRC *3
EC-SR-132
P0120
0120
THRTL POS SEN/CIRC *3
EC-SR-137
P0130
0130
HO2S1 (B1)
EC-SR-144
P0131
0131
HO2S1 (B1) *7
EC-SR-150
P0132
0132
HO2S1 (B1) *7
EC-SR-156
P0133
0133
HO2S1 (B1) *7
EC-SR-162
P0134
0134
HO2S1 (B1) *7
EC-SR-170
P0135
0135
HO2S1 HTR (B1) *7
EC-SR-175
EC-7
TROUBLE DIAGNOSIS — INDEX
SR20DE
Alphabetical & P No. Index for DTC (Cont’d) DTC*6 Items (CONSULT-II screen terms)
Reference page
CONSULT-II GST*2
ECM*1
P0137
0137
HO2S2 (B1) *7
EC-SR-180
P0138
0138
HO2S2 (B1) *7
EC-SR-187
P0139
0139
HO2S2 (B1) *7
EC-SR-194
P0140
0140
HO2S2 (B1) *7
EC-SR-201
P0141
0141
HO2S2 HTR (B1) *7
EC-SR-207
P0171
0171
FUEL SYS -LEAN/BK1 *7
EC-SR-212
P0172
0172
FUEL SYS -RICH/BK1 *7
EC-SR-218
P0300
0300
MULTI CYL MISFIRE *7
EC-SR-224
P0301
0301
CYL 1 MISFIRE *7
EC-SR-224
P0302
0302
CYL 2 MISFIRE *7
EC-SR-224
P0303
0303
CYL 3 MISFIRE *7
EC-SR-224
P0304
0304
CYL 4 MISFIRE *7
EC-SR-224
P0325
0325
KNOCK SEN/CIRC -B1
EC-SR-230
P0335
0335
CPS/CIRCUIT (POS) *7
EC-SR-234
P0340
0340
CAM POS SEN/CIRC
EC-SR-239
P0420
0420
TW CATALYST SYS -B1 *7
EC-SR-246
P0443
0443
PURG VOLUME CONT/V *7
EC-SR-250
P0500
0500
VEH SPEED SEN/CIRC *4
EC-SR-255
P0505
0505
IACV/AAC VLV/CIRC *7
EC-SR-263
P0510
0510
CLOSED TP SW/CIRC *7
EC-SR-271
P0605
0605
ECM *7
EC-SR-277
P0705
0705
PNP SW/CIRC *7
Refer to AT section.
P0710
0710
ATF TEMP SEN/CIRC *7
Refer to AT section.
P0715
0715
IN PY SPD SEN/CIRC *7
Refer to AT section.
P0720
0720
VEH SPD SEN/CIR AT *4 *7
Refer to AT section.
P0725
0725
ENGINE SPEED SIG *7
Refer to AT section.
P0740
0740
TCC SOLENOID/CIRC *7
Refer to AT section.
P0745
0745
L/PRESS SOL/CIRC *7
Refer to AT section.
P1217
1217
ENG OVER TEMP
EC-SR-279
P1336
1336
CPS/CIRC (OBD) COG *7
EC-SR-290
EC-8
TROUBLE DIAGNOSIS — INDEX
SR20DE
Alphabetical & P No. Index for DTC (Cont’d) P1605
1605
P1610 - 1615
1610 - 1615
P1705
A/T DIAG COMM LINE *7
EC-SR-295
NATS MALFUNCTION
Refer to EL section.
1705
TP SEN/CIRC A/T *7
Refer to AT section.
P1706
1706
P-N POS SW/CIRCUIT *7
P1777
1777
STEP MOTOR CIRC *7
Refer to AT section.
P1778
1778
STEP MOTOR FNC *7
Refer to AT section.
P1791
1791
LINE PRESS SE *7
Refer to AT section.
*1: *2: *3: *4:
EC-SR-298
In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO 15031-6. When the fail-safe operation occurs, the MI illuminates. The MI illuminates when the “Secondary speed sensor signal” and the “Vehicle speed sensor signal or ABS actuator and electric unit (control unit) signal” meet the fail-safe condition at the same time. *5: While engine is running. *6: 1st trip DTC No. is the same as DTC No. *7: Not available for “Eastern Europe models”.
EC-9
PRECAUTIONS
SR20DE
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
NCEC0002
The Supplemental Restraint System “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: I 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 dealer. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors).
Precautions for On Board Diagnostic (OBD) System of Engine and CVT
NCEC0003
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: I Be sure to turn the ignition switch “OFF” and disconnect the negative battery terminal before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. I 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.) I 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 EL section, “Description”, “HARNESS CONNECTOR”. I 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. I 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. I 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.
EC-10
SR20DE
PRECAUTIONS
Engine Fuel & Emission Control System
Engine Fuel & Emission Control System
NCEC0004
SEF331WB
EC-11
PRECAUTIONS
SR20DE
Precautions
Precautions
NCEC0005
I
Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned off.
I
When connecting or disconnecting ECM harness connector, use lever as shown. When connecting, fasten connector securely with lever moved until it stops.
I
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 terminals when connecting pin connectors.
I
Before replacing ECM, perform Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-SR-103.
I
After performing each TROUBLE DIAGNOSIS, perform “Overall Function Check” or “DTC Confirmation Procedure”. 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.
SEF289H
SEF908W
SEF291H
MEF040D
SAT652J
EC-12
SR20DE
PRECAUTIONS
Precautions (Cont’d)
I
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.
SEF348N
Wiring Diagrams and Trouble Diagnosis
NCEC0006
When you read Wiring diagrams, refer to the followings: I “HOW TO READ WIRING DIAGRAMS” in GI section I “POWER SUPPLY ROUTING” for power distribution circuit in EL section When you perform trouble diagnosis, refer to the followings: I “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” in GI section I “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” in GI section
EC-13
SR20DE
PREPARATION Special Service Tools
Special Service Tools Tool number Tool name
NCEC0007
Description
KV10117100 Heated oxygen sensor wrench
Loosening or tightening heated oxygen sensor 1 (front) with 22 mm (0.87 in) hexagon nut
NT379
KV10114400 Heated oxygen sensor wrench
Loosening or tightening heated oxygen sensor 2 (rear) a: 22 mm (0.87 in)
NT636
Commercial Service Tool Tool name
NCEC0008
Description
Fuel filler cap adapter
Checking fuel tank vacuum relief valve opening pressure
NT653
EC-14
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SR20DE
Engine Control Component Parts Location
Engine Control Component Parts Location
NCEC0009
Throttle position sensor IACV-AAC valve
Power steering oil pressure switch
Relay box
EVAP canister Mass air flow sensor and intake air temperature sensor
Heated oxygen sensor 1 (front) EVAP purge volume control solenoid valve
Ignition coil, power transistor & camshaft position sensor built into distributor Crankshaft position sensor
NEF235A
EC-15
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SR20DE
Engine Control Component Parts Location (Cont’d)
View from under the vehicle .
IACV-AAC valve Knock sensor harness connector
Knock sensor
.
Mass air flow sensor
Drive shaft
View from under the vehicle
Heated oxygen sensor 1 (front) harness connector
Radiator lower hose Crankshaft position sensor (OBD)
Heated oxygen sensor 1 (front)
NEF232A
EC-16
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SR20DE
Engine Control Component Parts Location (Cont’d) View from under the vehicle Front exhaust tube
ECM
Coolant temperature sensor harness connector
Glove box ECM harness connector Front
Heated oxygen sensor 2 (rear)
Fuel pump harness connector
Heated oxygen sensor 2 (rear)
Fuel tank gauge unit harness connector Under rear seat cushion Front exhaust tube
Power steering oil pressure switch Harness connector EVAP canister (LHD models)
Oil filler cap
EVAP canister purge volume control solenoid valve
SEF188X
EC-17
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SR20DE
Engine Control Component Parts Location (Cont’d)
Headlamp (Left side)
Intake manifold collector
Fuel pressure regulator
Front
Refrigerant pressure sensor and harness connector
Terminal for ignition coil
Power transistor
Camshaft position sensor, power transistor and ignition coil (built into distributor)
Camshaft position sensor Metal tip of ignition coil tower (Terminal of coil circuit) Terminal for camshaft position sensor and power transistor
NOTE: Power transistor, camshaft position sensor, and ignition coil have to be replaced as a distributor assembly.
SEF189X
EC-18
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SR20DE Circuit Diagram
Circuit Diagram
NCEC0010
YEC080A
EC-19
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SR20DE
System Diagram
System Diagram
NCEC0011
YEC117A
EC-20
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SR20DE
Vacuum Hose Drawing
Vacuum Hose Drawing
NCEC0012
Refer to “System Diagram” on EC-SR-20 for vacuum control system. NOTE: Do not use soapy water or any type of solvent while installing vacuum hoses or purge hoses. Rear view (Right side)
Rear view (Left side) Intake manifold collector
Intake manifold collector Throttle body
Fuel pressure regulator To brake booster
Air hose to power steering air valve EVAP purge line to engine
EVAP purge line to engine
Fuel filter
To EVAP canister (RHD models)
Front view EVAP purge volume control solenoid valve
EVAP canister (LHD models)
Power steering air valve
To intake manifold collector
To EVAP canister (LHD models) Air tube for power steering air valve
To EVAP canister (RHD models)
SEF191X
EC-21
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SR20DE
System Chart
System Chart Input (Sensor) I I I I I I I I I I I I I I I I I I I
Camshaft position sensor Mass air flow sensor Engine coolant temperature sensor Heated oxygen sensor 1 (front) Ignition switch Throttle position sensor PNP switch Air conditioner switch Knock sensor Crankshaft position sensor (OBD)*1 Battery voltage Power steering oil pressure switch Vehicle speed sensor or ABS actuator and electric unit (control unit) Intake air temperature sensor Heated oxygen sensor 2 (rear)*2 TCM (Transmission control module)*3 Closed throttle position switch Electrical load Refrigerant pressure sensor
NCEC0013
ECM Function
Output (Actuator)
Fuel injection & mixture ratio control
Injectors
Distributor ignition system
Power transistor
Idle air control system
IACV-AAC valve
Fuel pump control
Fuel pump relay
Heated oxygen sensor 1 (front) monitor & on board diagnostic system
Malfunction indicator (On the instrument panel)
Heated oxygen sensor 1 & 2 (front & rear) heater control
Heated oxygen sensor 1 & 2 heater (front & rear)
EVAP canister purge flow control
EVAP canister purge volume control solenoid valve
Cooling fan control
Cooling fan relay
Air conditioning cut control
Air conditioner relay
*1: These sensors are not used to control the engine system. They are used only for the on board diagnosis. *2: Under normal conditions, this sensor is not for engine control operation. *3: The DTC related to CVT will be sent to ECM.
EC-22
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
SR20DE
Multiport Fuel Injection (MFI) System
Multiport Fuel Injection (MFI) System DESCRIPTION Input/Output Signal Chart
NCEC0014 NCEC0014S01
Sensor
Input Signal to ECM
Camshaft position sensor
Engine speed and piston position
Mass air flow sensor
Amount of intake air
Engine coolant temperature sensor
Engine coolant temperature
Heated oxygen sensor 1 (front)
Density of oxygen in exhaust gas
Throttle position sensor
Throttle position Throttle valve idle position
PNP switch
Gear position
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Ignition switch
Start signal
Air conditioner switch
Air conditioner operation
Knock sensor
Engine knocking condition
Electrical load
Electrical load signal
Battery
Battery voltage
Power steering oil pressure switch
Power steering operation
Heated oxygen sensor 2 (rear)*
Density of oxygen in exhaust gas
ECM function
Fuel injection & mixture ratio control
Actuator
Injector
* Under normal conditions, this sensor is not for engine control operation.
Basic Multiport Fuel Injection System
NCEC0014S02
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 both the camshaft position sensor and the mass air flow sensor.
Various Fuel Injection Increase/Decrease Compensation
NCEC0014S03
In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. I During warm-up I When starting the engine I During acceleration I Hot-engine operation I When selector lever is changed from “N” to “D” (CVT models only) I High-load, high-speed operation I During deceleration I During high engine speed operation I During high vehicle speed operation (M/T models) I Extremely high engine coolant temperature
EC-23
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
SR20DE
Multiport Fuel Injection (MFI) System (Cont’d)
Mixture Ratio Feedback Control (Closed loop control)
NCEC0014S04
SEF336WA
The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The three way catalyst can then better reduce CO, HC and NOx emissions. This system uses a heated oxygen sensor 1 (front) in the exhaust manifold to monitor if the engine operation is rich or lean. The ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about the heated oxygen sensor 1 (front), refer to EC-SR-144. 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 (rear) is located downstream of the three way catalyst. Even if the switching characteristics of the heated oxygen sensor 1 (front) shift, the air-fuel ratio is controlled to stoichiometric by the signal from the heated oxygen sensor 2 (rear).
Open Loop Control
NCEC0014S05
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. I Deceleration and acceleration I High-load, high-speed operation I Malfunction of heated oxygen sensor 1 (front) or its circuit I Insufficient activation of heated oxygen sensor 1 (front) at low engine coolant temperature I High engine coolant temperature I During warm-up I When starting the engine
Mixture Ratio Self-learning Control
NCEC0014S06
The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the heated oxygen sensor 1 (front). 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 film) and characteristic changes during operation (i.e., 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 the heated oxygen sensor 1 (front) 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-24
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
SR20DE
Multiport Fuel Injection (MFI) System (Cont’d)
Fuel Injection Timing
NCEC0014S07
SEF337W
Two types of systems are used. Sequential Multiport Fuel Injection System NCEC0014S0701 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 NCEC0014S0702 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 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
NCEC0014S08
Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.
Distributor Ignition (DI) System DESCRIPTION Input/Output Signal Chart Sensor
NCEC0015 NCEC0015S01
Input Signal to ECM
Camshaft position sensor
Engine speed and piston position
Mass air flow sensor
Amount of intake air
Engine coolant temperature sensor
Engine coolant temperature
Throttle position sensor
Throttle position Throttle valve idle position
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Ignition switch
Start signal
Knock sensor
Engine knocking
PNP switch
Gear position
Battery
Battery voltage
ECM function
Actuator
Ignition timPower transistor ing control
EC-25
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
SR20DE
Distributor Ignition (DI) System (Cont’d)
System Description
NCEC0015S02
SEF742M
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. This data forms the map shown above. 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. e.g., N: 1,800 rpm, Tp: 1.50 msec A°BTDC During the following conditions, the ignition timing is revised by the ECM according to the other data stored in the ECM. I At starting I During warm-up I At idle I At low battery voltage I 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.
Air Conditioning Cut Control DESCRIPTION Input/Output Signal Chart Sensor
NCEC0016 NCEC0016S01
Input Signal to ECM
Air conditioner switch
Air conditioner “ON” signal
PNP switch
Neutral position
Throttle position sensor
Throttle valve opening angle
Camshaft position sensor
Engine speed
Engine coolant temperature sensor
Engine coolant temperature
Ignition switch
Start signal
Refrigerant pressure sensor
Refrigerant pressure
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Power steering oil pressure switch
Power steering operation
ECM function
Air conditioner cut control
System Description
Actuator
Air conditioner relay
NCEC0016S02
This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned off. I When the accelerator pedal is fully depressed. I When cranking the engine.
EC-26
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
SR20DE
Air Conditioning Cut Control (Cont’d)
I I I I
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.
Fuel Cut Control (at no load & high engine speed) DESCRIPTION Input/Output Signal Chart
NCEC0017 NCEC0017S01
Sensor
Input Signal to ECM
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
PNP switch
Neutral position
Throttle position sensor
Throttle position
Engine coolant temperature sensor
Engine coolant temperature
Camshaft position sensor
Engine speed
ECM function
Fuel cut control
Actuator
Injectors
If the engine speed is above 3,950 rpm with no load, (for example, in Neutral and engine speed over 4,000 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 1,150 rpm, then fuel cut is cancelled. NOTE: This function is different from deceleration control listed under “Multiport Fuel Injection (MFI) System”, EC-SR-23.
Evaporative Emission System DESCRIPTION
NCEC0018
Intake manifold Throttle body
Purge line
EVAP canister purge volume control solenoid valve Relief of vacuum
Sealing gas cap with pressure relief valve and vacuum relief valve
EVAP canister
Air Fuel vapor SEF916W
Fuel tank
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
EC-27
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
SR20DE
Evaporative Emission System (Cont’d)
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.
INSPECTION EVAP Canister
NCEC0019 NCEC0019S01
Check EVAP canister as follows: 1. Block port B. Orally blow air through port A. Check that air flows freely through port C with check valve resistance. 2. Block port A. Orally blow air through port B. Check that air flows freely through port C.
SEF917W
Fuel Tank Vacuum Relief Valve (Built into fuel fillerNCEC0019S03 cap) 1. 2.
SEF918W
3.
Wipe clean valve housing. Check valve opening pressure and vacuum. Pressure: 16.0 - 20.0 kPa (0.16 - 0.20 bar, 0.163 - 0.204 kg/cm2, 2.32 - 2.90 psi) Vacuum: −6.0 to −3.5 kPa (−0.060 to −0.035 bar, −0.061 to −0.036 kg/cm2, −0.87 to −0.51 psi) If out of specification, replace fuel filler cap as an assembly.
Evaporative Emission (EVAP) Canister Purge Volume Control Solenoid Valve NCEC0019S07 Refer to EC-SR-250.
SEF943S
EC-28
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
SR20DE
Evaporative Emission System (Cont’d)
EVAPORATIVE EMISSION LINE DRAWING
NCEC0020
NOTE: Do not use soapy water or any type of solvent while installing vacuum hoses or purge hoses. Rear view (Right side)
Rear view (Left side)
Intake manifold collector Intake manifold collector Throttle body
Fuel pressure regulator
To brake booster
Air hose to power steering air valve EVAP purge line to engine
EVAP purge line to engine
Fuel filter
To EVAP canister (RHD models)
Front view EVAP purge volume control solenoid valve
EVAP canister (LHD models) Power steering air valve
To intake manifold collector
To EVAP canister (LHD models) Air tube for power steering air valve
To EVAP canister (RHD models) SEF193X
EC-29
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
SR20DE
Positive Crankcase Ventilation
Positive Crankcase Ventilation DESCRIPTION
NCEC0022
SEF921W
This system returns blow-by gas to the intake collector. 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 duct 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 intake collector under all conditions.
INSPECTION PCV (Positive Crankcase Ventilation) Valve
NCEC0023 NCEC0023S01
With engine running at idle, remove PCV valve from breather separator. 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 the valve inlet.
SEC137A
Ventilation Hose 1. 2.
NCEC0023S02
Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.
ET277
EC-30
BASIC SERVICE PROCEDURE
SR20DE Fuel Pressure Release
Fuel Pressure Release
NCEC0024
Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.
WITH CONSULT-II 1. 2. 3. PEF823K
4.
WITHOUT CONSULT-II Fuel pump fuse
1. 2. 3. 4.
NCEC0024S01
Start engine. Perform “FUEL PRES RELEASE” in “WORK SUPPORT” mode with CONSULT-II. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. NCEC0024S02
Remove fuse for fuel pump. Refer to fuse block cover for fuse location. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF and reconnect fuel pump fuse.
Fuel pump relay
Data link connector
SEF192X
Fuel Pressure Check I I Fuel filter
SEF194X
I I I 1. 2. 3. 4. 5.
NCEC0025
When reconnecting fuel line, always use new clamps. Make sure that clamp screw does not contact adjacent parts. Use a torque driver to tighten clamps. Use Pressure Gauge to check fuel pressure. Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false readings. Release fuel pressure to zero. Disconnect fuel hose between fuel filter and fuel tube (engine side). Install pressure gauge between fuel filter and fuel tube. Start engine and check for fuel leakage. Read the indication of fuel pressure gauge. At idle speed: With vacuum hose connected Approximately 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) With vacuum hose disconnected Approximately 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi)
EC-31
BASIC SERVICE PROCEDURE
SR20DE
Fuel Pressure Regulator Check
If results are unsatisfactory, perform Fuel Pressure Regulator Check, EC-SR-32.
Fuel Pressure Regulator Check
NCEC0026
1.
SEF718B
Stop engine and disconnect fuel pressure regulator vacuum hose from intake manifold. 2. Plug intake manifold with a rubber cap. 3. Connect variable vacuum source to fuel pressure regulator. 4. Start engine and read indication of fuel pressure gauge as vacuum is changed. Fuel pressure should decrease as vacuum increases. If results are unsatisfactory, replace fuel pressure regulator. I Do not reuse O-ring.
Injector REMOVAL AND INSTALLATION 1. 2. 3. 4. 5. I I I 6. I I I I I I SEF927W
I 7. I 8. 9.
NCEC0027
Release fuel pressure to zero. Disconnect fuel hoses and injector harness connectors. Remove fuel tube assemblies with fuel injectors. Expand and remove clips securing fuel injectors. Extract fuel injectors straight from fuel tubes. Be careful not to damage injector nozzles during removal. Do not bump or drop fuel injectors. Do not disassemble or adjust fuel injectors. Install fuel injectors with extra care for O-rings. Do not reuse O-rings. Use bare hands to install O-rings. Do not wear gloves. Apply a coat of new engine oil (with a low viscosity of 5W-30, etc.) to O-rings before installation. Do not use solvent to clean O-rings and other parts. Make sure that O-rings and other parts are clean and free from foreign particles. Be careful not to damage O-rings with service tools, clip or finger nails. Do not expand or twist O-rings. If stretched, do not insert them into fuel tubes immediately after stretching. Always insert O-rings straight into fuel tubes. Do not tilt or rotate them during installation. Position clips in grooves on fuel injectors. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation. Align protrusions of fuel tubes with those of fuel injectors. Insert fuel injectors straight into fuel tubes. After properly inserting fuel injectors, check to make sure that fuel tube protrusions are engaged with those of fuel injectors, and that flanges of fuel tubes are engaged with clips.
EC-32
BASIC SERVICE PROCEDURE
SR20DE Injector (Cont’d)
I
Fuel tube
O-ring
Discard old clips; replace with new ones.
10. Install injectors with fuel tube assembly to intake manifold. I Pay extra care to prevent O-rings from being scratched by sharp edges. I Apply a coat of new engine oil to O-rings before installation.
Spacer Clip
Injector Apply engine oil.
SEF195X
SEF196X
11. Tighten fuel tube assembly mounting bolts in numerical sequence (indicated in the Figure at left) and in two stages. : Tightening torque N⋅m (kg-m, ft-lb) 1st stage: 9.4 - 10.7 (0.95 - 1.10, 83 - 95) 2nd stage: 21 - 26 (2.1 - 2.7, 16 - 19) 12. Insert fuel hoses into fuel tubes so that ends of fuel hoses butt up against fuel tubes; fasten with clamps, avoiding bulges. I Lubricate fuel hoses with a smear of silicone oil. 13. Reinstall any parts removed in reverse order of removal. CAUTION: After properly connecting fuel hose to injector and fuel tube assembly, check connection for fuel leakage.
EC-33
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment
NCEC0028
PREPARATION I a) b) c) d) e) f) g) h) i) j) k) I I I I I I I a) b) c) I
NCEC0028S01
Make sure that the following parts are in good order. Battery Ignition system Engine oil and coolant levels Fuses ECM harness connector Vacuum hoses Air intake system (Oil filler cap, oil level gauge, etc.) Fuel pressure Engine compression Throttle valve EVAP system On models equipped with air conditioner, checks should be carried out while the air conditioner is “OFF”. When checking idle speed on models equipped with CVT, ignition timing and mixture ratio, checks should be carried out while shift lever is in “P” or “N” position. When measuring “CO” percentage, insert probe more than 40 cm (15.7 in) into tail pipe. Turn off headlamps, heater blower, rear window defogger. On vehicles equipped with daytime running light systems, set lighting switch to the 1st position to light only small lamps. Keep front wheels pointed straight ahead. If engine stops immediately after starting or idle condition is unstable, perform the following to initialize IACV-AAC valve: Stop engine and wait 9 seconds. Turn ignition “ON” and wait 1 second. Turn ignition “OFF” and wait 9 seconds. Make the check after the cooling fan has stopped.
EC-34
SR20DE
BASIC SERVICE PROCEDURE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
Overall Inspection Sequence
NCEC0028S0101
INSPECTION
Perform diagnostic test mode II (Self-diagnostic results).
NG
Check ignition timing and idle speed.
Idle air volume learning.* COMPLETE
INCOMPLETE H Find reason for incompleteness, and remove.*
OK
Check heated oxygen sensor 1 (front) function.
Repair or replace.
NG
Check heated oxygen sensor 1 (front) harness.
NG Repair or replace harness.
OK
OK
Check CO%.
Replace front heated oxygen sensor.
NG
Check emission control parts and repair or replace if necessary.
NG
Check front heated oxygen sensor function.
OK
INSPECTION END
SEF104X
*: Refer to EC-SR-46.
EC-35
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
INSPECTION PROCEDURE 1
NCEC0028S02
INSPECTION START
1. Visually check the following: I Air cleaner clogging I Hoses and duct for leaks I Electrical connectors I Gasket (intake manifold, cylinder head, exhaust system) I Throttle valve and throttle position sensor operation 2. Start engine and warm it up until engine coolant temperature indicator points to the middle of gauge. Ensure engine speed stays below 1,000 rpm.
SEF935W
3. Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load. 4. Perform the Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-SR-61.
SAT652J
OK or NG OK
©
I GO TO 2. (With CONSULT-II) I GO TO 3. (Without CONSULT-II)
NG
©
1. Repair or replace components as necessary. 2. GO TO 2. (With CONSULT-II) 3. GO TO 3. (Without CONSULT-II)
EC-36
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
2
CHECK IGNITION TIMING
With CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Rev engine two or three times under no-load, then run engine at idle speed for about 1 minute.
SEF978U
3. Select “IGNITION TIMING ADJ” in WORK SUPPORT mode. 4. Touch “START”.
PEF546N
5. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. 6. Check ignition timing with a timing light.
BTDC
White painting
AEC804
15°±2° BTDC (in “P” or “N” position for CVT)
OK
©
I GO TO 5. (With CONSULT-II) I GO TO 6. (Without CONSULT-II)
NG
©
1. Perform “Idle air volume learning”. Refer to EC-SR-46 2. If still NG, GO TO 4.
EC-37
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
3
CHECK IGNITION TIMING
Without CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Rev engine two or three times under no-load, then run engine at idle speed for about 1 minute.
SEF978U
3. Turn off engine and disconnect throttle position sensor harness connector (CVT models only). Throttle position sensor harness connector
Throttle body
Closed throttle position switch harness connector (CVT models)
SEF197X
4. Start engine and rev it (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. 5. Check ignition timing with a timing light. BTDC
White painting
AEC804
15°±2° BTDC (in “P” or “N” position for CVT) OK or NG OK
©
GO TO 5.
NG
©
1. Perform “Idle air volume learning”. Refer to EC-SR-46. 2. If still NG, GO TO 4.
EC-38
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
4
ADJUST IGNITION TIMING
With CONSULT-II 1. Adjust ignition timing to the specified value by turning distributor after loosening bolts which secure distributor. Without CONSULT-II 1. Adjust ignition timing to the specified value by turning distributor after loosening bolts which secure distributor. 2. Turn off engine and connect throttle position sensor harness connector to throttle position sensor. (CVT models only) Throttle position sensor harness connector
Throttle body
Closed throttle position switch harness connector (CVT models) SEF197X
Models with CONSULT-II
©
GO TO 2.
Models without CONSULT-II
©
GO TO 3.
5
CHECK TARGET IDLE SPEED
With CONSULT-II 1. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. 2. Read idle speed in “DATA MONITOR” mode with CONSULT-II.
NEF059A
750±50 rpm (in “P” or “N” position for CVT) OK or NG OK
©
GO TO 8.
NG
©
1. Perform “Idle air volume learning”. Refer to EC-SR-46. 2. If still NG, GO TO 7.
EC-39
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
6
CHECK TARGET IDLE SPEED
Without CONSULT-II 1. Turn off engine and connect throttle position sensor harness connector (CVT models only). Throttle position sensor harness connector
Throttle body
Closed throttle position switch harness connector (CVT models) SEF197X
2. Start engine. 3. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. 4. Check target idle speed. 750±50 rpm (in “P” or “N” position for CVT) OK or NG OK
©
GO TO 8.
OK (Ignition timing NG)
©
GO TO 7.
NG
©
GO TO 7.
7
DETECT MALFUNCTIONING PART
Check the following. 1. Check closed throttle position switch idle position. Refer to EC-SR-84. 2. Check IACV-AAC valve and replace if necessary. Refer to EC-SR-263. 3. Check IACV-AAC valve harness and repair if necessary. Refer to EC-SR-263. 4. Perform “Idle air volume learning”. Refer to EC-SR-46. 5. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.)
©
GO TO 8.
EC-40
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
8
CHECK HEATED OXYGEN SENSOR 1 (FRONT) SIGNAL
With CONSULT-II 1. See “HO2S1 MNTR (B1)” in “DATA MONITOR” mode. 2. Run engine at about 2,000 rpm for about 2 minutes under no-load. 3. Maintain engine at 2,000 rpm under no-load (engine is warmed up to normal operating temperature) and check that the monitor fluctuates between “LEAN” and “RICH” more than five times during 10 seconds.
SEF820Y
1 cycle: RICH → LEAN → RICH 2 cycles: RICH → LEAN → RICH → LEAN → RICH Without CONSULT-II 1. Set “Heated oxygen sensor 1 (front) monitor” in the Diagnostic Test Mode II. (See page EC-SR-58.) Short terminals between “IGN” and “CHK” for 2 seconds or more. Then open the circuit.
SEF945W
2. Run engine at about 2,000 rpm for about 2 minutes under no-load (engine is warmed up to normal operating temperature). 3. Maintain engine at 2,000 rpm under no-load and check that MI goes on more than five times during 10 seconds.
SAT652J
OK or NG OK
©
INSPECTION END
NG
©
GO TO 9.
EC-41
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
9 1. 2. 3. 4.
CHECK HEATED OXYGEN SENSOR 1 (FRONT) HARNESS Turn off engine and disconnect battery ground cable. Disconnect ECM harness connector. Disconnect heated oxygen sensor 1 (front) harness connector. Then connect harness connector terminal for heated oxygen sensor 1 (front) to ground with a jumper wire. Heated oxygen sensor 1 (front) harness connector
MEF031DA
5. Check for continuity between terminal 62 of ECM harness connector and body ground. Continuity exists...OK Continuity does not exist...NG OK or NG OK
©
1. Connect ECM harness connector to ECM. 2. GO TO 10.
NG
©
1. Repair or replace harness. 2. GO TO 5. (With CONSULT-II) 3. GO TO 6. (Without CONSULT-II)
EC-42
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
10 1. 2. 3. 4.
PREPARATION FOR “CO” % CHECK With CONSULT-II Connect ECM harness connector to ECM. Connect battery ground cable. Select “ENGINE COOLANT TEMP” in “ACTIVE TEST” mode. Set “COOLANT TEMP” to 5°C (41°F) by touching “Qu” and “Qd” and “UP”, “DOWN”.
NEF061A
Without CONSULT-II 1. Connect ECM harness connector to ECM. 2. Disconnect engine coolant temperature sensor harness connector. 3. Connect a resistor (4.4 kΩ) between terminals of engine coolant temperature sensor harness connector.
Engine coolant temperature sensor harness connector
4.4 kΩ resistor
4. Connect battery ground cable.
©
GO TO 11.
EC-43
SEF053RA
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
11
CHECK “CO” %
1. Start engine and warm it up until engine coolant temperature indicator points to middle of gauge. (Be sure to start engine after setting “COOLANT TEMP” or installing a 4.4 kΩ resistor.)
SEF935W
2. Rev engine two or three times under no-load, then run engine at idle speed.
SEF978U
3. Check “CO”%. Idle CO: Less than 11% and engine runs smoothly. 4. Without CONSULT-II After checking CO%, stop engine and a. Disconnect the resistor from terminals of engine coolant temperature sensor harness connector. b. Connect engine coolant temperature sensor harness connector to engine coolant temperature sensor. OK or NG OK
©
GO TO 12.
NG
©
GO TO 13.
12
CHECK HEATED OXYGEN SENSOR 1 (FRONT) SIGNAL
With CONSULT-II 1. Replace heated oxygen sensor 1 (front). 2. See “HO2S1 MNTR (B1)” in “DATA MONITOR” mode. 3. Maintain engine at 2,000 rpm under no-load (engine is warmed up to normal operating temperature.). Check that the monitor fluctuates between “LEAN” and “RICH” more than five times during 10 seconds. 1 cycle: RICH → LEAN → RICH 2 cycles: RICH → LEAN → RICH → LEAN → RICH Without CONSULT-II 1. Replace heated oxygen sensor 1 (front). 2. Set “Heated oxygen sensor 1 (front) monitor” in the Diagnostic Test Mode II. (See page EC-SR-61.) 3. Maintain engine at 2,000 rpm under no-load. Check that the malfunction indicator goes on and off more than five times during 10 seconds. OK or NG OK
©
GO TO 5. (With CONSULT-II) GO TO 6. (Without CONSULT-II)
NG
©
GO TO 13.
EC-44
BASIC SERVICE PROCEDURE
SR20DE
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)
13
DETECT MALFUNCTIONING PART
1. Connect heated oxygen sensor 1 (front) harness connector to heated oxygen sensor 1 (front). 2. Check fuel pressure regulator. Refer to EC-SR-32. 3. Check mass air flow sensor and its circuit. Refer to EC-SR-120. 4. Check injector and its circuit. Refer to EC-SR-302. Clean or replace if necessary. 5. Check engine coolant temperature sensor and its circuit. Refer to EC-SR-132. 6. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.)
©
GO TO 5. (With CONSULT-II) GO TO 6. (Without CONSULT-II)
I
If a vehicle contains a part which is operating outside of design specifications with no MI illumination, the part shall not be replaced prior to emission testing unless it is determined that the part has been tampered with or abused in such a way that the diagnostic system cannot reasonably be expected to detect the resulting malfunction.
EC-45
BASIC SERVICE PROCEDURE
SR20DE
Idle Air Volume Learning
Idle Air Volume Learning
NCEC0541
DESCRIPTION
NCEC0541S01
“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: I Each time IACV-AAC valve, throttle body or ECM is replaced. I Idle speed or ignition timing is out of specification.
PRE-CONDITIONING SEF712X
SEF713X
OPERATION PROCEDURE With CONSULT-II SEF714X
NCEC0541S04
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. I Battery voltage: More than 12.9V (At idle) I Engine coolant temperature: 70 - 94°C (158 - 201°F) I PNP switch: ON I Electric load switch: OFF (Air conditioner, headlamp, rear window defogger) On vehicles equipped with daytime running light systems, set lighting switch to the 1st position to light only small lamps. I Cooling fan motor: Not operating I Steering wheel: Neutral (Straight-ahead position) I Vehicle speed: Stopped I Transmission : Warmed up For CVT models with CONSULT-II, drive vehicle until “FLUID TEMP SE” in “DATA MONITOR” mode of “CVT” system indicates less than 0.9V. For CVT models without CONSULT-II and M/T models, drive vehicle for 10 minutes.
1. 2. 3. 4. 5. 6. 7.
8.
NCEC0541S02 NCEC0541S0201
Start engine and warm it up to normal operating temperature. Check that all items listed under the topic “Pre-Conditioning” (previously mentioned) are in good order. Turn ignition switch “OFF” and wait at least 9 seconds. Start the engine and allow it to idle for at least 28 seconds. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode. Touch “START” and wait 20 seconds. Make sure that “CMPLT” is displayed on CONSULT-II screen. If “INCMP” is displayed, “Idle Air Volume Learning” will not be carried out successfully. In this case, find the cause of the problem by referring to the NOTE below. Rev up the engine two or three times. Make sure that idle speed and ignition timing are within specifications.
ITEM
SPECIFICATION
Idle speed
750 ± 50rpm (in “P” or “N” position for CVT)
Ignition timing
15 ± 2° BTDC
EC-46
BASIC SERVICE PROCEDURE
SR20DE Idle Air Volume Learning (Cont’d)
Throttle body
Throttle position sensor harness connector
Without CONSULT-II 1. 2. 3. 4. 5.
Closed throttle position switch harness connector (CVT models) SEF197X
6. 7.
8.
NCEC0541S0202
Start engine and warm it up to normal operating temperature. Check that all items listed under the topic “Pre-Conditioning” (previously mentioned) are in good order. Turn ignition switch “OFF” and wait at least 9 seconds. Start the engine and allow it to idle for at least 28 seconds. Disconnect throttle position sensor harness connector (brown), then re-connect it within 5 seconds. (CVT models only) Wait 20 seconds. Make sure that the idle speed is within specifications. If not, the result will be incomplete. In this case, find the cause of the problem by referring to the NOTE below. Rev up the engine two or three times. Make sure that idle speed and ignition timing are within specifications.
ITEM
SPECIFICATION
Idle speed
750 ± 50rpm (in “P” or “N” position for CVT)
Ignition timing
15 ± 2° BTDC
NOTE: I If idle air volume learning cannot be performed successfully, proceed as follows: a) Check the throttle valve is fully closed. b) Check that downstream of throttle valve is free from air leakage. c) Adjust closed throttle position switch and reset memory. (Refer to Basic Inspection, EC-SR-84.) d) When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the problem. e) If any of the following conditions occur after the engine has started, eliminate the cause of the problem and perform “Idle air volume learning” all over again: I Engine stalls. I Erroneous idle. I Blown fuses related to the IACV-AAC valve system.
EC-47
SR20DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Introduction
Introduction
NCEC0029
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: Diagnostic Trouble Code (DTC)
Mode 3 of ISO 15031-5
Freeze Frame data
Mode 2 of ISO 15031-5
System Readiness Test (SRT) code
Mode 1 of ISO 15031-5
1st Trip Diagnostic Trouble Code (1st Trip DTC)
Mode 7 of ISO 15031-5
1st Trip Freeze Frame data Test values and Test limits
Mode 6 of ISO 15031-5
Calibration ID
Mode 9 of ISO 15031-5
The above information can be checked using procedures listed in the table below. X: Applicable
—: Not applicable
DTC
1st trip DTC
Freeze Frame data
1st trip Freeze Frame data
SRT code
Test value
ECM*3
X
X*1
—
—
—
—
CONSULT-II*4
X
X
X
X
X
—
GST*4
X
X*2
X
—
X
X
*1: *2: *3: *4:
When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other. 1st trip DTCs for self-diagnoses concerning SRT items cannot be shown on the GST display. In diagnostic test mode II (Self-diagnostic results), DTC is displayed on MI. DTC uses a set of four digit numbers. In SELF-DIAGNOSTIC RESULTS mode, DTC is displayed. DTC uses “P” and a set of four digit numbers.
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-SR-93.)
Two Trip Detection Logic
NCEC0030
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. X: Applicable MI
DTC
1st trip
Items
—: Not applicable 1st trip DTC
2nd trip 1st trip displaying
2nd trip displaying
1st trip displaying
2nd trip displaying
—
X
—
X
—
X
—
—
X
—
—
X
—
—
X*1
—
X*1
—
—
—
X
—
X
X
X
Blinking
Lighting up
Blinking
Lighting up
Misfire (Possible three way catalyst damage) — DTC: P0300 - P0304 (0300 - 0304) is being detected
X
—
—
Misfire (Possible three way catalyst damage) — DTC: P0300 - P0304 (0300 - 0304) has been detected
—
—
Fail-safe items (Refer to ECSR-93.)
—
Except above
—
*1: Except “ECM”.
EC-48
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Emission-related Diagnostic Information
Emission-related Diagnostic Information DTC AND 1ST TRIP DTC
NCEC0031 NCEC0031S01
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 “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”. Refer to EC-SR-56. For malfunctions in which 1st trip DTCs are displayed, refer to EC-SR-54. 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 Mode 7 of ISO 15031-5. 1st trip DTC detection occurs without lighting up the MI and therefore does not warn the driver of a problem. 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 II, refer to page EC-SR-82. Then perform “DTC Confirmation Procedure” or “Overall Function Check” to try to duplicate the problem. If the malfunction is duplicated, the item requires repair.
How to read DTC and 1st Trip DTC
NCEC0031S0101
DTC and 1st trip DTC can be read by the following methods. 1) No Tools The number of blinks of MI in the Diagnostic Test Mode II (Self-Diagnostic Results) Examples: 0340, 1320, 0705, 0750, etc. These DTCs are controlled by NISSAN. 2) With CONSULT-II With GST CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P1320, P0705, P0750, etc. These DTCs are prescribed by ISO 15031-6. (CONSULT-II also displays the malfunctioning component or system.) I 1st trip DTC No. is the same as DTC No. I Output of a DTC indicates a malfunction. However, Mode II and GST 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 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]”.
1st trip DTC display
DTC display
NEF065A
EC-49
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Emission-related Diagnostic Information (Cont’d)
FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA
NCEC0031S02
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 and absolute pressure sensor 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-SR-71. 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
Items Freeze frame data
2 3
Misfire — DTC: P0300 - P0304 (0300 - 0304) Fuel Injection System Function — DTC: P0171 (0171), P0172 (0172) Except the above items (Includes CVT related items)
1st trip freeze frame data
For example, the CVT 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 CVT 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 “HOW TO ERASE EMISSIONRELATED DIAGNOSTIC INFORMATION”. Refer to EC-SR-56.
SYSTEM READINESS TEST (SRT) CODE
NCEC0031S03
System Readiness Test (SRT) code is specified in Mode 1 of ISO 15031-5. It indicates whether the self-diagnostic tests for non-continuously monitored items have been completed or not. Inspection/Maintenance (I/M) tests of the on board diagnostic (OBD) II system may become the legal requirements in some states/areas. All SRT codes must be set in this case. Unless all SRT codes are set, conducting the I/M test may not be allowed. SRT codes are set after self-diagnosis has been performed one or more times. This occurs regardless of whether the diagnosis is in “OK” or “NG”, and whether or not the diagnosis is performed in consecutive trips. The following table lists the four SRT items (14 test items) for the ECM used in P11 models. SRT items
Self-diagnostic test items
Catalyst monitoring
I Three way catalyst function P0420 (0420)
Oxygen sensor monitoring
I I I I I I I I I
Oxygen sensor heater monitoring
I Heated oxygen sensor 1 (front) heater P0135 (0135) I Heated oxygen sensor 2 (rear) heater P0141 (0141)
Heated Heated Heated Heated Heated Heated Heated Heated Heated
oxygen oxygen oxygen oxygen oxygen oxygen oxygen oxygen oxygen
sensor sensor sensor sensor sensor sensor sensor sensor sensor
EC-50
1 1 1 1 1 2 2 2 2
(front) (Circuit) P0130 (0130) (front) (Lean shift monitoring) P0131 (0131) (front) (Rich shift monitoring) P0132 (0132) (front) (Response monitoring) P0133 (0133) (front) (High voltage) P0134 (0134) (rear) (Min. voltage monitoring) P0137 (0137) (rear) (Max. voltage monitoring) P0138 (0138) (rear) (Response monitoring) P0139 (0139) (rear) (High voltage) P0140 (0140)
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Emission-related Diagnostic Information (Cont’d)
Together with the DTC, the SRT code is cleared from the ECM memory using the method described later (Refer to EC-SR-56). In addition, after engine control components/system are repaired or if the battery terminals remain disconnected for more than 24 hours, all SRT codes may be cleared from the ECM memory.
How to Display SRT Code 1.
NCEC0031S0301
With CONSULT-II Selecting “SRT STATUS” in “DTC 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 as shown below.
NEF249A
2.
With GST Selecting Mode 1 with GST (Generic Scan Tool)
How to Set SRT Code
NCEC0031S0302
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. 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-51
HO2S HTR
HO2S
EC-52
Pattern 1
*1
Engine coolant temperature becomes 70°C (158°F). Engine start [Engine coolant temperature is below 50°C (122°F).]
0 km/h (0 MPH)
26 - 96 km/h (53 - 60 MPH)
*2
HO2S2 HTR
HO2S1 HTR
HO2S2
Keep idling
TW CATALYST SYS
CATALYST
HO2S1
Self-diagnostic test item (CONSULT-II screen term)
Zone A
Zone B
Pattern 2
Note: Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws. Refer to next page for more information and explanation of chart.
SRT item (CONSULT-II screen term)
Driving pattern
Engine stop
(minutes)
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION SR20DE
Emission-related Diagnostic Information (Cont’d)
Driving Pattern NCEC0031S0303
NEF234A
SR20DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Emission-related Diagnostic Information (Cont’d)
I
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: I The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F) (where the voltage between the ECM terminals 70 and 58 is 3.0 - 4.3V). I 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 terminals 70 and 58 is lower than 1.4V). Pattern 2: I 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 CONSULT-II or GST is advised. Suggested transmission gear position for CVT models Set the selector lever in the “D” position with “SPORTS MODE SW” “OFF” or without “MANUAL MODE”. Suggested upshift speeds for M/T models Shown below are suggested vehicle speeds for shifting into a higher gear. These suggestions relate to fuel economy and vehicle performance. Actual upshift speeds will vary according to road conditions, the weather and individual driving habits. Gear change
ACCEL shift point km/h (MPH)
1st to 2nd
15 (9)
2nd to 3rd
35 (22)
3rd to 4th
50 (31)
4th to 5th
70 (43)
TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)
NCEC0031S04
The following is the information specified in Mode 6 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. Items for which these data (test value and test limit) are displayed are the same as SRT code items (6 test items). 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. X: Applicable
—: Not applicable
Test value (GST display) SRT item
CATALYST
Self-diagnostic test item
Test limit
Application
01H
Max.
X
81H
Min.
X
TID
CID
01H 02H
Three way catalyst function
EC-53
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Emission-related Diagnostic Information (Cont’d) Test value (GST display) SRT item
Self-diagnostic test item
Heated oxygen sensor 1 (front)
HO2S
Heated oxygen sensor 2 (rear)
Heated oxygen sensor 1 (front) heater
Test limit
Application
04H
Max.
X
0AH
84H
Min.
X
0BH
04H
Max.
X
0CH
04H
Max.
X
0DH
04H
Max.
X
19H
86H
Min.
X
1AH
86H
Min.
X
1BH
06H
Max.
X
1CH
06H
Max.
X
29H
08H
Max.
X
2AH
88H
Min.
X
2DH
0AH
Max.
X
2EH
8AH
Min.
X
TID
CID
09H
HO2S HTR Heated oxygen sensor 2 (rear) heater
EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS
NCEC0031S05
X: Applicable DTC*4 Items (CONSULT-II screen terms)
SRT code
Test value/Test limit 1st trip DTC*4 (GST only)
—: Not applicable Reference page
CONSULT-II GST*2
ECM*1
NO SELF DIAGNOSTIC FAILURE INDICATED
P0000
0000
—
—
—
—
MAF SEN/CIRCUIT
P0100
0100
—
—
X
EC-SR-120
AIR TEMP SEN/CIRC *5
P0110
0110
—
—
X
EC-SR-127
COOLANT T SEN/CIRC
P0115
0115
—
—
X
EC-SR-132
THRTL POS SEN/CIRC
P0120
0120
—
—
X
EC-SR-137
HO2S1 (B1)
P0130
0130
X
X
X*3
EC-SR-144
HO2S1 (B1)*5
P0131
0131
X
X
X*3
EC-SR-150
HO2S1 (B1)*5
P0132
0132
X
X
X*3
EC-SR-156
HO2S1 (B1)*5
P0133
0133
X
X
X*3
EC-SR-162
HO2S1 (B1)*5
P0134
0134
X
X
X*3
EC-SR-170
HO2S1 HTR (B1)*5
P0135
0135
X
X
X*3
EC-SR-175
HO2S2 (B1) *5
P0137
0137
X
X
X*3
EC-SR-180
HO2S2 (B1) *5
P0138
0138
X
X
X*3
EC-SR-187
HO2S2 (B1) *5
P0139
0139
X
X
X*3
EC-SR-194
HO2S2 (B1) *5
P0140
0140
X
X
X*3
EC-SR-201
HO2S2 HTR (B1) *5
P0141
0141
X
X
X*3
EC-SR-207
FUEL SYS LEAN/BK1*5
P0171
0171
—
—
X
EC-SR-212
FUEL SYS RICH/BK1 *5
P0172
0172
—
—
X
EC-SR-218
MULTI CYL MISFIRE *5
P0300
0300
—
—
X
EC-SR-224
EC-54
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Emission-related Diagnostic Information (Cont’d) DTC*4 Items (CONSULT-II screen terms)
SRT code
Test value/Test limit 1st trip DTC*4 (GST only)
Reference page
CONSULT-II GST*2
ECM*1
CYL 1 MISFIRE *5
P0301
0301
—
—
X
EC-SR-224
CYL 2 MISFIRE *5
P0302
0302
—
—
X
EC-SR-224
CYL 3 MISFIRE *5
P0303
0303
—
—
X
EC-SR-224
CYL 4 MISFIRE *5
P0304
0304
—
—
X
EC-SR-224
KNOCK SEN/CIRC-B1
P0325
0325
—
—
—
EC-SR-230
CPS/CIRCUIT (OBD) *5
P0335
0335
—
—
X
EC-SR-234
CAM POS SEN/CIRC
P0340
0340
—
—
X
EC-SR-239
TW CATALYST SYS-B1 *5
P0420
0420
X
X
X*3
EC-SR-246
PURG VOLUME CONT/V *5
P0443
0443
—
—
X
EC-SR-250
VEH SPEED SEN/CIRC
P0500
0500
—
—
X
EC-SR-255
IACV/AAC VLV/CIRC *5
P0505
0505
—
—
X
EC-SR-263
CLOSED TP SW/CIRC *5 *6
P0510
0510
—
—
X
EC-SR-271
ECM *5
P0605
0605
—
—
X
EC-SR-277
PNP SW/CIRC *5
P0705
0705
—
—
X
AT section
ATF TEMP SEN/CIRC *5
P0710
0710
—
—
X
AT section
IN PY SPD SEN/CIRC *5
P0715
0715
—
—
X
AT section
VEH SPD SEN/CIR AT *5
P0720
0720
—
—
X
AT section
ENGINE SPEED SIG *5
P0725
0725
—
—
X
AT section
TCC SOLENOID/CIRC *5
P0740
0740
—
—
X
AT section
L/PRESS SOL/CIRC *5
P0745
0745
—
—
X
AT section
ENG OVER TEMP
P1217
1217
—
—
X
EC-SR-279
CPS/CIRC (OBD) COG *5
P1336
1336
—
—
X
EC-SR-290
A/T DIAG COMM LINE *5
P1605
1605
—
—
X
EC-SR-295
TP SEN/CIRC A/T *5
P1705
1705
—
—
X
AT section
P-N POS SW/CIRCUIT *5
P1706
1706
—
—
X
EC-SR-298
STEP MOTOR CIRC *5
P1777
1777
—
—
X
AT section
STEP MOTOR FNC *5
P1778
1778
—
—
X
AT section
LINE PRESSURE SEN *5
P1791
1791
—
—
X
AT section
*1: *2: *3: *4: *5: *6:
In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO 15031-6. These are not displayed with GST. 1st trip DTC No. is the same as DTC No. Not available for “Eastern Europe models”. CVT models only
EC-55
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Emission-related Diagnostic Information (Cont’d)
HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC (With CONSULT-II)
NCEC0031S06 NCEC0031S0601
NOTE: If the diagnostic trouble code is not for CVT related items (see EC-SR-6), 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 9 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.) I 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).
EC-56
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Emission-related Diagnostic Information (Cont’d)
SEF950W
The emission-related diagnostic information can be erased by selecting “ERASE” in the “SELF-DIAG RESULTS” mode with CONSULT-II.
How to Erase DTC (With GST)
NCEC0031S0602
NOTE: If the diagnostic trouble code is not for CVT related items (see EC-SR-6), skip step 2. 1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” (engine stopped) again. 2. Perform “SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II)” in AT section titled “TROUBLE DIAGNOSIS”, “Self-diagnosis”. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) 3. Select Mode 4 with GST (Generic Scan Tool). The emission-related diagnostic information can be erased by selecting Mode 4 with GST (Generic Scan Tool).
EC-57
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Emission-related Diagnostic Information (Cont’d)
How to Erase DTC (No Tools)
NCEC0031S0603
NOTE: If the diagnostic trouble code is not for CVT related items (see EC-SR-6), skip step 2. 1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” again. 2. Perform “SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II)” in AT section titled “TROUBLE DIAGNOSIS”, “Self-diagnosis”. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) 3. Change the diagnostic test mode from Mode II to Mode I by using the data link connector. (See EC-SR61.) The emission-related diagnostic information can be erased by changing the diagnostic test mode from Diagnostic Test Mode II to Mode I by using the data link connector. (Refer to EC-SR-61.) NOTE: I If the battery is disconnected, the emission-related diagnostic information will be lost after approx. 24 hours. I Erasing the emission-related diagnostic information using CONSULT-II or GST is easier and quicker than switching the mode using the data link connector. I The following data are cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data 4) 1st trip freeze frame data 5) System readiness test (SRT) codes 6) Test values 7) Distance traveled while MI is activated 8) Others 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) NATS (NISSAN ANTI-THEFT SYSTEM)
SEF543X
I I I
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 NATS (Nissan Anti-Theft System) in EL section. 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 with CONSULT-II using NATS program card. Therefore, be sure to receive all keys from vehicle owner. Regarding the procedure of NATS initilialization and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.
EC-58
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Malfunction Indicator (MI) (Cont’d)
DESCRIPTION
NCEC0032
SAT652J
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. I If the MI does not light up, refer to EL section (“WARNING LAMPS”) or see EC-SR-329. 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.
On Board Diagnostic System Function
NCEC0032S01
The on board diagnostic system has the following four functions. Diagnostic Test Mode I 1. BULB CHECK: This function checks the MI bulb for damage (blown, open circuit, etc.). If the MI does not come on, check MI circuit and ECM test mode selector. (See the following page.) 2. 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. I “Misfire (Possible three way catalyst damage)” I “Closed loop control” I Fail-safe mode Diagnostic Test Mode II 3. SELF-DIAGNOSTIC RESULTS: This function allows DTCs and 1st trip DTCs to be read. 4. HEATED OXYGEN SENSOR 1 (FRONT) MONITOR: This function allows the fuel mixture condition (lean or rich), monitored by heated oxygen sensor 1 (front), to be read. MI Flashing without DTC NCEC0032S0101 If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM test mode following “HOW TO SWITCH DIAGNOSTIC TEST MODES”. How to switch the diagnostic test (function) modes, and details of the above functions are described later. (Refer to EC-SR-61.) Condition
Diagnostic Test Mode I
Diagnostic Test Mode II
BULB CHECK
SELF-DIAGNOSTIC RESULTS
MALFUNCTION WARNING
HEATED OXYGEN SENSOR 1 (FRONT) MONITOR
Engine stopped Ignition switch in “ON” position Engine running
The following emission-related diagnostic information is cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data
EC-59
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator (MI) (Cont’d)
4) 5) 6) 7) 8)
1st trip freeze frame data System readiness test (SRT) codes Test values Distance traveled while MI is activated Others
EC-60
SR20DE
SR20DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator (MI) (Cont’d)
How to Switch Diagnostic Test Modes
NCEC0032S02
NG
Check MI circuit. *1
Turn ignition switch “ON” (Do not start engine.)
Repair harness or connector.
OK
Mode I - MALFUNCTION INDICATOR LAMP CHECK. *2 MI should come on.
NG Diagnostic Test Mode I — MALFUNCTION WARNING Start engine.
NG
NG
Repair harness or connectors.
Check MI and DDL circuits. *3
Data link connector
OK OK
Connect CHK and IGN terminals with a suitable harness. MI should come off.
Check ECM fail-safe. *4 OK
OK Wait at least 2 seconds.
Data link connector
Disconnect the suitable harness between CHK and IGN terminals.
DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS (ERASING ECM MEMORY)
Data link connector
Start engine
Diagnostic Test Mode II — HEATED OXYGEN SENSOR 1 (FRONT) MONITOR
● Switching the modes is not possible when the
engine is running. ● When ignition switch is turned off during
diagnosis, power to ECM will drop after approx. 9 seconds. The diagnosis will automatically return to Diagnostic Test Mode I. Wait at least 2 seconds.
Data link connector
*1: EC-SR-329 *2: EC-SR-59
If the suitable harness is disconnected at this time, the diagnostic trouble code will be erased from the backup memory in the ECM.
*3: EC-SR-329
EC-61
*4: EC-SR-93
SEF951W
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Malfunction Indicator (MI) (Cont’d)
Diagnostic Test Mode I — Bulb Check
NCEC0032S03
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the MI bulb. Refer to EL section (“WARNING LAMPS”) or see EC-SR-329.
Diagnostic Test Mode I — Malfunction Warning MI
I
NCEC0032S04
Condition
ON
When the malfunction is detected or the ECM’s CPU is malfunctioning.
OFF
No malfunction.
These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS).
Diagnostic Test Mode II — Self-diagnostic Results
NCEC0032S05
In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI. 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 or GST. A DTC will be used as an example for how to read a code.
SEF952W
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 1000th-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 latter 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 TROUBLE DIAGNOSIS — INDEX, EC-SR-6.) How to Erase Diagnostic Test Mode II (Self-diagnostic results) NCEC0032S0501 The DTC can be erased from the backup memory in the ECM when the diagnostic test mode is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to “HOW TO SWITCH DIAGNOSTIC TEST MODES”.) I If the battery is disconnected, the DTC will be lost from the backup memory after approx. 24 hours. I Be careful not to erase the stored memory before starting trouble diagnoses.
EC-62
SR20DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator (MI) (Cont’d)
Diagnostic Test Mode II — Front Heated Oxygen Sensor Monitor
NCEC0032S06
In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated oxygen sensor 1 (front). 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 (front) 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
NCEC0033
RELATIONSHIP BETWEEN MI, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS I I I I
I
NCEC0033S01
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 “Two Trip Detection Logic” on EC-SR-48. The MI will go off after the vehicle is driven 3 times 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 MI (goes off) DTC, Freeze Frame Data (no display) 1st Trip DTC (clear) 1st Trip Freeze Frame Data (clear)
NCEC0033S02
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-SR-65. For details about patterns “A” and “B” under “Other”, see EC-SR-67. *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-63
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
OBD System Operation Chart (Cont’d)
RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE” <EXHAUST QUALITY DETERIORATION>, “FUEL INJECTION SYSTEM”
NCEC0033S03
SEF392S
*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
EC-64
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.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
OBD System Operation Chart (Cont’d)
EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” Driving Pattern B
NCEC0033S04 NCEC0033S0401
Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. I The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. I The B counter will be counted up when driving pattern B is satisfied without any malfunction. I The MI will go off when the B counter reaches 3. (*2 in EC-SR-64)
Driving Pattern C
NCEC0033S0402
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) × (1±0.1) [%] Engine coolant temperature (T) condition: I When the freeze frame data shows lower than 70°C (158°F), “T” should be lower than 70°C (158°F). I 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) I The C counter will be cleared when the malfunction is detected regardless of driving pattern C. I The C counter will be counted up when driving pattern C is satisfied without the same malfunction. I The DTC will not be displayed after C counter reaches 80. I The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC is stored in ECM.
EC-65
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
OBD System Operation Chart (Cont’d)
RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” NCEC0033S05
SEF393S
*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
EC-66
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.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
OBD System Operation Chart (Cont’d)
EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” NCEC0033S06 Driving Pattern A NCEC0033S0601
AEC574
I I I
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
NCEC0033S0602
Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. I The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. I The B counter will be counted up when driving pattern B is satisfied without any malfunctions. I The MI will go off when the B counter reaches 3 (*2 in EC-SR-66).
EC-67
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
CONSULT-II
CONSULT-II Fuel pump fuse
CONSULT-II INSPECTION PROCEDURE
=NCEC0034 NCEC0034S01
1. 2.
Turn ignition switch OFF. Connect “CONSULT-II” to data link connector. (Data link connector is located behind the fuse box cover.)
3. 4.
Turn ignition switch ON. Touch “START”.
5.
Touch “ENGINE”.
Fuel pump relay
Data link connector
SEF192X
PBR455D
PEF895K
6.
Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual.
PEF216U
EC-68
SR20DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d)
ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION NCEC0034S02 DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS
ENGINE CONTROL COMPONENT PARTS
Item
INPUT
WORK SUPPORT
DATA MONITOR
DATA MONITOR (SPEC)
X
X
X
X
X
X
DTC CONFIRMATION ACTIVE TEST
SRT STATUS
DTC WORK SUPPORT
DTC*1
FREEZE FRAME DATA*2
Camshaft position sensor
X
X
Mass air flow sensor
X
Engine coolant temperature sensor
X
Heated oxygen sensor 1 (front)
X
X
X
X
X
Heated oxygen sensor 2 (rear)
X
X
X
X
X
Vehicle speed sensor or ABS actuator and electric unit (control unit)
X
X
X
Throttle position sensor
X
X
X
Intake air temperature sensor
X
X
X
Crankshaft position sensor (OBD)
X
X
X
Knock sensor
X X
X
X
X
Closed throttle position switch (throttle position sensor signal)
X
X
Air conditioner switch
X
X
Refrigerant pressure sensor
X
X
X
X
Power steering oil pressure switch
X
X
Battery voltage
X
X
Electrical load
X
X
Ignition switch (start signal) Closed throttle position switch
Park/Neutral position (PNP) switch
X
X
EC-69
X
X
X
X
SR20DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS WORK SUPPORT
Item
DTC*1
FREEZE FRAME DATA*2
ENGINE CONTROL COMPONENT PARTS
Injectors
DATA MONITOR
DATA MONITOR (SPEC)
ACTIVE TEST
X
X
X
Power transistor (Ignition timing)
X
X (Ignition signal)
X
X
X
IACV-AAC valve
X
X
X
X
X
X
X
X
X
X
X
X
X
EVAP canister purge volume control solenoid valve OUTPUT
DTC CONFIRMATION
Air conditioner relay Fuel pump relay
X
SRT STATUS
X
Heated oxygen sensor 1 (front) heater
X
X
X
X
Heated oxygen sensor 2 (rear) heater
X
X
X
X
Cooling fan
X
X
X
X
X
Calculated load value
X
DTC WORK SUPPORT
X
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-SR-50.
FUNCTION Diagnostic test mode
NCEC0034S03
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.*1
Data monitor
Input/Output data in the ECM can be read.
Data monitor (spec)
Input/Output specifications of the basic fuel schedule, AFM, A/F feedback control value and the other data monitor items 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.
DTC confirmation
The status of system monitoring tests and the self-diagnosis status/result can be confirmed.
ECM part number
ECM part numbers can be read.
*1 The following emission-related diagnostic information is cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data 4) 1st trip freeze frame data 5) System readiness test (SRT) codes 6) Test values 7) Distance traveled while MI is activated 8) Others
EC-70
SR20DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d)
WORK SUPPORT MODE WORK ITEM
NCEC0034S04
CONDITION
USAGE
IGNITION TIMING ADJ
I IGNITION TIMING FEEDBACK CONTROL WILL BE HELD BY TOUCHING “START”. AFTER DOING SO, ADJUST IGNITION TIMING WITH A TIMING LIGHT BY TURNING THE CAMSHAFT POSITION SENSOR.
When adjusting initial ignition timing
FUEL PRESSURE RELEASE
I FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS.
When releasing fuel pressure from fuel line
TARGET IDLE RPM ADJ
I IDLE CONDITION
When setting target idle speed
TARGET IGNITION TIMING ADJ
I IDLE CONDITION
When adjusting target ignition timing After adjustment, confirm target ignition timing with a timing light.
SELF DIAGNOSTIC MODE DTC and 1st Trip DTC
NCEC0034S05 NCEC0034S0501
Regarding items of “DTC and 1st trip DTC”, refer to “TROUBLE DIAGNOSIS — INDEX”, EC-SR-6.
Freeze Frame Data and 1st Trip Freeze Frame Data NCEC0034S0502 Freeze frame data item*
Description
DIAG TROUBLE CODE [PXXXX]
I Engine Control component part/control system has a trouble code, it is displayed as “PXXXX”. [Refer to “Alphabetical & P No. Index for DTC” (EC-SR-6).]
FUEL SYS DATA
I “Fuel injection system status” at the moment a malfunction is detected is displayed. I One mode in the following is displayed. “MODE 2”: Open loop due to detected system malfunction “MODE 3”: Open loop due to driving conditions (power enrichment, deceleration enrichment) “MODE 4”: Closed loop - using oxygen sensor(s) as feedback for fuel control “MODE 5”: Open loop - has not yet satisfied condition to go to closed loop
CAL/LD VALUE [%]
I The calculated load value at the moment a malfunction is detected is displayed.
COOLANT TEMP [°C] or [°F]
I The engine coolant temperature at the moment a malfunction is detected is displayed.
S-FUEL TRIM [%]
I “Short-term fuel trim” at the moment a malfunction is detected is displayed. I The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule.
L-FUEL TRIM [%]
I “Long-term fuel trim” at the moment a malfunction is detected is displayed. I The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim.
ENGINE SPEED [rpm] I The engine speed at the moment a malfunction is detected is displayed. VHCL SPEED [km/h] or [mph]
I The vehicle speed at the moment a malfunction is detected is displayed.
*: The items are the same as those of 1st trip freeze frame data.
EC-71
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
CONSULT-II (Cont’d)
DATA MONITOR MODE Monitored item [Unit]
ECM input signals
NCEC0034S06
Main signals
Description
Remarks I Accuracy becomes poor if engine speed drops below the idle rpm. I If the signal is interrupted while the engine is running, an abnormal value may be indicated.
ENG SPEED [rpm]
q
q
I Indicates the engine speed computed from the REF signal (180° signal) of the camshaft position sensor.
MAS A/F SE-B1 [V]
q
q
I The signal voltage of the mass air flow sensor is displayed.
I When the engine is stopped, a certain value is indicated. I 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.
COOLAN TEMP/S [°C] or [°F]
q
q
I The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed.
HO2S1 (B1) [V]
q
q
I The signal voltage of the heated oxygen sensor 1 (front) is displayed.
HO2S2 (B1) [V]
q
I The signal voltage of the heated oxygen sensor 2 (rear) is displayed.
q
I Display of heated oxygen sensor 1 (front) 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]
q
I Display of heated oxygen sensor 2 (rear) signal: RICH ... means the amount of oxygen I When the engine is stopped, a cerafter three way catalyst is relatively tain value is indicated. small. LEAN ... means the amount of oxygen after three way catalyst is relatively large.
VHCL SPEED SE [km/h] or [mph]
q
BATTERY VOLT [V]
q
THRTL POS SEN [V]
q
INT/A TEMP SE [°C] or [°F]
q
START SIGNAL [ON/OFF]
q
HO2S1 MNTR (B1) [RICH/LEAN]
q
I The vehicle speed computed from the vehicle speed sensor signal or ABS actuator and electric unit (control unit) signal is displayed. I The power supply voltage of ECM is displayed.
q
I The throttle position sensor signal voltage is displayed. I The intake air temperature determined by the signal voltage of the intake air temperature sensor is indicated.
q
I Indicates [ON/OFF] condition from the starter signal. I Indicates mechanical contact [ON/OFF] condition of the closed throttle position switch.
CLSD THL/P SW [ON/OFF] CLSD THL POS [ON/OFF]
q
I After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. I When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously.
q
I Indicates idle position [ON/OFF] computed by ECM according to the throttle position sensor signal.
EC-72
I After starting the engine, [OFF] is displayed regardless of the starter signal.
SR20DE
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d) ECM input signals
Main signals
AIR COND SIG [ON/OFF]
q
q
I Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioning signal.
P/N POSI SW [ON/OFF]
q
q
I Indicates [ON/OFF] condition from the PNP switch signal.
q
I Indicates [ON/OFF] condition of the power steering oil pressure switch determined by the power steering oil pressure switch signal.
q
I Indicates [ON/OFF] condition from the electrical load signal and/or lighting switch. ON ... rear defogger is operating and/or lighting switch is on. OFF ... rear defogger is not operating and lighting switch is not on.
Monitored item [Unit]
PW/ST SIGNAL [ON/OFF]
q
Description
LOAD SIGNAL [ON/OFF]
q
IGNITION SW [ON/OFF]
q
I Indicates [ON/OFF] condition from ignition switch.
HEATER FAN SW [ON/OFF]
q
I Indicates [ON/OFF] condition from the heater fan switch.
INJ PULSE -B1 [msec]
q
I Indicates the actual fuel injection pulse I When the engine is stopped, a cerwidth compensated by ECM according to tain computed value is indicated. the input signals. I “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction.
B/FUEL SCHDL [msec]
IGN TIMING [BTDC]
q
I Indicates the ignition timing computed by ECM according to the input signals.
IACV-AAC/V [step]
q
I Indicates the IACV-AAC valve control value computed by ECM according to the input signals.
A/F ALPHA -B1 [%]
q
I Indicates the mean value of the air-fuel ratio feedback correction factor per cycle.
AIR COND RLY [ON/OFF]
q
I Indicates the air conditioner relay control condition determined by ECM according to the input signals.
FUEL PUMP RLY [ON/OFF]
q
I Indicates the fuel pump relay control condition determined by ECM according to the input signals.
q
I Indicates the control condition of the cooling fan determined by ECM according to the input signals. HI ... High speed operation LOW ... Low speed operation OFF ... Stop
COOLING FAN [HI/LOW/OFF]
HO2S1 HTR (B1) [ON/OFF]
Remarks
I Indicates [ON/OFF] condition of heated oxygen sensor 1 (front) heater determined by ECM according to the input signals.
EC-73
I When the engine is stopped, a certain value is indicated. I This data also includes the data for the air-fuel ratio learning control.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
CONSULT-II (Cont’d)
Monitored item [Unit]
ECM input signals
Main signals
Description
HO2S2 HTR (B1) [ON/OFF]
I Indicates [ON/OFF] condition of heated oxygen sensor 2 (rear) heater determined by ECM according to the input signals.
PURG VOL C/V [%]
I Indicates the EVAP canister purge volume control solenoid valve computed by the ECM according to the input signals. I The opening becomes larger as the value increases.
CAL/LD VALUE [%]
I “Calculated load value” indicates the value of the current airflow divided by peak airflow.
ABSOL TH⋅P/S [%]
I “Absolute throttle position sensor” indicates the throttle opening computed by ECM according to the signal voltage of the throttle position sensor.
MASS AIRFLOW [gm/s]
I Indicates the mass airflow computed by ECM according to the signal voltage of the mass air flow sensor.
IDL A/V LEAN
I 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. INCMP...Idle air volume learning has not been performed successfully.
TRVL AFTER MIL [km] or [Mile]
I Distance traveled while MI is activated
VOLTAGE [V]
I Voltage measured by the voltage probe.
I Pulse width, frequency or duty cycle measured by the pulse probe.
PULSE [msec] or [Hz] or [%]
Remarks
I Only “#” is displayed if item is unable to be measured. I Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured.
DATA MONITOR (SPEC) MODE Monitored item [Unit]
MAS A/F SE-B1 [V]
ECM input signals
Main signals
q
q
Description
NLEC1365S07
Remarks
I The signal voltage of the mass air flow sen- I When the engine is running, specifisor specification is displayed. cation range is indicated.
B/FUEL SCHDL [msec]
I “Base fuel schedule” indicates the fuel injecI When the engine is running, specifition pulse width programmed into ECM, cation range is indicated. prior to any learned on board correction.
A/F ALPHA-B1 [%]
I When the engine is running, specifiI Indicates the mean value of the air-fuel ratio cation range is indicated. feedback correction factor per cycle. I This data also includes the data for the air-fuel ratio learning control.
q
NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
EC-74
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE CONSULT-II (Cont’d)
ACTIVE TEST MODE TEST ITEM
CONDITION
NCEC0034S07
JUDGEMENT
CHECK ITEM (REMEDY)
FUEL INJECTION
I Engine: Return to the original trouble condition If trouble symptom disappears, see I Change the amount of fuel injec- CHECK ITEM. tion using CONSULT-II.
I Harness and connector I Fuel injectors I Heated oxygen sensor 1 (front)
IACV-AAC/V OPENING
I Engine: After warming up, idle the engine. I Change the IACV-AAC valve opening steps using CONSULTII.
Engine speed changes according to the opening steps.
I Harness and connector I IACV-AAC valve
ENG COOLANT TEMP
I Engine: Return to the original trouble condition I Change the engine coolant temperature indication using CONSULT-II.
If trouble symptom disappears, see CHECK ITEM.
I Harness and connector I Engine coolant temperature sensor I Fuel injectors
IGNITION TIMING
I Engine: Return to the original trouble condition I Timing light: Set I Retard the ignition timing using CONSULT-II.
If trouble symptom disappears, see CHECK ITEM.
I Adjust initial ignition timing
POWER BALANCE
I Engine: After warming up, idle the engine. I Air conditioner switch “OFF” I Shift lever “N” I Cut off each injector signal one at a time using CONSULT-II.
Engine runs rough or dies.
I I I I I I
COOLING FAN
I Ignition switch: ON I Turn the cooling fan “ON” and “OFF” using CONSULT-II.
Cooling fan moves and stops.
I Harness and connector I Cooling fan motor
FUEL PUMP RELAY
I Ignition switch: ON (Engine stopped) I Turn the fuel pump relay “ON” and “OFF” using CONSULT-II and listen to operating sound.
Fuel pump relay makes the operating sound.
I Harness and connector I Fuel pump relay
Harness and connector Compression Injectors Power transistor Spark plugs Ignition coils
SELF-LEARNING I In this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by touching CONT “CLEAR” on the screen.
PURG VOL CONT/V
I Engine: After warming up, idle the engine. I Change the EVAP canister purge Engine speed changes according volume control solenoid valve to the opening percent. opening percent using CONSULT-II.
IDLE AIR VOL LEARN
I In this test, the idle air volume that keeps the engine within the specified range is memorized in ECM.
DTC CONFIRMATION MODE SRT STATUS Mode
I Harness and connector I EVAP canister purge volume control solenoid valve
NCEC0034S08 NCEC0034S0801
For details, refer to “SYSTEM READINESS TEST (SRT) CODE”, EC-SR-49.
SRT Work Support Mode This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status.
EC-75
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
CONSULT-II (Cont’d)
DTC Work Support Mode TEST MODE
Heated oxygen sensor 1 (front)
TEST ITEM
CONDITION
REFERENCE PAGE
HO2S1 (B1) P0130
EC-SR-144
HO2S1 (B1) P0131
EC-SR-150
HO2S1 (B1) P0132
Refer to corresponding trouble diagnosis for DTC.
HO2S1 (B1) P0133 HO2S2 (B1) P0137 Heated oxygen sensor 2 (rear)
NCEC0034S0802
EC-SR-156 EC-SR-162 EC-SR-180
HO2S2 (B1) P0138
EC-SR-187
HO2S2 (B1) P0139
EC-SR-194
REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA) NCEC0034S10
SEF705Y
SEF707X
CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1) “AUTO TRIG” (Automatic trigger): I 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 left, and the data after the malfunction detection is recorded. Then when the percentage reached is 100%, “REAL-TIME DIAG” screen is displayed. If “STOP” is touched on the screen during “Recording Data...xx%”, “REALTIME DIAG” screen is also displayed. 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): I 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. Use these triggers as follows: 1) “AUTO TRIG” I 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. I While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO TRIG)” mode, especially in case the incident is intermittent.
EC-76
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE CONSULT-II (Cont’d)
2) I
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 GI section, “Incident Simulation Tests” in “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.
SEF720X
EC-77
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Generic Scan Tool (GST)
Generic Scan Tool (GST) DESCRIPTION
NCEC0035 NCEC0035S01
Generic Scan Tool (OBDII scan tool) complying with ISO 15031-4 ISO 15031-4 has 9 different functions explained on the next page. ISO9141 is used as the protocol. The name “GST” or “Generic Scan Tool” is used in this service manual.
SEF139P
GST INSPECTION PROCEDURE Fuel pump fuse
1. 2.
NCEC0035S02
Turn ignition switch OFF. Connect “GST” to data link connector. (Data link connector is located under the fuse box cover.)
Fuel pump relay
Data link connector
SEF192X
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.)
SEF398S
5.
Perform each diagnostic mode according to each service procedure. For further information, see the GST Operation Manual of the tool maker.
SEF416S
EC-78
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SR20DE
Generic Scan Tool (GST) (Cont’d)
FUNCTION Diagnostic test mode
NCEC0035S03
Function
MODE 1
READINESS TESTS
This mode gains access to current emission-related data values, including analog inputs and outputs, digital inputs and outputs, distance traveled while MI is activated and system status information.
MODE 2
(FREEZE DATA)
This mode gains access to emission-related data value which were stored by ECM during the freeze frame. [For details, refer to “Freeze Frame Data” (EC-SR-68).]
MODE 3
DTCs
This mode gains access to emission-related power train trouble codes which were stored by ECM.
MODE 4
CLEAR DIAG INFO
This mode can clear all emission-related diagnostic information. This includes: I Clear number of diagnostic trouble codes (MODE 1) I Clear diagnostic trouble codes (MODE 3) I Clear trouble code for freeze frame data (MODE 1) I Clear freeze frame data (MODE 2) I Reset status of system monitoring test (MODE 1) I Clear on board monitoring test results (MODE 6 and 7)
MODE 6
(ON BOARD TESTS)
This mode accesses the results of on board diagnostic monitoring tests of specific components/systems that are not continuously monitored.
MODE 7
(ON BOARD TESTS)
This mode enables the off board test drive to obtain test results for emission-related powertrain components/systems that are continuously monitored during normal driving conditions.
MODE 8 MODE 9
— (CALIBRATION ID)
This mode is not applicable on this vehicle. This mode enables the off-board (External test equipment) to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs.
EC-79
TROUBLE DIAGNOSIS — INTRODUCTION
SR20DE
Introduction
Introduction
MEF036D
SEF233G
NCEC0036
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 problems such as vacuum leaks, fouled spark plugs, or other problems with the engine. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems 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 problems. A road test with CONSULT-II (or GST) or a circuit tester connected should be performed. Follow the “Work Flow” on EC-SR-82. 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 problems, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “Diagnostic Worksheet” like the example on next page should be used. Start your diagnosis by looking for “conventional” problems first. This will help troubleshoot driveability problems on an electronically controlled engine vehicle.
SEF234G
DIAGNOSTIC WORKSHEET KEY POINTS WHAT ..... WHEN ..... WHERE ..... HOW .....
Vehicle & engine model Date, Frequencies Road conditions Operating conditions, Weather conditions, Symptoms SEF907L
NCEC0036S01
There are many operating conditions that lead to the malfunction of engine components. A good grasp of such conditions can make trouble-shooting faster and more accurate. In general, each customer feels differently about a problem. 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 malfunction indicator to come on steady or blink and DTC to be detected. Example: Vehicle ran out of fuel, which caused the engine to misfire.
EC-80
TROUBLE DIAGNOSIS — INTRODUCTION
SR20DE Introduction (Cont’d)
Worksheet Sample
NCEC0036S0101
MTBL0311
EC-81
TROUBLE DIAGNOSIS — INTRODUCTION
SR20DE
Work Flow
Work Flow
NCEC0037
SEF510ZD
*1: If the incident cannot be duplicated, refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. *2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to “TROUBLE DIAGNOSIS FOR POWER SUPPLY”, EC-SR-115.
*3: If time data of “SELF-DIAG RESULTS” is other than “0” or “1t” refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. *4: If the malfunctioning part cannot
EC-82
be found, refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. *5: EC-SR-93 *6: EC-SR-52 *7: EC-SR-110
TROUBLE DIAGNOSIS — INTRODUCTION
SR20DE Work Flow (Cont’d)
DESCRIPTION FOR WORK FLOW STEP
NCEC0037S01
DESCRIPTION
STEP I
Get detailed information about the conditions and the environment when the incident/symptom occurred using the “DIAGNOSTIC WORK SHEET”, EC-SR-82.
STEP II
Before confirming the concern, check and write down (print out using CONSULT-II or Generic Scan Tool) the (1st trip) Diagnostic Trouble Code (DTC) and the (1st trip) freeze frame data, then erase the code and the data. (Refer to EC-SR-49.) The (1st trip) DTC and the (1st trip) freeze frame data can be used when duplicating the incident at STEP III & IV. Study the relationship between the cause, specified by (1st trip) DTC, and the symptom described by the customer. (The “Symptom Matrix Chart” will be useful. See EC-SR-94.) Also check related service bulletins for information.
STEP III
Try to confirm the symptom and under what conditions the incident occurs. The “DIAGNOSTIC WORK SHEET” and the freeze frame data are useful to verify the incident. Connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to GI section.) If the malfunction code is detected, skip STEP IV and perform STEP V.
STEP IV
Try to detect the (1st trip) Diagnostic Trouble Code by driving in (or performing) the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE”. Check and read the (1st trip) DTC and (1st trip) freeze frame data by using CONSULT-II or Generic Scan Tool. During the (1st trip) DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to GI section.) In case the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” is not available, perform the “OVERALL FUNCTION CHECK” instead. The (1st trip) DTC cannot be displayed by this check, however, this simplified “check” is an effective alternative. The “NG” result of the “OVERALL FUNCTION CHECK” is the same as the (1st trip) DTC detection.
STEP V
Take the appropriate action based on the results of STEP I through IV. If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC PXXXX. If the normal code is indicated, proceed to the BASIC INSPECTION. (Refer to EC-SR-84.) If CONSULT-II is available, perform “DATA MONITOR (SPEC)” mode with CONSULT-II and proceed to the “TROUBLE DIAGNOSIS-SPECIFICATION VALUE”. (Refer to EC-SR-110.) (If malfunction is detected, proceed to “REPAIR/ REPLACE”). Then perform inspections according to the Symptom Matrix Chart. (Refer to EC-SR-94.)
STEP VI
Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) “Harness Layouts”. Gently shake the related connectors, components or wiring harness with CONSULT-II set in “DATA MONITOR (AUTO TRIG)” mode. Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II. Refer to EC-SR-103. The “DIAGNOSTIC PROCEDURE” in EC section contains a description based on open circuit inspection. A short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details, refer to GI section (“HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”, “Circuit Inspection”). Repair or replace the malfunction parts.
STEP VII
Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions and circumstances which resulted in the customer’s initial complaint. Perform the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” and confirm the normal code [Diagnostic trouble code No. P0000 or 0000] is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the previous one. Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) (1st trip) DTC in ECM. (Refer to EC-SR-49.)
EC-83
TROUBLE DIAGNOSIS — BASIC INSPECTION
SR20DE
Basic Inspection
Basic Inspection
NCEC0038
Precaution: Perform Basic Inspection without electrical or mechanical loads applied; I Headlamp switch is OFF, I On vehicles equipped with daytime running light systems, set lighting switch to the 1st position to light only small lamps. I Air conditioner switch is OFF, I Rear window defogger switch is OFF, I Steering wheel is in the straight-ahead position, etc. 1
INSPECTION START
1. Check service records for any recent repairs that may indicate a related problem, or the current need for scheduled maintenance. 2. Open engine hood and check the following: I Harness connectors for improper connections I Vacuum hoses for splits, kinks, or improper connections I Wiring for improper connections, pinches, or cuts I Air cleaner clogging I Hoses and ducts for leaks
SEF983U
©
2
GO TO 2.
CHECK THROTTLE DRUM OPERATION
Confirm that throttle drum is in contact with stopper. OK or NG OK (With CONSULT-II)
©
GO TO 5.
OK (Without CONSULT-II)
©
GO TO 8.
NG
©
GO TO 3.
3
CHECK ACCELERATOR WIRE INSTALLATION
Check accelerator wire for slack. OK or NG OK
©
GO TO 4.
NG
©
Adjust accelerator wire. Refer to FE-section, “Adjusting Accelerator Wire”.
4
CHECK THROTTLE VALVE OPERATION
1. Remove intake air ducts. 2. Check throttle valve operation when moving throttle drum by hand. OK or NG OK
©
Retighten the throttle drum fixing nuts.
NG
©
Clean the throttle body and throttle valve.
EC-84
TROUBLE DIAGNOSIS — BASIC INSPECTION
SR20DE Basic Inspection (Cont’d)
5 1. 2. 3. 4. 5.
CHECK THROTTLE POSITION SENSOR IDLE POSITION With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Turn ignition switch “ON”. Select ”THRTL POS SEN” and “CLSD THL POS” in “DATA MONITOR” mode with CONSULT-II. Make sure that “THRTL POS SEN” indicates 0.35 to 0.65 V, and “CLSD THL POS” indicates “ON”. (Accelerator pedal is fully released.)
NEF238A
OK or NG OK
©
GO TO 11.
NG
©
GO TO 6.
6
ADJUSTMENT THROTTLE POSITION SENSOR IDLE POSITION
With CONSULT-II 1. Loosen throttle position sensor fixing bolts. 2. Turn throttle position sensor body clockwise or counterclockwise until “THRTL POS SEN” indication becomes 0.35 to 0.65 V.
SEF964W
3. Tighten the throttle position sensor fixing bolts. ©
GO TO 7.
EC-85
TROUBLE DIAGNOSIS — BASIC INSPECTION
SR20DE
Basic Inspection (Cont’d)
7
RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY
With CONSULT-II NOTE: Always warm up engine to normal operating temperature. If engine is cold, the throttle position sensor idle position memory will not reset correctly. 1. Start engine and warm it up to normal operating temperature. 2. Select “CLSD THL POS” in “DATA MONITOR” mode with CONSULT-II. 3. Stop engine. (Turn ignition switch “OFF”.) 4. Turn ignition switch “ON” and wait at least 5 seconds.
or
SEF864V
5. Turn ignition switch “OFF” and wait at least 5 seconds. 6. Repeat steps 4 and 6 until “CLSD THL POS” indication changes to “ON”.
SEF061Y
©
8 1. 2. 3. 4.
GO TO 11.
CHECK THROTTLE POSITION SENSOR IDLE POSITION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Turn ignition switch “ON”. Check voltage between ECM terminal 92 and ground with accelerator pedal fully released.
NEF239A
Voltage: 0.35 to 0.65V OK or NG OK
©
GO TO 6.
NG
©
GO TO 9.
EC-86
SR20DE
TROUBLE DIAGNOSIS — BASIC INSPECTION
Basic Inspection (Cont’d)
9
ADJUST THROTTLE POSITION SENSOR IDLE POSITION
Without CONSULT-II 1. Loosen throttle position sensor fixing bolts. 2. Turn throttle position sensor body clockwise or counterclockwise until the voltage between ECM terminal 92 and ground becomes 0.35 to 0.65 V.
SEF964W
3. Tighten the throttle position sensor fixing bolts. ©
10
GO TO 10.
RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY
Without CONSULT-II NOTE: Always warm up engine to normal operating temperature. If engine is cold, the throttle position sensor idle position memory will not reset correctly. 1. Start engine and warm it up to normal operating temperature. 2. Stop engine. (Turn ignition switch “OFF”.) 3. Turn ignition switch “ON” and wait at least 5 seconds.
SEF864V
4. Turn ignition switch “OFF” and wait at least 9 seconds. 5. Repeat steps 4 and 6, 20 times. ©
11
GO TO 11.
CHECK (1ST TRIP) DTC
1. Start engine and warm it up to normal operating temperature. 2. Rev (2,000 to 3,000 rpm) two or three times. 3. Make sure no (1st trip) DTC is displayed with CONSULT-II, GST or Diagnostic Test Mode II (Self-diagnostic Result). OK or NG OK
©
GO TO 13.
NG
©
GO TO 12.
EC-87
TROUBLE DIAGNOSIS — BASIC INSPECTION Basic Inspection (Cont’d)
12
REPAIR MALFUNCTION
Repair or replace components as necessary according to corresponding “Diagnostic Procedure”. ©
13
GO TO 11.
CHECK TARGET IDLE SPEED
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode with CONSULT-II. 3. Check idle speed. 750±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm OK or NG OK
©
GO TO 22.
NG
©
GO TO 14.
14
PERFORM IDLE AIR VOLUME LEARNING
Refer to “Idle Air Volume Learning”, EC-SR-46 Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT
©
GO TO 15.
INCMP
©
1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 14.
15
CHECK TARGET IDLE SPEED AGAIN
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode with CONSULT-II. 3. Check idle speed. 750±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm OK or NG OK
©
GO TO 20.
NG
©
GO TO 16.
16
REPLACE IACV-AAC VALVE
Replace IACV-AAC valve. ©
17
GO TO 17.
PERFORM IDLE AIR VOLUME LEARNING
Refer to “Idle Air Volume Learning”, EC-SR-46 Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT
©
GO TO 18.
INCMP
©
1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 14.
EC-88
SR20DE
TROUBLE DIAGNOSIS — BASIC INSPECTION
SR20DE Basic Inspection (Cont’d)
18
CHECK TARGET IDLE SPEED AGAIN
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode with CONSULT-II. 3. Check idle speed. 750±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm OK or NG OK
©
GO TO 20.
NG
©
GO TO 19.
19
CHECK ECM FUNCTION
1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of a problem, but this is rarely the case.) 2. Perform initialization of NATS system and registration of NATS ignition key IDs. Refer to “NATS (Nissan Anti-Theft System)”, EC-SR58. ©
20
GO TO 14.
CHECK IGNITION TIMING
1. Start engine and warm it up to normal operating temperature. 2. Check ignition timing at idle using a timing light. Timing light
SEF984U
Ignition timing: 15°±2° BTDC OK or NG OK
©
GO TO 28.
NG
©
GO TO 21.
21
CHECK TIMING CHAIN INSTALLATION
Check timing chain installation. Refer to EM-section. OK or NG OK
©
GO TO 19.
NG
©
1. Repair the timing chain installation. 2. GO TO 14.
EC-89
TROUBLE DIAGNOSIS — BASIC INSPECTION
SR20DE
Basic Inspection (Cont’d)
22
CHECK IGNITION TIMING
1. Start engine and let it idle. 2. Check ignition timing at idle using a timing light.
Timing light
SEF984U
Ignition timing: 15°±2° BTDC OK or NG OK
©
GO TO 28.
NG
©
GO TO 23.
23
PERFORM IDLE AIR VOLUME LEARNING
Refer to “Idle Air Volume Learning”, EC-SR-46 Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT
©
GO TO 24.
INCMP
©
GO TO 23.
24
CHECK TARGET IDLE SPEED AGAIN
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode with CONSULT-II. 3. Check idle speed. 750±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm OK or NG OK
©
GO TO 26.
NG
©
GO TO 15.
25
CHECK ECM FUNCTION
1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of a problem, but this is rarely the case.) 2. Perform initialization of NATS system and registration of NATS ignition key IDs. Refer to “NATS (Nissan Anti-Theft System)”, EC-SR-58. ©
26
GO TO 23.
CHECK IGNITION TIMING AGAIN
Check ignition timing again. Refer to Test No. 22. OK or NG OK
©
GO TO 28.
NG
©
GO TO 27.
EC-90
TROUBLE DIAGNOSIS — BASIC INSPECTION
SR20DE Basic Inspection (Cont’d)
27
CHECK TIMING CHAIN INSTALLATION
Check timing chain installation. Refer to EM-section. OK or NG OK
©
GO TO 25.
NG
©
1. Repair the timing chain installation. 2. GO TO 23.
28
ERASE UNNECESSARY DTC
After this inspection, unnecessary DTC No. might be displayed. Erase the stored memory in ECM. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. ©
INSPECTION END
EC-91
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
DTC Inspection Priority Chart
DTC Inspection Priority Chart
NCEC0039
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. Priority
Detected items (DTC)
1
I I I I I I I I I I I
P0100 Mass air flow sensor P0110 Intake air temperature sensor P0115 Engine coolant temperature sensor P0120 Throttle position sensor P0325 Knock sensor P0340 Camshaft position sensor P0500 Vehicle speed sensor P0605 ECM P0335, P1336 Crankshaft position sensor (OBD) P1605 A/T diagnosis communication line P1706 Park/Neutral position switch
2
I I I I I I I I
P0130 P0135 P0137 P0141 P0443 P0510 P0705 P1217
3
I I I I I
P0171, P0172 Fuel injection system function P0300 - P0304 Misfire P0420 Three way catalyst function P0505 IACV-AAC valve P1778 CVT step motor function
- P0134 Heated oxygen sensor 1 (front) Heated oxygen sensor 1 (front) heater - P0140 Heated oxygen sensor 2 (rear) Heated oxygen sensor 2 (rear) heater EVAP canister purge volume control solenoid valve Closed throttle position switch - P0725, P0740 - P1791 CVT related sensors, solenoid valves and switches Overheat (Cooling system)
EC-92
SR20DE
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Fail-safe Chart
Fail-safe Chart
NCEC0040
The ECM enters fail-safe mode if any of the following malfunctions is detected due to the open or short circuit. When the ECM enters the fail-safe mode, the MI illuminates. DTC No. CONSULT-II GST
ECM*1
P0100
0100
Mass air flow sensor circuit
P0115
0115
Engine coolant tempera- Engine coolant temperature will be determined by ECM based on the time ture sensor circuit after turning ignition switch “ON” or “START”. CONSULT-II displays the engine coolant temperature decided by ECM. The radiator fan operates.
Detected items
Engine operating condition in fail-safe mode
Engine speed will not rise more than 2,400 rpm due to the fuel cut.
Condition 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 P0120
0120
Throttle position sensor circuit
When engine is idling When accelerating Unable to access Diagnostic Test Mode II
ECM
40 - 80°C (104 - 176°F) (Depends on the time)
Throttle position will be determined based on the injected fuel amount and the engine speed. Therefore, acceleration will be poor. Condition
Unable to access ECM
Engine coolant temperature decided (CONSULT-II display)
Driving condition Normal Poor acceleration
ECM fail-safe activating condition The computing function of the ECM was judged to be malfunctioning. When the fail-safe system activates (i.e., if the ECM detects a malfunction condition in the CPU of ECM), the MI on the instrument panel lights to warn the driver. However it is not possible to access ECM and DTC cannot be confirmed. Engine control with fail-safe When ECM fail-safe is operating, fuel injection, ignition timing, fuel pump operation and IACV-AAC valve operation are controlled under certain limitations. ECM fail-safe operation Engine speed
Engine speed will not rise more than 3,000 rpm
Fuel injection
Simultaneous multiport fuel injection system
Ignition timing
Ignition timing is fixed at the preset valve
Fuel pump
Fuel pump relay is “ON” when engine is running and “OFF” when engine stalls
IACV-AAC valve
Full open
Replace ECM, if ECM fail-safe condition is confirmed. *: In Diagnostic Test Mode II (Self-diagnostic results)
EC-93
SR20DE
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart
Symptom Matrix Chart
NCEC0041
SYSTEM — ENGINE CONTROL SYSTEM
NCEC0041S01
Fuel
Fuel pump circuit
1
1
2
3
2
Fuel pressure regulator system
3
3
4
4
4
Injector circuit
1
1
2
3
2
Evaporative emission system
3
3
4
4
4
Positive crankcase ventilation system
3
3
4
4
4
Incorrect idle speed adjustment
3
3
IACV-AAC valve circuit
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
Air conditioner circuit
2
2
Air
Ignition
EXCESSIVE FUEL CONSUMPTION
AL AM HA
2
2
4
4
2
2
4
4
4
4
4
1 2
EC-SR-316 EC-SR-32
2
EC-SR-32
4
4
EC-SR-27
4
4
4
1
1
1
1
2
2
2
2
1
1
1
1
EC-SR-34
2
2
2
2
2
EC-SR-306
3
3
3
3
3
3
3
3
3
3
EC-94
3
4
2
Reference page
4
1 - 6: The numbers refer to the order of inspection. (continued on next page)
4
3
BATTERY DEAD (UNDER CHARGE)
OVERHEATS/WATER TEMPERATURE HIGH AK
EXCESSIVE OIL CONSUMPTION
SLOW/NO RETURN TO IDLE AJ
ROUGH IDLE/HUNTING
AF AG AH
HIGH IDLE/LOW IDLE
LACK OF POWER/POOR ACCELERATION
SPARK KNOCK/DETONATION
HESITATION/SURGING/FLAT SPOT
AA AB AC AD AE
IDLING VIBRATION
Warranty symptom code
ENGINE STALL
HARD/NO START/RESTART (EXCP. HA)
SYMPTOM
2 3
1
EC-SR-30 EC-SR-34 2
EC-SR-263
3
2
EC-SR-115
3
2
HA section
SR20DE
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEATS/WATER TEMPERATURE HIGH
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
BATTERY DEAD (UNDER CHARGE)
AK
AL
AM
HA
3
3
3
3
EC-SR239
2
2
2
2
2
EC-SR120
2
3
2
2
2
2
EC-SR144, 150
1
2
3
2
3
2
2
3
2
EC-SR132
Throttle position sensor circuit
1
2
2
2
2
2
2
2
EC-SR137
Incorrect throttle position sensor adjustment
3
1
1
1
1
1
1
1
EC-SR-84
Vehicle speed sensor circuit or ABS actuator and electric unit (control unit) circuit
2
3
3
3
EC-SR255
3
EC-SR230
3
EC-SR277, 93
LACK OF POWER/POOR ACCELERATION
AJ
SPARK KNOCK/DETONATION
AH
HESITATION/SURGING/FLAT SPOT
AG
ENGINE STALL
AF
HARD/NO START/RESTART (EXCP. HA)
HIGH IDLE/LOW IDLE
SYMPTOM
AA
AB
AC
AD
AE
Camshaft position sensor circuit
2
2
3
3
Mass air flow sensor circuit
1
1
2
1
Warranty symptom code
Heated oxygen sensor 1 (front) circuit Engine coolant temperature sensor circuit
1
Knock sensor circuit
2
ECM
2
Start signal circuit
2
2
3
3
3
3
3
3
3
EC-SR312
PNP switch circuit Power steering oil pressure switch circuit
3
Reference page
3
3
2
Electrical load signal circuit 1 - 6: The numbers refer to the order of inspection. (continued on next page)
EC-95
3
EC-SR298
3
3
3
3
EC-SR322
3
3
EC-SR326
SR20DE
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart (Cont’d)
SYSTEM — ENGINE MECHANICAL & OTHER
NCEC0041S03
Fuel
EXCESSIVE FUEL CONSUMPTION
AL AM HA
BATTERY DEAD (UNDER CHARGE)
OVERHEATS/WATER TEMPERATURE HIGH AK
EXCESSIVE OIL CONSUMPTION
SLOW/NO RETURN TO IDLE AJ
ROUGH IDLE/HUNTING
AF AG AH
HIGH IDLE/LOW IDLE
LACK OF POWER/POOR ACCELERATION
SPARK KNOCK/DETONATION
HESITATION/SURGING/FLAT SPOT
AA AB AC AD AE
IDLING VIBRATION
Warranty symptom code
ENGINE STALL
HARD/NO START/RESTART (EXCP. HA)
SYMPTOM
Fuel tank
Reference page
FE section 5
Fuel piping Vapor lock
5
5
5
5
5
5
5
5
5
5
5
5
5
Valve deposit Poor fuel (Heavy weight gasoline, Low octane) Air
5
—
Air duct Air cleaner Air leakage from air duct (Mass air flow sensor — throttle body) Throttle body, Throttle wire
5
5
5
5 5
5
5
5
5 5
FE section
Air leakage from intake manifold/ Collector/Gasket Cranking
—
Battery 1
1
1
1
1
1
1
Alternator circuit
EL section
Starter circuit
3
Flywheel
6
EM section
PNP switch
4
AT section
1
1 - 6: The numbers refer to the order of inspection. (continued on next page)
EC-96
SR20DE
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)
Engine
EXCESSIVE FUEL CONSUMPTION
AL AM HA
BATTERY DEAD (UNDER CHARGE)
OVERHEATS/WATER TEMPERATURE HIGH AK
EXCESSIVE OIL CONSUMPTION
SLOW/NO RETURN TO IDLE AJ
ROUGH IDLE/HUNTING
AF AG AH
HIGH IDLE/LOW IDLE
LACK OF POWER/POOR ACCELERATION
SPARK KNOCK/DETONATION
HESITATION/SURGING/FLAT SPOT
AA AB AC AD AE
IDLING VIBRATION
Warranty symptom code
ENGINE STALL
HARD/NO START/RESTART (EXCP. HA)
SYMPTOM
Reference page
Cylinder head 5
5
5
5
5
5
5
5
Cylinder head gasket
4
3
Cylinder block Piston
4 EM section
Piston ring 6
6
6
6
6
6
6
6
5
5
5
5
5
5
5
5
Connecting rod Bearing Crankshaft Valve mechanism
Timing chain Camshaft EM section
Intake valve 3 Exhaust valve Exhaust
Exhaust manifold/Tube/Muffler/ Gasket
5
5
5
5
5
5
5
5
FE section
5
5
5
5
5
5
5
5
MA, EM and LC sections
Three way catalyst Lubrication
Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery Oil level (Low)/Filthy oil
Cooling
Radiator/Hose/Radiator filler cap Thermostat
5
LC section
Water pump Water gallery
5
5
5
5
Cooling fan
5
5
5
4 5
Coolant level (low)/Contaminated coolant
5 EC-SR-279 MA section
1 - 6: The numbers refer to the order of inspection.
EC-97
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0042
Remarks: I Specification data are reference values. I 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. Specification data might be displayed even when ignition timing is not adjusted to specification. This IGN TIMING monitors the data calculated by the ECM according to the input signals from the camshaft position sensor and other ignition timing related sensors.) I If the real-time diagnosis results are NG, and the on board diagnostic system results are OK, when diagnosing the mass air flow sensor, first check to see if the fuel pump control circuit is normal. MONITOR ITEM
CONDITION
ENG SPEED
I Tachometer: Connect I Run engine and compare tachometer indication with the CONSULT-II value.
MAS A/F SE -B1
I I I I
COOLAN TEMP/S
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
HO2S2 (B1) HO2S2 MNTR (B1)
Almost the same speed as the CONSULT-II value.
Idle
1.0 - 1.7V
2,500 rpm
1.5 - 2.4V
I Engine: After warming up
More than 70°C (158°F) 0 - 0.3V +, 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
SPECIFICATION
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
I Engine: After warming up
Revving engine from idle to 3,000 rpm quickly
0 - 0.3V +, 0.6 - 1.0V LEAN +, RICH
VHCL SPEED SE
I Turn drive wheels and compare speedometer indication with the CONSULT-II value
Almost the same speed as the CONSULT-II value
BATTERY VOLT
I Ignition switch: ON (Engine stopped)
11 - 14V
I Engine is idling
Throttle valve fully closed
0.35 - 0.65V
I Ignition switch: ON (Engine stopped)
Throttle valve fully opened
3.5 - 4.5V
THRTL POS SEN START SIGNAL
I Ignition switch: ON , START , ON
CLSD THL/P SW CLSD THL POS
I Engine: Idle
AIR COND SIG
I Engine: After warming up, idle the engine
P/N POSI SW
PW/ST SIGNAL
I Ignition switch: ON I Engine: After warming up, idle the engine
IGNITION SW
I Ignition switch: ON , OFF
INJ PULSE -B1
I I I I
HEATER FAN SW
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
I Ignition switch: ON
OFF , ON , OFF
Throttle valve: Idle position
ON
Throttle valve: Slightly open
OFF
A/C switch “OFF”
OFF
A/C switch “ON” (Compressor operates)
ON
Shift lever “P” or “N”
ON
Except above
OFF
Steering wheel in neutral position (forward direction)
OFF
The steering wheel is fully turned
ON ON , OFF
Idle
2.4 - 3.2 msec
2,000 rpm
1.9 - 2.8 msec
Heater fan switch: ON
ON
Heater fan switch: OFF
OFF
EC-98
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM LOAD SIGNAL
B/FUEL SCHDL
IGN TIMING
IACV-AAC/V
PURG VOL C/V
CONDITION I Engine: running
SPECIFICATION
Rear window defogger or headlamp “ON”
ON
Except the above
OFF
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
2.4 - 3.2 msec
2,000 rpm
1.4 - 2.8 msec
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
15° BTDC
2,000 rpm
Approx. 40° BTDC
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
5 - 20 steps
2,000 rpm
—
Vehicle stopped
0%
Vehicle running
—
Maintaining engine speed at 2,000 rpm
53 - 155%
I Engine: Running
A/F ALPHA -B1
I Engine: After warming up
AIR COND RLY
I Air conditioner switch: OFF , ON
OFF , ON ON
FUEL PUMP RLY
I Ignition switch is turned to ON (Operates for 2 seconds) I Engine running and cranking I When engine is stopped (stops in 1.5 seconds) I Except as shown above
OFF Engine coolant temperature is 94°C (201°F) or less
COOLING FAN
I After warming up engine, idle the Engine coolant temperature is engine. between 95°C (203°F) and 104°C I Air conditioner switch: OFF (219°F). Engine coolant temperature is 105°C (221°F) or more
HO2S1 HTR (B1)
HO2S2 HTR (B1)
CAL/LD VALUE
ABSOL TH⋅P/S
MASS AIRFLOW
OFF
LOW
HIGH
I Engine speed: Below 3,200 rpm
ON
I More than 20 seconds after exceeding 3,200 rpm
OFF
I Engine speed: Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]
ON
I Engine speed: Above 3,600 rpm I Ignition switch ON (Engine stopped)
OFF
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
Not used
2,500 rpm
Not used
I Engine: Idle
Throttle valve fully closed
0.0°
I Ignition switch: ON (Engine stopped)
Throttle valve fully opened
Approx. 80°
Idle
2.5 - 5.0 g⋅m/s
2,500 rpm
7.1 - 12.5 g⋅m/s
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: N No-load
EC-99
SR20DE
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM
IDL A/V LEARN
TRVL AFTER MIL
CONDITION
I Ignition switch: ON
I Ignition switch: ON
SPECIFICATION
IDLE AIR VOL LEARN in ACTIVE TEST has not been performed
YET
IDLE AIR VOL LEARN in ACTIVE TEST has already been performed successfully
CMPLT
IDLE AIR VOL LEARN in ACTIVE TEST has not been performed successfully
INCMP
Vehicle has travelled after MI has turned ON.
0 - 65,535 km (0 - 40,722 mile)
Major Sensor Reference Graph in Data Monitor Mode
NCEC0043
The following are the major sensor reference graphs in “DATA MONITOR” mode. (Select “HI SPEED” in “DATA MONITOR” with CONSULT-II.)
THRTL POS SEN, ABSOL TH⋅P/S, CLSD THL POS
NCEC0043S01
Below is the data for “THRTL POS SEN”, “ABSOL TH⋅P/S” and “CLSD THL POS” when depressing the accelerator pedal with the ignition switch “ON”. The signal of “THRTL POS SEN” and “ABSOL TH⋅P/S” should rise gradually without any intermittent drop or rise after “CLSD THL POS” is changed from “ON” to “OFF”. CLSD THL POS 10:22 OFF
-00"09 +02"69 ON
ABSOL TH P/S 10:22 % 0
25
50
-00"09 +02"69 75
100
THRTL POS SEN 10:22 x0.1V 0
13
26
-00"09 +02"69 38
51
Full Release
Full Depress SEF580W
ENG SPEED, MAS A/F SE -B1, THRTL POS SEN, HO2S2 (B1), HO2S1 (B1), INJ PULSE NCEC0043S02 -B1 Below is the data for “ENG SPEED”, “MAS A/F SE -B1”, “THRTL POS SEN”, “HO2S2 (B1)”, “HO2S1 (B1)” and “INJ PULSE -B1” when revving engine quickly up to 4,800 rpm under no load after warming up engine to normal operating temperature. Each value is for reference, the exact value may vary.
EC-100
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
Major Sensor Reference Graph in Data Monitor Mode (Cont’d)
● “ENG SPEED” should increase gradually while
.
ENG SPEED
depressing the accelerator pedal and should decrease gradually after releasing the pedal without any intermittent drop or rise.
● “MAS A/F SE -B1” should increase when
.
MAS A/F SE -B1
depressing the accelerator pedal and should decrease at the moment “THRTL POS SEN” is closed (accelerator pedal is released).
NEF066A
SEF601Y
EC-101
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
Major Sensor Reference Graph in Data Monitor Mode (Cont’d)
SEF170YA
EC-102
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
ECM Terminals and Reference Value
ECM Terminals and Reference Value PREPARATION 1. 2.
NCEC0044 NCEC0044S01
ECM is located behind the center console. For this inspection: Remove the front passenger center console panel. Remove ECM harness protector.
SEF967W
3. I I I
Perform all voltage measurements with the connector connected. Extend tester probe as shown to perform tests easily. Open harness securing clip to make testing easier. Use extreme care not to touch 2 pins at one time. Data is for comparison and may not be exact.
SEF367I
ECM HARNESS CONNECTOR TERMINAL LAYOUTNCEC0044S02
SEF970W
ECM INSPECTION TABLE
NCEC0044S03
Specification data are reference values and are measured between each terminal and 48 (ECM ground).
EC-103
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
3
4
WIRE COLOR
W/R
L
ITEM
Heated oxygen sensor 2 (rear) heater
Heated oxygen sensor 1 (front) heater
CONDITION
DATA (DC Voltage)
[Engine is running] I Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]
Approximately 0.7V
[Ignition switch “ON”] I Engine stopped I Engine speed is above 3,600 rpm
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Idle speed
Approximately 0V
[Engine is running] I More than 20 seconds after exceeding 3,200 rpm
BATTERY VOLTAGE (11 - 14V)
6 7 15 16
BR Y/B P OR
IACV-AAC valve
[Engine is running] I Warm-up condition I Idle speed
0 - 14V
10
R/W
CVT signal No. 3
[Engine is running] I Idle speed
0V
[Engine is running] I Cooling fan is not operating
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Cooling fan is operating
Approximately 0V
[Engine is running] I Warm-up condition I Idle speed
BATTERY VOLTAGE (11 - 14V)
13
LG/R
Cooling fan relay
5 - 12V 14
P/B
EVAP canister purge volume control solenoid valve (ON/OFF duty)
[Engine is running] I Warm-up condition I 2,000 rpm
SEF975W
19
21
22
23
L/R
B/P
OR/L
—
CVT signal No. 5
Fuel pump relay
Malfunction indicator
Air conditioner switch
[Engine is running] I Idle speed
Approximately 7.5V
[Ignition switch “ON”] I For 2 seconds after turning ignition switch “ON” [Engine is running]
0 - 1V
[Ignition switch “ON”] I More than 1 second after turning ignition switch “ON”
BATTERY VOLTAGE (11 - 14V)
[Ignition switch “ON”]
0 - 1V
[Engine is running] I Idle speed
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Both A/C switch and blower switch are “ON”
Approximately 0V
[Engine is running] I A/C switch is “OFF”
BATTERY VOLTAGE (11 - 14V)
EC-104
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
31
WIRE COLOR
W/G
ITEM
ECM relay (Self shutoff)
CONDITION
DATA (DC Voltage)
[Engine is running] [Ignition switch “OFF”] I For 9 seconds after turning ignition switch “OFF”
0 - 1V
[Ignition switch “OFF”] I 9 seconds passed after turning ignition switch “OFF”
BATTERY VOLTAGE (11 - 14V) Approximately 10.5V
[Engine is running] I Warm-up condition I Idle speed
SEF973W
32
L/OR
Tachometer Approximately 10.5V
[Engine is running] I Engine speed is 2,000 rpm
SEF974W
Approximately 0.3V
[Engine is running] I Warm-up condition I Idle speed
SEF996V
35
W/L
Ignition signal
Approximately 0.8V
[Engine is running] I Engine speed is 2,000 rpm
SEF997V
EC-105
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
WIRE COLOR
ITEM
CONDITION
DATA (DC Voltage) Approximately 13V
[Engine is running] I Warm-up condition I Idle speed
SEF998V
36*1
G
Ignition check Approximately 12V
[Engine is running] I Engine speed is 2,000 rpm
SEF999V
40
41
42
43
44
46
Y
B/Y
G/OR
B/R
—
PU/W
Throttle position switch (Closed position)
[Engine is running] I Accelerator pedal released
BATTERY VOLTAGE (11 - 14V)
[Ignition switch “ON”] I Accelerator pedal depressed
Approximately 0V
[Ignition switch “ON”]
Approximately 0V
[Ignition switch “START”]
9 - 12V
[Ignition switch “ON”] I Gear position is “Neutral position” (M/T models) I Gear position is “P” or “N” (CVT models)
Approximately 0V
[Ignition switch “ON”] I Except the above gear position
BATTERY VOLTAGE (11 - 14V)
[Ignition switch “OFF”]
0V
[Ignition switch “ON”]
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Both air conditioner switch and blower switch are “ON” (Compressor operates)
Approximately 0V
[Engine is running] I Air conditioner switch is “OFF”
Approximately 5V
[Engine is running] I Steering wheel is fully turned
Approximately 0V
[Engine is running] I Steering wheel is not turned
Approximately 5V
Start signal
PNP switch
Ignition switch
Air conditioner switch
Power steering oil pressure switch
48
B
ECM ground
[Engine is running] I Idle speed
Engine ground (Probe this terminal with (−) tester probe when measuring)
50
R
Electric load signal
[Engine is running] I Headlamp switch or rear window defogger switch is “ON”
BATTERY VOLTAGE (11 - 14V)
*1: If so equipped
EC-106
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
51
WIRE COLOR
LG/B
ITEM
Blower fan SW
CONDITION
DATA (DC Voltage)
[Ignition switch “ON”] I Blower fan switch is “ON”
Approximately 0V
[Ignition switch “ON”] I Blower fan switch is “OFF”
Approximately 5V
54
W/L
CVT signal No. 1
[Engine is running] I Idle speed
Approximately 0 - 3.5V
55
W/PU
CVT signal No. 2
[Engine is running] I Idle speed
Approximately 0 - 3.5V
56
LG/B
CVT signal No. 4
[Engine is running] I Idle speed I “R” position
0 - 3.5V
57
B
ECM ground
[Engine is running] I Idle speed
Engine ground
58
B
Sensors’ ground
[Engine is running] I Warm-up condition I Idle speed
Approximately 0V
[Engine is running] I Warm-up condition I Idle speed
1.3 - 1.7V
[Engine is running] I Warm-up condition I Engine speed is 2,500 rpm
1.8 - 2.4V
61
B
Mass air flow sensor
0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I Warm-up condition I Engine speed is 2,000 rpm
SEF008W
63
L
Heated oxygen sensor 2 (rear)
[Engine is running] I After warming up to normal operating temperature and engine speed is 3,000 rpm
0 - Approximately 1.0V
64
G
Intake air temperature sensor
[Engine is running]
Approximately 0 - 4.8V Output voltage varies with intake air temperature 3 - 5V (AC range)
[Engine is running] I Warm-up condition I Idle speed 0.2 ms
65
W
SEF721W
Crankshaft position sensor (OBD)
6 - 9V (AC range)
[Engine is running] I Engine speed is 2,000 rpm 0.2 ms SEF722W
EC-107
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
WIRE COLOR
ITEM
CONDITION
DATA (DC Voltage) 0.1 - 0.4V
[Engine is running] I Warm-up condition I Idle speed
66*2 75
L L
SEF006W
Camshaft position sensor (REF)
0.1 - 0.4V
[Engine is running] I Engine speed is 2,000 rpm
SEF007W
67
W/L
Power supply for ECM (Back-up)
[Ignition switch “OFF”]
BATTERY VOLTAGE (11 - 14V)
70
BR/Y
Engine coolant temperature sensor
[Engine is running]
Approximately 0 - 4.8V Output voltage varies with engine coolant temperature
— Y
[Engine is running] I Accelerator pedal released
0.35 - 0.65V
71 92
[Ignition switch “ON”] I Accelerator pedal fully depressed
Approximately 4V
Throttle position sensor
W
Mass air flow sensor ground
[Engine is running] I Warm-up condition I Idle speed
Approximately 0V
74
R/L
Refrigerant pressure sensor
[Engine is running] I Warm-up condition I Idle speed I Air conditioner is “ON”
More than 1.5V
81
W
Knock sensor
[Engine is running] I Idle speed
2.0 - 3.0V
73
Approximately 2.5V
[Engine is running] I Warm-up condition I Idle speed
SEF004W
85
B/W
Camshaft position sensor (Position signal)
Approximately 2.4V
[Engine is running] I Engine speed is 2,000 rpm
SEF005W
*2: Models before VIN - P11U0548750
EC-108
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
SR20DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
WIRE COLOR
ITEM
CONDITION
DATA (DC Voltage) Approximately 2.5V
86
OR/W
[Engine is running] Vehicle speed sensor or I Lift up the vehicle ABS actuator and elecI In 2nd gear position tric unit (control unit) I Vehicle speed is 40 km/h (25 MPH) SEF976W
91
PU/Y
CVT check signal
[Engine is running] I Idle speed
0 - Approximately 5V
93*1
G/R
Data link connector
[Engine is running] ● Idle speed (CONSULT-II or GST is disconnected)
Approximately 0V BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Warm-up condition I Idle speed 101 103 105 107
R/B Y/B G/B L/B
Injector Injector Injector Injector
No. No. No. No.
1 2 3 4
SEF011W
BATTERY VOLTAGE (11 - 14V) [Engine is running] I Warm-up condition I Engine speed is 2,000 rpm
SEF012W
106 108
B/Y
ECM ground
[Engine is running] I Idle speed
0V
110 112
R R
Power supply for ECM
[Ignition switch “ON”]
BATTERY VOLTAGE (11 - 14V)
111
G
Sensors’ power supply
[Ignition switch “ON”]
Approximately 5V
G/W
Adjust switch
[Engine is running] I Idle speed
0V
BR/W
Data link connector
[Engine is running] I Idle speed (CONSULT-II or GST is disconnected)
0 - 10V
Refer to EL section
Immobilizer
[Engine is running] I Idle speed
BATTERY VOLTAGE (11 - 14V)
114*1
115
116
*1: If so equipped
EC-109
TROUBLE DIAGNOSIS — SPECIFICATION VALUE
SR20DE
Description
Description
NLEC1748
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 MIL. The SP value will be displayed for the following three items: I B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction) I A/F ALPHA-B1/B2 (The mean value of air-fuel ratio feedback correction factor per cycle) I MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)
Testing Condition
NLEC1749
I Vehicle driven distance: More than 5,000 km (3,107 miles) I Barometric pressure: 98.3 - 104.3 kPa (0.983 - 1.043 bar, 1.003 - 1.064 kg/cm2, 14.25 - 15.12 psi) I Atmospheric temperature: 20 - 30°C (68 - 86°F) I Engine coolant temperature: 75 - 95°C (167 - 203°F) I Transmission: Warmed-up*1 I Electrical load: Not applied*2 I Engine speed: Idle *1: For after the engine is warmed up to normal operating temperature, drive vehicle until “FLUID TEMP SE” (CVT fluid temperature sensor signal) indicates less than 0.9V. *2: Rear window defogger switch, air conditioner switch, lighting switch are “OFF”. Cooling fans are not operating. Steering wheel is straight ahead.
Inspection Procedure
SEF601Z
NLEC1750
NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform “Basic Inspection”, EC-84. 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1” and “MAS A/F SE-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 “Diagnostic Procedure”, EC-111.
EC-110
TROUBLE DIAGNOSIS — SPECIFICATION VALUE
SR20DE Diagnostic Procedure
Diagnostic Procedure
NLEC1751
SEF613ZA
EC-111
TROUBLE DIAGNOSIS — SPECIFICATION VALUE
SR20DE
Diagnostic Procedure (Cont’d)
SEF768Z
EC-112
TROUBLE DIAGNOSIS — SPECIFICATION VALUE
SR20DE
Diagnostic Procedure (Cont’d)
SEF615Z
EC-113
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
SR20DE
Description
Description
NCEC0045
Intermittent incidents (I/I) may occur. In many cases, the problem 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 DTC (1st trip) visits. Realize also that the most frequent cause of I/I 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 problem area.
COMMON I/I REPORT SITUATIONS
NCEC0045S01
STEP in Work Flow
Situation
II
The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than “0” or “1t”.
III
The symptom described by the customer does not recur.
IV
(1st trip) DTC data does not appear during the DTC CONFIRMATION PROCEDURE.
VI
The TROUBLE DIAGNOSIS for PXXXX does not indicate the problem area.
Diagnostic Procedure 1
INSPECTION START
Erase (1st trip) DTCs. Refer to “HOW TO ERASE EMISSION-RELATED INFORMATION” (EC-SR-56).
©
2
GO TO 2.
CHECK GROUND TERMINALS
Check ground terminals for corroding or loose connection. Refer to “Circuit Inspection”, “GROUND INSPECTION” in GI section. OK or NG OK
©
GO TO 3.
NG
©
Repair or replace.
3
SEARCH FOR ELECTRICAL INCIDENT
Perform “Incident Simulation Tests” in GI section. OK or NG OK
©
GO TO 4.
NG
©
Repair or replace.
4
CHECK CONNECTOR TERMINALS
Refer to “How to Check Enlarged Contact Spring of Terminal” in GI section. OK or NG OK
©
INSPECTION END
NG
©
Repair or replace connector.
EC-114
NCEC0046
SR20DE
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
Main Power Supply and Ground Circuit WIRING DIAGRAM
NCEC0047
BATTERY
Refer to EL-POWER.
ST
OFF
ECM RELAY
ACC
IGNITION SWITCH
ON
FUSE BLOCK (J/B)
To EC-IBN/SG, EC-TP/SW, EC-AAC/V, EC-EGR
ECM
★ 1 :
C
17
M
23
: Detectable line for DTC : Non-detectable line for DTC : Hyper CVT models : M/T models
.
REFER TO THE FOLLOWING M1 FUSE BLOCK Junction Box (J/B) E103 FUSE BLOCK Junction Box (J/B)
YEC828
EC-115
SR20DE
TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d)
ECM TERMINALS AND REFERENCE VALUE
NCEC0048
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.
31
WIRE COLOR
W/G
43
ITEM
CONDITION
ECM relay (Self shut-off)
B/R
DATA (DC Voltage)
[Engine is running] [Ignition switch “OFF”] I For 9 seconds after turning ignition switch “OFF”
0 - 1V
[Ignition switch “OFF”] I 9 seconds passed after turning ignition switch “OFF”
BATTERY VOLTAGE (11 - 14V)
[Ignition switch “OFF”]
0V
[Ignition switch “ON”]
BATTERY VOLTAGE (11 - 14V) Engine ground (Probe this terminal with (−) tester probe when measuring)
Ignition switch
48
B
ECM ground
[Engine is running] I Idle speed
57
B
ECM ground
[Engine is running] I Idle speed
Engine ground
67
W/L
Power supply for ECM (Back-up)
[Ignition switch “OFF”]
BATTERY VOLTAGE (11 - 14V)
106 108
B/Y B/Y
ECM ground
[Engine is running] I Idle speed
Engine ground
110 112
R R
Power supply for ECM
[Ignition switch “ON”]
BATTERY VOLTAGE (11 - 14V)
DIAGNOSTIC PROCEDURE 1
NCEC0049
INSPECTION START
Start engine. Is engine running? Yes or No Yes
©
GO TO 4.
No
©
GO TO 2.
2
CHECK POWER SUPPLY-I
1. Turn ignition switch “OFF” and then “ON”. 2. Check voltage between ECM terminal 43 and ground with CONSULT-II or tester.
SEF981W
Voltage: Battery voltage OK or NG OK
©
GO TO 4.
NG
©
GO TO 3.
EC-116
TROUBLE DIAGNOSIS FOR POWER SUPPLY
SR20DE
Main Power Supply and Ground Circuit (Cont’d)
3
DETECT MALFUNCTIONING PART
Check the following. I Fuse 10A, 40A I Harness connectors M50, F104 (CVT: M81, F115) I Harness for open or short between ECM and fuse block I Harness for open or short between fuse block and ignition switch. Refer to wiring diagram. ©
4
Repair harness or connectors.
CHECK POWER SUPPLY-II
1. Stop engine. 2. Check voltage between ECM terminals 67 and ground with CONSULT-II or tester.
SEF982W
Voltage: Battery voltage OK or NG © ©
OK NG
5
GO TO 6. GO TO 5.
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I 10A fuse I Harness for open or short between ECM and fuse ©
6
Repair harness or connectors.
CHECK POWER SUPPLY-III
1. Turn ignition switch “ON” and then “OFF”. 2. Check voltage between ECM terminals 110, 112 and ground with CONSULT-II or tester.
SEF983W
Voltage: After turning ignition switch “OFF”, battery voltage will exist for a few seconds, then drop to approximately 0V. OK or NG OK NG (Battery voltage does not exist.) NG (Battery voltage exists for more than a few seconds.)
© ©
GO TO 14. GO TO 7.
©
GO TO 13.
EC-117
TROUBLE DIAGNOSIS FOR POWER SUPPLY
SR20DE
Main Power Supply and Ground Circuit (Cont’d)
7
CHECK HARNESS CONTINUITY BETWEEN ECM RELAY AND ECM
1. Disconnect ECM harness connector. 2. Disconnect ECM relay.
SEF984W
3. Check harness continuity between ECM terminals 110, 112 and relay 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 9.
NG
©
GO TO 8.
8
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I Harness for open or short between ECM relay and ECM ©
9
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK VOLTAGE BETWEEN ECM RELAY AND GROUND
Check voltage between relay terminals 1, 3 and ground with CONSULT-II or tester.
SEF985W
Voltage: Battery voltage OK or NG OK
©
GO TO 11.
NG
©
GO TO 10.
10
DETECT MALFUNCTIONING PART
Check the harness for open or short between ECM relay and fuse. ©
Repair harness or connectors.
EC-118
TROUBLE DIAGNOSIS FOR POWER SUPPLY
SR20DE
Main Power Supply and Ground Circuit (Cont’d)
11
CHECK OUTPUT SIGNAL CIRCUIT
1. Check harness continuity between ECM terminal 31 and relay 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 13.
NG
©
GO TO 12.
12
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E42, F4 I Harness for open or short between ECM relay and ECM ©
13
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK ECM RELAY
1. Apply 12V direct current between relay terminals 1 and 2. 2. Check continuity between relay terminals 3 and 5, 6 and 7.
SEC202BC
12V (1 - 2) applied: Continuity exists. No voltage applied: No continuity OK or NG OK
©
GO TO 14.
NG
©
Replace ECM relay.
14
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 48, 57, 106, 108 and engine ground. 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 15.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
15
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©
INSPECTION END
EC-119
SR20DE
DTC P0100 MASS AIR FLOW SENSOR (MAFS) Component Description
Component Description
SEF987W
NCEC0050
The mass air flow sensor is placed in the stream of intake air. It measures the intake flow rate by measuring a part of the entire intake flow. It consists of a hot wire that is supplied with electric current from the ECM. The temperature of the hot wire is controlled by the ECM 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 ECM must supply more electric current to maintain the temperature of the hot wire as air flow increases. The ECM detects the air flow by means of this current change.
CONSULT-II Reference Value in Data Monitor Mode
NCEC0051
Specification data are reference values. MONITOR ITEM
MAS A/F SE -B1
CAL/LD VALUE
MASS AIRFLOW
CONDITION
SPECIFICATION
I I I I
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load
Idle
1.0 - 1.7V
2,500 rpm
1.5 - 2.4V
I I I I
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load
Idle
Not used
2,500 rpm
Not used
I I I I
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load
Idle
2.5 - 5.0 g⋅m/s
2,500 rpm
7.1 - 12.5 g⋅m/s
ECM Terminals and Reference Value
NCEC0052
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.
61
73
WIRE COLOR
B
ITEM
Mass air flow sensor
Mass air flow sensor ground
W
CONDITION
DATA (DC Voltage)
[Engine is running] I Warm-up condition I Idle speed
1.3 - 1.7V
[Engine is running] I Warm-up condition I Engine speed is 2,500 rpm
1.8 - 2.4V
[Engine is running] I Warm-up condition I Idle speed
Approximately 0V
On Board Diagnosis Logic DTC No. P0100* 0100
Malfunction is detected when ...
NCEC0053
Check Items (Possible Cause)
A)
An excessively high voltage from the sensor is sent to ECM when engine is not running.
I Harness or connectors (The sensor circuit is open or shorted.) I Mass air flow sensor
B)
An excessively low voltage from the sensor is sent to ECM when engine is running.
I Harness or connectors (The sensor circuit is open or shorted.) I Intake air leaks I Mass air flow sensor
*: When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
EC-120
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
SR20DE
DTC Confirmation Procedure Detected items
Engine operating condition in fail-safe mode Engine speed will not rise more than 2,400 rpm due to the fuel cut.
Mass air flow sensor circuit
DTC Confirmation Procedure
NCEC0054
Perform “PROCEDURE FOR MALFUNCTION A” first. If the 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. 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 9 seconds before conducting the next test.
PROCEDURE FOR MALFUNCTION A
NCEC0054S05
With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 2 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-123. With GST Follow the procedure “With CONSULT-II” above. NEF068A
PROCEDURE FOR MALFUNCTION B
NCEC0054S06
With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and wait 2 seconds at most. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-123. With GST Follow the procedure “With CONSULT-II” above. NEF068A
EC-121
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0056
YEC081A
EC-122
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0057
INSPECTION START
Which malfunction (A or B) is duplicated? Malfunction A or B A
©
GO TO 3.
B
©
GO TO 2.
2
CHECK INTAKE SYSTEM
Check the following for connection. I Air cut I Vacuum hoses I Intake air passage between air duct to collector OK or NG OK
©
GO TO 3.
NG
©
Reconnect the parts.
3
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector
Engine ground SEF202X
©
GO TO 4.
EC-123
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
SR20DE
Diagnostic Procedure (Cont’d)
4
CHECK POWER SUPPLY-I
1. Disconnect mass air flow sensor harness connector. Mass air flow sensor harness connector
Air cleaner SEF203X
2. Turn ignition switch “ON”. 3. Check voltage between terminal 2 and ground with CONSULT-II or tester.
SEF996W
Voltage: Battery voltage OK or NG OK
©
GO TO 6.
NG
©
GO TO 5.
5
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I Harness for open or short between ECM relay and mass air flow sensor I Harness for open or short between mass air flow sensor and ECM
©
Repair harness or connectors.
EC-124
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
SR20DE
Diagnostic Procedure (Cont’d)
6
CHECK POWER SUPPLY-II
Check voltage between terminal 4 and ground with CONSULT-II or tester.
SEF201X
Voltage: 5V OK or NG OK
©
GO TO 8.
NG
©
GO TO 7.
7
DETECT MALFUNCTIONING PART
Check the harness for open or short between mass air flow sensor terminal 4 and ECM terminal 111. ©
8
Repair harness.
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between mass air flow sensor harness connector terminal 3 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 9.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
9
CHECK INPUT SIGNAL CIRCUIT
1. Check harness continuity between mass air flow sensor harness connector terminal 5 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 10.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
10
CHECK MASS AIR FLOW SENSOR
Refer to “Component Inspection”, EC-SR-126. OK or NG OK
©
GO TO 11.
NG
©
Replace mass air flow sensor.
11
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©
INSPECTION END
EC-125
DTC P0100 MASS AIR FLOW SENSOR (MAFS)
SR20DE
Component Inspection
Component Inspection
NCEC0058
MASS AIR FLOW SENSOR 1. 2. 3.
Conditions Ignition switch “ON” (Engine stopped.) SEF993W
NCEC0058S01
Turn ignition switch “ON”. Start engine and warm it up to normal operating temperature. Check voltage between ECM terminal 61 (Mass air flow sensor signal) and ground. Voltage V Less than 1.2
Idle (Engine is warmed-up to normal operating temperature.)
1.3 - 1.7
2,500 rpm (Engine is warmed-up to normal operating temperature.)
1.8 - 2.4
Idle to about 4,000 rpm*
1.3 - 1.7 to Approx. 4.0
*: Check for linear voltage rise in response to increases to about 4,000 rpm in engine speed.
4. SEF987W
5.
If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Repeat above check. If NG, remove mass air flow sensor from air duct. Check hot film for damage or dust.
EC-126
SR20DE
DTC P0110 INTAKE AIR TEMPERATURE SENSOR
Component Description
Component Description
NCEC0066
The intake air temperature sensor is built into the 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.
SEF987W
Intake air temperature °C (°F)
Resistance kΩ
20 (68)
2.2 - 2.6
80 (176)
0.31 - 0.37
*: These data are reference values and are measured between ECM terminal 64 (Intake air temperature sensor) and ECM terminal 48 (ECM ground). SEF012P
On Board Diagnosis Logic DTC No. P0110 0110
Malfunction is detected when ... An excessively low or high voltage from the sensor is sent to ECM.
NCEC0067
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Intake air temperature sensor
DTC Confirmation Procedure
NCEC0068
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test.
With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-129. With GST Follow the procedure “With CONSULT-II” above. 1) 2) 3) 4)
NEF068A
EC-127
DTC P0110 INTAKE AIR TEMPERATURE SENSOR
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0069
: Detectable line for DTC : Non-detectable line for DTC INTAKE AIR TEMPERATURE SENSOR
: Hyper CVT models
ECM
YEC830
EC-128
DTC P0110 INTAKE AIR TEMPERATURE SENSOR
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0070
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect mass air flow sensor harness connector. Mass air flow sensor harness connector
Air cleaner SEF203X
3. Turn ignition switch “ON”. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.
NEF228A
Voltage: Approximately 5V OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness for open or short between ECM and intake air temperature sensor
©
Repair harness or connectors.
EC-129
DTC P0110 INTAKE AIR TEMPERATURE SENSOR
SR20DE
Diagnostic Procedure (Cont’d)
3
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Check harness continuity between intake air temperature sensor (mass air flow sensor) harness connector terminal 3 and ECM terminal 73. 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. I Harness for open or short between ECM and intake air temperature sensor
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK INTAKE AIR TEMPERATURE SENSOR
Refer to “Component Inspection”, EC-SR-131. OK or NG OK
©
GO TO 6.
NG
©
Replace mass air flow sensor.
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-130
SR20DE
DTC P0110 INTAKE AIR TEMPERATURE SENSOR
Component Inspection
Component Inspection
NCEC0071
INTAKE AIR TEMPERATURE SENSOR
NCEC0071S01
Check resistance between mass air flow sensor terminal 1 and 3. Intake air temperature °C (°F)
Resistance kΩ
20 (68)
2.2 - 2.6
80 (176)
0.31 - 0.37
SEF012P
If NG, replace mass air flow sensor.
EC-131
DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)
SR20DE
Component Description
Component Description
NCEC0072
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)
Voltage* V
Resistance kΩ
−10 (14)
4.4
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
SEF012P
*: These data are reference values and are measured between ECM terminal 70 (Engine coolant temperature sensor) and ECM terminal 48 (ECM ground).
CONSULT-II Reference Value in Data Monitor Mode
NCEC0073
MONITOR ITEM COOLAN TEMP/S
CONDITION
SPECIFICATION
I Engine: After warming up
More than 70°C (158°F)
On Board Diagnosis Logic DTC No. P0115 0115
Malfunction is detected when ... I An excessively high or low voltage from the sensor is sent to ECM.*
NCEC0074
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Engine coolant temperature sensor
*: 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 the engine is running.
EC-132
DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)
SR20DE
DTC Confirmation Procedure
DTC Confirmation Procedure
PEF002P
NCEC0075
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 5 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-135. With GST Follow the procedure “With CONSULT-II” above.
EC-133
DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0076
YEC082A
EC-134
DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0077
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect engine coolant temperature sensor harness connector. Front exhaust tube
Coolant temperature sensor harness connector
Front SEF205X
3. Turn ignition switch “ON”. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.
SEF997W
Voltage: Approximately 5V OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the harness for open or short between ECM and engine coolant temperature sensor.
©
3
Repair harness or connectors.
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Check harness continuity between engine coolant temperature sensor harness connector terminal 1 and engine 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.
EC-135
DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)
SR20DE
Component Inspection
4
DETECT MALFUNCTIONING PART
Check the following. I Harness for open or short between ECM and engine coolant temperature sensor I Harness for open or short between engine coolant temperature sensor and TCM (Transmission control module)
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to “Component Inspection”, EC-SR-136. OK or NG OK
©
GO TO 6.
NG
©
Replace engine coolant temperature sensor.
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
Component Inspection
NCEC0078
ENGINE COOLANT TEMPERATURE SENSOR Check resistance as shown in the figure.
SEF152P
Temperature °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
EC-136
NCEC0078S01
SR20DE
DTC P0120 THROTTLE POSITION SENSOR
Component Description
Component Description
NCEC0079
NOTE: If DTC P0120 (0120) is displayed with DTC P0510 (0510), first perform trouble diagnosis for DTC P0510, EC-SR-271. The throttle position sensor responds to the accelerator pedal movement. This sensor is a kind of potentiometer which transforms the throttle position into output voltage, and emits the voltage signal to the ECM. In addition, the sensor detects the opening and closing speed of the throttle valve and feeds the voltage signal to the ECM. Idle position of the throttle valve is determined by the ECM receiving the signal from the throttle position sensor. This sensor controls engine operation such as fuel cut. On the other hand, the “Wide open and closed throttle position switch”, which is built into the throttle position sensor unit, is not used for engine control.
YEC118A
CONSULT-II Reference Value in Data Monitor Mode
NCEC0080
Specification data are reference values. MONITOR ITEM
THRTL POS SEN
ABSOL TH⋅P/S
CONDITION
SPECIFICATION
I Engine is idling.
Throttle valve: fully closed
0.35 - 0.65V
I Ignition switch: ON (Engine stopped)
Throttle valve: fully opened
3.5 - 4.5V
I Engine: Idle the engine
Throttle valve: fully closed
0.0°
I Ignition switch: ON (Engine stopped)
Throttle valve: fully opened
Approx. 80°
EC-137
SR20DE
DTC P0120 THROTTLE POSITION SENSOR ECM Terminals and Reference Value
ECM Terminals and Reference Value
=NCEC0081
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 58
92
111
WIRE COLOR
B
ITEM
CONDITION
Sensors’ ground
Y
Throttle position sensor
G
Sensors’ power supply
DATA (DC Voltage)
[Engine is running] I Warm up condition I Idle speed
Approximately 0V
[Engine is running] I Accelerator pedal fully released
0.35 - 0.65V
[Ignition switch “ON”] I Accelerator pedal fully depressed
Approximately 4.0V
[Ignition switch “ON”]
Approximately 5V
On Board Diagnosis Logic DTC No. P0120 0120
Malfunction is detected when ... An excessively low or high voltage from the sensor is sent to ECM while driving*.
NCEC0082
Check Items (Possible Cause) I Harness or connectors (The throttle position sensor circuit is open or shorted.) I Throttle position sensor
*: 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 Throttle position will be determined based on the injected fuel amount and the engine speed. Therefore, acceleration will be poor.
Throttle position sensor circuit
Condition
Driving condition
When engine is idling
Normal
When accelerating
Poor acceleration
DTC Confirmation Procedure
NCEC0083
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: I Before performing the following procedure, confirm that battery voltage is more than 10V at idle. I This test 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.
EC-138
DTC P0120 THROTTLE POSITION SENSOR
SR20DE
DTC Confirmation Procedure (Cont’d)
With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and maintain the following conditions for at least 5 consecutive seconds.
PEF651U
VHCL SPEED SE
More than 4 km/h (2 MPH)
Selector lever
Suitable position except “P” or “N” position
3)
If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-141. With GST Follow the procedure “With CONSULT-II” above.
EC-139
DTC P0120 THROTTLE POSITION SENSOR
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0084
YEC083A
EC-140
DTC P0120 THROTTLE POSITION SENSOR
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0085
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector
Engine ground SEF202X
©
2
GO TO 2.
CHECK POWER SUPPLY
1. Disconnect throttle position sensor harness connector. Throttle position sensor harness connector
Throttle body
Closed throttle position switch harness connector (CVT models)
SEF197X
2. Turn ignition switch “ON”. 3. Check voltage between terminal 3 and ground with CONSULT-II or tester.
SEF209W
Voltage: Approximately 5V OK or NG OK
©
GO TO 3.
NG
©
Repair harness or connectors.
3
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Check harness continuity between throttle position sensor harness connector terminal 1 and engine 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.
EC-141
SR20DE
DTC P0120 THROTTLE POSITION SENSOR Component Inspection
4
DETECT MALFUNCTIONING PART
Check the following. I Harness for open or short between ECM and throttle position sensor I Harness for open or short between throttle position sensor and TCM (Transmission control module)
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 92 and throttle position sensor harness connector 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 6.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
6
CHECK THROTTLE POSITION SENSOR
Refer to “Component Inspection”, EC-SR-142. OK or NG OK
©
GO TO 7.
NG
©
Replace throttle position sensor. To adjust it, perform “Basic Inspection”, EC-SR-84.
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
Component Inspection
NCEC0086
THROTTLE POSITION SENSOR
NEF069A
NCEC0086S01
With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine (ignition switch OFF). 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Check voltage of “THRTL POS SEN” under the following conditions. NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle. Throttle valve conditions Completely closed Partially open Completely open
Voltage V 0.35 - 0.65 (a) Between (a) and (b) 3.5 - 4.5 (b)
If NG, adjust throttle position sensor idle position. Refer to “Basic Inspection”, EC-SR-84.
EC-142
SR20DE
DTC P0120 THROTTLE POSITION SENSOR
Component Inspection (Cont’d)
6)
If it is impossible to adjust throttle position sensor idle position in “Basic Inspection”, replace throttle position sensor.
Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine (ignition switch OFF). Turn ignition switch ON. Check voltage between ECM terminal 92 (Throttle position sensor signal) and ground under the following conditions. NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle. 1) 2) 3) 4)
SEF007X
Throttle valve conditions Completely closed Partially open Completely open
5)
Voltage V 0.35 - 0.65 (a) Between (a) and (b) Approx. 4.0 (b)
If NG, adjust throttle position sensor idle position. Refer to “Basic Inspection”, EC-SR-84. If it is impossible to adjust throttle position sensor idle position in “Basic Inspection”, replace throttle position sensor.
EC-143
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
SR20DE
Component Description
Component Description
NCEC0094
The heated oxygen sensor 1 (front) 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 (front) 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 (front) 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
NCEC0095
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
ECM Terminals and Reference Value
NCEC0096
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL NO. COLOR
ITEM
CONDITION
DATA (DC Voltage) 0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W
EC-144
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
SR20DE On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0097
Under the condition in which the heated oxygen sensor 1 (front) 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. P0130 0130
Malfunction is detected when ... I The voltage from the sensor is constantly approx. 0.3V.
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front)
DTC Confirmation Procedure
SEF825Y
SEF826Y
SEF645Y
NCEC0098
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “HO2S1 (B1) P0130” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 3) Touch “START”. 4) Let it idle for at least 3.5 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 4. 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
1,500 - 3,200 rpm
Vehicle speed
64 - 130 km/h (40 - 81 MPH)
B/FUEL SCHDL
2.4 - 11.0 msec
Selector lever
Suitable position
If “TESTING” is not displayed after 5 minutes, retry from step 2.
EC-145
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
SR20DE
Overall Function Check
6)
Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-148.
Overall Function Check
SEF011X
NCEC0099
Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The voltage does not remain in the range of 0.2 - 0.4V. 4) If NG, go to “Diagnostic Procedure”, EC-SR-148.
EC-146
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
SR20DE Wiring Diagram
Wiring Diagram
NCEC0100
YEC084A
EC-147
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0101
INSPECTION START
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector
Engine ground SEF202X
3. Disconnect heated oxygen sensor 1 (front) harness connector.
Heated oxygen sensor 1 (front) harness connector
Heated oxygen sensor 1 (front) SEF207X
©
2
GO TO 2.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for 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 HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-SR-149. OK or NG OK
©
GO TO 4.
NG
©
Replace heated oxygen sensor 1 (front).
4
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-148
DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)
SR20DE Component Inspection
Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)
SEF646Y
NCEC0102S01
With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. 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.
FR O2 SENSOR x0.01V
-09″99 -02″89
SEF647Y
NCEC0102
SEF648Y
Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. 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. 1) 2)
SEF011X
EC-149
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
SR20DE
Component Description
Component Description
NCEC0103
The heated oxygen sensor 1 (front) 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 (front) 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 (front) 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
NCEC0104
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
ECM Terminals and Reference Value
NCEC0105
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) 0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W
EC-150
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
SR20DE On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0106
To judge the malfunction, the output from the heated oxygen sensor 1 (front) 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. P0131 0131
Malfunction is detected when ... I The maximum and minimum voltages from the sensor are not reached to the specified voltages.
Check Items (Possible Cause) I I I I I
Heated oxygen sensor 1 (front) Heated oxygen sensor 1 (front) heater Fuel pressure Injectors Intake air leaks
DTC Confirmation Procedure
SEF827Y
SEF828Y
NCEC0107
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 P0131” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3.5 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 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 20 seconds or more.)
SEF651Y
EC-151
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
SR20DE
DTC Confirmation Procedure (Cont’d) ENG SPEED
1,800 - 2,900 rpm (CVT) 2,000 - 3,100 rpm (M/T)
Vehicle speed
80 - 120 km/h (50 - 75 MPH)
B/FUEL SCHDL
4.5 - 14.0 msec (CVT) 3.5 - 12.0 msec (M/T)
Selector lever
Suitable position
7)
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 “Diagnostic Procedure”, EC-SR-153.
Overall Function Check
SEF011X
NCEC0108
Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The maximum voltage is over 0.6V at least one time. I The minimum voltage is over 0.1V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-SR-153.
EC-152
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0109
RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)
1. Turn ignition switch “OFF”. 2. Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb)
©
2
GO TO 2.
CLEAR THE SELF-LEARNING DATA.
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.
SEF652Y
4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector
Air cleaner SEF203X
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0171. Refer to EC-SR-212.
No
©
GO TO 3.
EC-153
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
SR20DE
Diagnostic Procedure (Cont’d)
3
CHECK HEATED OXYGEN SENSOR 1 (FRONT) HEATER
Refer to “Component Inspection”, EC-SR-179. OK or NG OK
©
GO TO 4.
NG
©
Replace heated oxygen sensor 1 (front).
4
CHECK HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-SR-154. OK or NG OK
©
GO TO 5.
NG
©
Replace heated oxygen sensor 1 (front).
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. Refer to “Wiring Diagram”, EC-SR-147, for circuit.
©
INSPECTION END
Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)
NCEC0110 NCEC0110S02
With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. 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. 1) 2)
SEF646Y
FR O2 SENSOR x0.01V
-09″99 -02″89
SEF647Y
SEF648Y
EC-154
DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)
SR20DE
Component Inspection (Cont’d)
SEF011X
Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. 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-155
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
SR20DE
Component Description
Component Description
NCEC0111
The heated oxygen sensor 1 (front) 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 (front) 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 (front) 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
NCEC0112
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
ECM Terminals and Reference Value
NCEC0113
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) 0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W
EC-156
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
SR20DE On Board Diagnosis Logic
On Board Diagnosis Logic OK
NCEC0114
To judge the malfunction, the output from the heated oxygen sensor 1 (front) is monitored to determine whether the “rich” output is sufficiently high. The “lean” output is sufficiently low. When both the outputs are shifting to the rich side, the malfunction will be detected.
NG
1V 0.8V
0.35V 0V SEF299U
DTC No. P0132 0132
Malfunction is detected when ... I The maximum and minimum voltages from the sensor are beyond the specified voltages.
Check Items (Possible Cause) I I I I
Heated oxygen sensor 1 (front) Heated oxygen sensor 1 (front) heater Fuel pressure Injectors
DTC Confirmation Procedure
SEF829Y
SEF830Y
NCEC0115
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 (B1) P0132” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3.5 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 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 20 seconds or more.)
SEF655Y
EC-157
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
SR20DE
DTC Confirmation Procedure (Cont’d) ENG SPEED
1,800 - 2,900 rpm (CVT) 2,000 - 3,100 rpm (M/T)
Vehicle speed
80 - 120 km/h (50 - 75 MPH)
B/FUEL SCHDL
4.5 - 14.0 msec (CVT) 3.5 - 12.0 msec (M/T)
Selector lever
Suitable position
7)
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 “Diagnostic Procedure”, EC-SR-159.
Overall Function Check
SEF011X
NCEC0116
Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The maximum voltage is below 0.8V at least one time. I The minimum voltage is below 0.35V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-SR-159.
EC-158
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
=NCEC0117
RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)
1. Turn ignition switch “OFF”. 2. Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb)
©
2
GO TO 2.
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.
SEF652Y
4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector
Air cleaner SEF203X
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0172. Refer to EC-SR-218.
No
©
GO TO 3.
EC-159
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
SR20DE
Diagnostic Procedure (Cont’d)
3
CHECK HARNESS CONNECTOR
1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector. 3. Check harness connector for water. Water should not exit. OK or NG OK
©
GO TO 4.
NG
©
Repair or replace harness connector.
4
CHECK HEATED OXYGEN SENSOR 1 (FRONT) HEATER
Refer to “Component Inspection”, EC-SR-179. OK or NG OK
©
GO TO 5.
NG
©
Replace heated oxygen sensor 1 (front).
5
CHECK HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-SR-160. OK or NG OK
©
GO TO 6.
NG
©
Replace heated oxygen sensor 1 (front).
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. Refer to “Wiring Diagram”, EC-SR-147, for circuit.
©
INSPECTION END
Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)
SEF646Y
SEF647Y
NCEC0118 NCEC0118S02
With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. 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-160
DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)
SR20DE
FR O2 SENSOR x0.01V
-09″99 -02″89
Component Inspection (Cont’d)
SEF648Y
Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than 5 times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. 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. 1) 2)
SEF011X
EC-161
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
SR20DE
Component Description
Component Description
NCEC0119
The heated oxygen sensor 1 (front) 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 (front) 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 (front) 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
NCEC0120
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
ECM Terminals and Reference Value
NCEC0121
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) 0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W
EC-162
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
SR20DE On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0122
To judge the malfunction of heated oxygen sensor 1 (front), this diagnosis measures response time of heated oxygen sensor 1 (front) signal. The time is compensated by engine operating (speed and load), fuel feedback control constant, and heated oxygen sensor 1 (front) temperature index. Judgment is based on whether the compensated time (heated oxygen sensor 1 (front) cycling time index) is inordinately long or not. SEF010V
DTC No. P0133 0133
Malfunction is detected when ...
Check Items (Possible Cause)
I The response of the voltage signal from the sensor takes I Harness or connectors more than the specified time. (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front) I Heated oxygen sensor 1 (front) heater I Fuel pressure I Injectors I Intake air leaks I Exhaust gas leaks I PCV I Mass air flow sensor
DTC Confirmation Procedure
SEF831Y
SEF832Y
NCEC0123
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 (B1) P0133” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3.5 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 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 20 seconds.)
SEF658Y
EC-163
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
SR20DE
DTC Confirmation Procedure (Cont’d) ENG SPEED
1,800 - 2,900 rpm (CVT) 2,000 - 3,100 rpm (M/T)
Vehicle speed
80 - 120 km/h (50 - 75 MPH)
B/FUEL SCHDL
4.5 - 14.0 msec (CVT) 3.5 - 12.0 msec (M/T)
Selector lever
Suitable position
7)
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 “Diagnostic Procedure”, EC-SR-166.
Overall Function Check
SEF011X
NCEC0124
Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). 4) If NG, go to “Diagnostic Procedure”, EC-SR-166.
EC-164
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
SR20DE Wiring Diagram
Wiring Diagram
NCEC0125
YEC084A
EC-165
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0126
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector
Engine ground SEF202X
©
2
GO TO 2.
RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)
Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb)
©
3
GO TO 3.
CHECK EXHAUST AIR LEAK
1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.
SEF099P
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-166
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
SR20DE
Diagnostic Procedure (Cont’d)
5
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.
SEF652Y
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? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector
Air cleaner SEF203X
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 or 0172 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0171, P0172. Refer to EC-SR-212, 218.
No
©
GO TO 6.
6
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for 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-167
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING) Diagnostic Procedure (Cont’d)
7
CHECK HEATED OXYGEN SENSOR 1 (FRONT) HEATER
Refer to “Component Inspection”, EC-SR-179. OK or NG OK
©
GO TO 8.
NG
©
Replace heated oxygen sensor 1 (front).
8
CHECK HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-SR-169. OK or NG OK
©
GO TO 9.
NG
©
Replace heated oxygen sensor 1 (front).
9
CHECK MASS AIR FLOW SENSOR
Refer to “Component Inspection”, EC-SR-126. OK or NG OK
©
GO TO 10.
NG
©
Replace mass air flow sensor.
10
CHECK PCV VALVE
Refer to “Positive Crankcase Ventilation”, EC-SR-30. OK or NG OK
©
GO TO 11.
NG
©
Repair or replace PCV valve.
11
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-168
SR20DE
DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)
SR20DE Component Inspection
Component Inspection HEATED OXYGEN SENSOR 1 (B1)
SEF646Y
NCEC0127S02
With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” five times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. 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.
FR O2 SENSOR x0.01V
-09″99 -02″89
SEF647Y
NCEC0127
SEF648Y
Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. 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. 1) 2)
SEF011X
EC-169
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
SR20DE
Component Description
Component Description
NCEC0128
The heated oxygen sensor 1 (front) 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 (front) 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 (front) 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
NCEC0129
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S1 (B1) HO2S1 MNTR (B1)
I Engine: After warming up
Maintaining engine speed at 2,000 rpm
LEAN +, RICH Changes more than 5 times during 10 seconds.
ECM Terminals and Reference Value
NCEC0130
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) 0 - Approximately 1.0V
62
R
Heated oxygen sensor 1 (front)
[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W
EC-170
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
SR20DE On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0131
To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 (front) output is not inordinately high.
SEF301U
DTC No. P0134 0134
Malfunction is detected when ... I An excessively high voltage from the sensor is sent to ECM.
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front)
DTC Confirmation Procedure
SEF058Y
NCEC0132
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON”. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Restart engine and let it idle for 2 minutes. 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-173. With GST 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Restart engine and let it idle for 2 minutes. 4) Turn ignition switch “OFF” and wait at least 9 seconds. 5) Restart engine and let it idle for 2 minutes. 6) Select “MODE 3” with GST. 7) If DTC is detected, go to “Diagnostic Procedure”, EC-SR-173. I When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II or ECM (Diagnostic Test Mode II) because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II or ECM (Diagnostic Test Mode II) is recommended.
EC-171
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0133
YEC084A
EC-172
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0134
RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)
Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb)
©
2
GO TO 2.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector.
Heated oxygen sensor 1 (front) harness connector
Heated oxygen sensor1 (front) SEF207X
2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for 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 HARNESS CONNECTOR
Check heated oxygen sensor 1 (front) harness connector for water. Water should not exist. OK or NG OK
©
GO TO 4.
NG
©
Repair or replace harness connector.
4
CHECK HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-SR-174. OK or NG OK
©
GO TO 5.
NG
©
Replace heated oxygen sensor 1 (front).
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-173
DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)
SR20DE
Component Inspection
Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)
SEF646Y
NCEC0135S01
With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” five times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. 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.
FR O2 SENSOR x0.01V
-09″99 -02″89
SEF647Y
NCEC0135
SEF648Y
Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. 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. 1) 2)
SEF011X
EC-174
DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER SR20DE Description
Description
NCEC0136
SYSTEM DESCRIPTION
NCEC0136S01
Sensor
ECM function
Input Signal to ECM
Camshaft position sensor
Actuator
Heated oxygen sensor Heated oxygen sensor 1 (front) 1 (front) heater heater control
Engine speed
The ECM performs ON/OFF control of the heated oxygen sensor 1 (front) heater corresponding to the engine operating condition.
OPERATION
NCEC0136S02
Engine speed
Heated oxygen sensor 1 (front) heater
Above 3,200 rpm
OFF
More than 20 seconds after exceeding 3,200 rpm
ON
CONSULT-II Reference Value in Data Monitor Mode
NCEC0137
Specification data are reference values. MONITOR ITEM HO2S2 HTR (B1)
CONDITION
SPECIFICATION
I Engine speed: Below 3,200 rpm
ON
I More than 20 seconds after exceeding 3,200 rpm
OFF
ECM Terminals and Reference Value
NCEC0138
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.
4
WIRE COLOR
L
ITEM
Heated oxygen sensor 1 (front) heater
CONDITION
DATA (DC Voltage)
[Engine is running] I Engine speed is below 3,200 rpm.
Approximately 0V
[Engine is running] I More than 20 seconds after exceeding 3,200 rpm.
BATTERY VOLTAGE (11 - 14V)
On Board Diagnosis Logic DTC No. P0135 0135
Malfunction is detected when ... I The current amperage in the heated oxygen sensor 1 (front) heater circuit is out of the normal range. (An improper voltage drop signal is sent to ECM through the heated oxygen sensor 1 (front) heater.)
NCEC0139
Check Items (Possible Cause) I Harness or connectors (The heated oxygen sensor 1 (front) heater circuit is open or shorted.) I Heated oxygen sensor 1 (front) heater
DTC Confirmation Procedure
NCEC0140
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 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-175
DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER SR20DE DTC Confirmation Procedure (Cont’d)
1) 2) 3)
NEF068A
1) 2) 3) 4) 5) I
With CONSULT-II 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 “Diagnostic Procedure”, ECSR-178. With GST Start engine and run it for at least 5 seconds at idle speed. Turn ignition switch “OFF” and wait at least 9 seconds. Start engine and run it for at least 5 seconds at idle speed. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-SR-178. When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II or ECM (Diagnostic Test Mode II) because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II or ECM (Diagnostic Test Mode II) is recommended.
EC-176
DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER SR20DE Wiring Diagram
Wiring Diagram
NCEC0141
YEC085A
EC-177
DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0142
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector.
Heated oxygen sensor 1 (front) harness connector
Heated oxygen sensor 1 (front) SEF207X
3. Turn ignition switch “ON”. 4. Check voltage between terminal 3 and ground with CONSULT or tester. DISCONNECT
SEF025X
Voltage: Battery voltage OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104 (M81, F115 for CVT models) I 10A fuse I Harness for open or short between heated oxygen sensor 1 (front) and fuse
©
3
Repair harness or connectors.
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between heated oxygen sensor 1 (front) harness connector terminal 1 and ECM terminal 4. 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-178
DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER SR20DE Component Inspection
4
CHECK HEATED OXYGEN SENSOR 1 (FRONT) HEATER
Refer to “Component Inspection”, EC-SR-179. OK or NG OK
©
GO TO 5.
NG
©
Replace heated oxygen sensor 1 (front).
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
Component Inspection HEATED OXYGEN SENSOR 1 (FRONT) HEATER DISCONNECT
SEF026X
NCEC0143 NCEC0143S01
Check resistance between terminals 3 and 1. Resistance: 2.3 - 4.3 Ω at 25°C (77°F) Check continuity between terminals 2 and 1, 3 and 2. Continuity should not exist. If NG, replace the heated oxygen sensor 1 (front). 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-179
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
SR20DE
Component Description
Component Description
SEF327R
NCEC0144
The heated oxygen sensor 2 (rear) (Rear HO2S), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). 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 (rear) is not used for engine control operation.
CONSULT-II Reference Value in Data Monitor Mode
NCEC0145
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S2 (B) I Engine: After warming up
HO2S2 MNTR (B1)
Revving engine from idle to 3,000 rpm
LEAN +, RICH
ECM Terminals and Reference Value
NCEC0146
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 63
WIRE COLOR
ITEM
CONDITION
Heated oxygen sensor 2 (rear)
L
DATA (DC Voltage)
[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and engine speed is 3,000 rpm
On Board Diagnosis Logic OK 1V 0.43V
0V
SEF258V
DTC No. P0137 0137
NCEC0147
The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the minimum voltage of the sensor is sufficiently low during various driving conditions such as fuel-cut.
NG
Malfunction is detected when ... I The minimum voltage from the sensor does not reach the specified voltage.
EC-180
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
SR20DE DTC Confirmation Procedure
DTC Confirmation Procedure
SEF682X
SEF684X
NCEC0148
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0137” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) 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 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED
1,650 - 3,600 rpm (CVT) 1,500 - 3,600 rpm (M/T)
Vehicle speed
68 - 130 km/h (42 - 81 MPH)
B/FUEL SCHDL
3.2 - 15.0 msec (CVT) 3.2 - 13.5 msec (M/T)
Selector lever
D position (CVT) 4th gear position (M/T)
NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG
EC-181
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
SR20DE
Overall Function Check
RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-184.
Overall Function Check
SEF032X
NCEC0149
Use this procedure to check the overall function of the heated oxygen sensor 2 (rear) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage when revving engine 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 0.43V at least once during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) 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 (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be below 0.43V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-SR-184.
EC-182
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
SR20DE Wiring Diagram
Wiring Diagram
NCEC0150
YEC086A
EC-183
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0151
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector
Engine ground SEF202X
©
2
GO TO 2.
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.
SEF652Y
4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector
Air cleaner SEF203X
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0172. Refer to EC-SR-218.
No
©
GO TO 3.
EC-184
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
SR20DE
Diagnostic Procedure (Cont’d)
3
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector. Heated oxygen sensor 2 (rear) harness connector
Heated oxygen sensor 2 (rear)
Front exhaust tube SEF209X
3. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 63 (or terminal 2) and ground. Continuity should not exist. 5. 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 harness for open or short between heated oxygen sensor 2 (rear) and ECM.
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and body ground. 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 HEATED OXYGEN SENSOR 2 (REAR)
Refer to “Component Inspection”, EC-SR-186. OK or NG OK
©
GO TO 7.
NG
©
Replace heated oxygen sensor 2 (rear).
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-185
DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)
SR20DE
Component Inspection
Component Inspection
NCEC0152
HEATED OXYGEN SENSOR 2 (REAR)
SEF662Y
NCEC0152S01
With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “RR O2 SEN -B1” should be above 0.48V at least once when the “FUEL INJECTION” is +25%.“HO2S2 (B1)” should be below 0.43V 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.
x0.01V
(Reference data)
The voltage should be above 0.48V at least one time.
The voltage should be below 0.43V at least one time. SEF989R
CONNECT
Without CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) 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 0.48V at least once. If the voltage is above 0.48V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or 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 (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be below 0.43V at least once. 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. 1)
SEF032X
EC-186
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
SR20DE Component Description
Component Description
SEF327R
NCEC0153
The heated oxygen sensor 2 (rear) (Rear HO2S), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). 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 (rear) is not used for engine control operation.
CONSULT-II Reference Value in Data Monitor Mode
NCEC0154
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S2 (B1) I Engine: After warming up
HO2S2 MNTR (B1)
Revving engine from idle to 3,000 rpm
LEAN +, RICH
ECM Terminals and Reference Value
NCEC0155
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 63
WIRE COLOR
ITEM
CONDITION
Heated oxygen sensor 2 (rear)
L
DATA (DC Voltage)
[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and engine speed is 2,000 rpm
On Board Diagnosis Logic OK 1V 0.43V
0V
SEF259V
DTC No. P0138 0138
NCEC0156
The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the maximum voltage of the sensor is sufficiently high during various driving conditions such as fuel-cut.
NG
Malfunction is detected when ... I The maximum voltage from the sensor does not reach the specified voltage.
EC-187
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors I Intake air leaks
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
SR20DE
DTC Confirmation Procedure
DTC Confirmation Procedure
SEF685X
SEF687X
NCEC0157
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0138” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) 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 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED
1,650 - 3,600 rpm (CVT) 1,500 - 3,600 rpm (M/T)
Vehicle speed
68 - 130 km/h (42 - 81 MPH)
B/FUEL SCHDL
3.2 - 15.0 msec (CVT) 3.2 - 13.5 msec (M/T)
Selector lever
D position (CVT) 4th gear position (M/T)
NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG
EC-188
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
SR20DE Overall Function Check
RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-191.
Overall Function Check
CONNECT
SEF032X
NCEC0158
Use this procedure to check the overall function of the heated oxygen sensor 2 (rear) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage when revving engine 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 0.48V at least once during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) 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 (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be above 0.48V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-SR-191.
EC-189
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0159
YEC086A
EC-190
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0160
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector
Engine ground SEF202X
©
2
GO TO 2.
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.
SEF652Y
4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector
Air cleaner SEF203X
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0171. Refer to EC-SR-212.
No
©
GO TO 3.
EC-191
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
SR20DE
Diagnostic Procedure (Cont’d)
3
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 (or terminal 2) and ground. Continuity should not exist. 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
Check the harness for open or short between ECM and heated oxygen sensor 2 (rear).
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and engine ground. 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 HEATED OXYGEN SENSOR 2 (REAR)
Refer to “Component Inspection”, EC-SR-193. OK or NG OK
©
GO TO 7.
NG
©
Replace heated oxygen sensor 2 (rear).
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-192
DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)
SR20DE Component Inspection
Component Inspection
NCEC0161
HEATED OXYGEN SENSOR 2 (REAR)
NEF091A
NCEC0161S01
With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes.. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.48V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.43V 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.
x0.01V
(Reference data)
The voltage should be above 0.48V at least one time.
The voltage should be below 0.43V at least one time. SEF989R
Without CONSULT-II Start engine and drive vehicle at a speed of 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) 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 0.48V at least once. If the voltage is above 0.48V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or 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 (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be below 0.43V at least once. 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. 1)
SEF032X
EC-193
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
SR20DE
Component Description
Component Description
SEF327R
NCEC0162
The heated oxygen sensor 2 (rear) (Rear HO2S), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). 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 (rear) is not used for engine control operation.
CONSULT-II Reference Value in Data Monitor Mode
NCEC0163
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S2 (B1) I Engine: After warming up
HO2S2 MNTR (B1)
Revving engine from idle to 3,000 rpm
LEAN +, RICH
ECM Terminals and Reference Value
NCEC0164
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 63
WIRE COLOR
ITEM
CONDITION
Heated oxygen sensor 2 (rear)
L
DATA (DC Voltage)
[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 2,000 rpm
On Board Diagnosis Logic OK
SEF302U
DTC No. P0139 0139
NCEC0165
The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the switching response of the sensor’s voltage is faster than specified during various driving conditions such as fuel-cut.
NG
Malfunction is detected when ... I It takes more than the specified time for the sensor to respond between rich and lean.
EC-194
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors I Intake air leaks
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
SR20DE DTC Confirmation Procedure
DTC Confirmation Procedure
SEF688X
SEF690X
NCEC0166
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0139” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) 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 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED
1,650 - 3,600 rpm (CVT) 1,500 - 3,600 rpm (M/T)
Vehicle speed
68 - 130 km/h (42 - 81 MPH)
B/FUEL SCHDL
3.2 - 15.0 msec (CVT) 3.2 - 13.5 msec (M/T)
Selector lever
D position (CVT) 4th gear position (M/T)
NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG
EC-195
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
SR20DE
Overall Function Check
RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-198.
Overall Function Check
CONNECT
SEF032X
NCEC0167
Use this procedure to check the overall function of the heated oxygen sensor 2 (rear) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) 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 change at more than 0.06V for 1 second during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) 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 (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should change at more than 0.06V for 1 second during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-SR-198.
EC-196
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
SR20DE Wiring Diagram
Wiring Diagram
NCEC0168
YEC086A
EC-197
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0169
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector
Engine ground SEF202X
©
2
GO TO 2.
CLEAR THE SELF-LEARNING DATA
With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.
SEF652Y
4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? 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 harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector
Air cleaner SEF203X
4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes
©
Perform trouble diagnosis for DTC P0172. Refer to EC-SR-218.
No
©
GO TO 3.
EC-198
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
SR20DE
Diagnostic Procedure (Cont’d)
3
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector. Heated oxygen sensor 2 (rear) harness connector
Heated oxygen sensor 2 (rear)
Front exhaust tube SEF209X
2. Check harness continuity between ECM terminal 63 and rear heated oxygen harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 (or terminal 2) and ground. Continuity should not exist. 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
Check the harness for open or short between heated oxygen sensor 2 (rear) and ECM.
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 1 and engine ground. 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 HEATED OXYGEN SENSOR 2 (REAR)
Refer to “Component Inspection”, EC-SR-200. OK or NG OK
©
GO TO 7.
NG
©
Replace heated oxygen sensor 2 (rear).
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-199
DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)
SR20DE
Component Inspection
Component Inspection
NCEC0170
HEATED OXYGEN SENSOR 2 (REAR)
SEF662Y
NCEC0170S01
With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.48V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.43V 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.
x0.01V
(Reference data)
The voltage should be above 0.48V at least one time.
The voltage should be below 0.43V at least one time. SEF989R
Without CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) 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 0.48V at least once. If the voltage is above 0.48V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or 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 (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be below 0.43V at least once. 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. 1)
SEF032X
EC-200
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
SR20DE Component Description
Component Description
SEF327R
NCEC0171
The heated oxygen sensor 2 (rear) (Rear HO2S), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). 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 (rear) is not used for engine control operation.
CONSULT-II Reference Value in Data Monitor Mode
NCEC0172
Specification data are reference values. MONITOR ITEM
CONDITION
SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V
HO2S2 (B1) I Engine: After warming up
HO2S2 MNTR (B1)
Revving engine from idle to 3,000 rpm
LEAN +, RICH
ECM Terminals and Reference Value
NCEC0173
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 63
WIRE COLOR
ITEM
CONDITION
Heated oxygen sensor 2 (rear)
L
DATA (DC Voltage)
[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 2,000 rpm
On Board Diagnosis Logic OK
SEF305U
DTC No. P0140 0140
NCEC0174
The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether or not the voltage is too high during various driving conditions such as fuelcut.
NG
Malfunction is detected when ... I An excessively high voltage from the sensor is sent to ECM.
EC-201
Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear)
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
SR20DE
DTC Confirmation Procedure
DTC Confirmation Procedure
NEF102A
ENG SPEED
1,650 - 3,600 rpm (CVT) 1,500 - 3,600 rpm (M/T)
VHCL SPEED SE
68 - 130 km/h (42 - 81 MPH)
B/FUEL SCHDL
3.2 - 15.0 msec (CVT) 3.2 - 13.5 msec (M/T)
COOLAN TEMP/S
70 - 100°C (158 - 212°F)
Selector lever
Suitable position
6)
If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-204.
Overall Function Check
SEF032X
NCEC0175
NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 3) Stop vehicle with engine running. 4) Let engine idle for 1 minute. 5) Maintain the following conditions for at least 5 consecutive seconds.
NCEC0176
Use this procedure to check the overall function of the heated oxygen sensor 2 (rear) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage after 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 2V during this procedure. 5) If NG, go to “Diagnostic Procedure”, EC-SR-204.
EC-202
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
SR20DE Wiring Diagram
Wiring Diagram
NCEC0177
YEC086A
EC-203
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0178
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector
Engine ground SEF202X
©
2
GO TO 2.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector. Heated oxygen sensor 2 (rear) harness connector
Heated oxygen sensor 2 (rear)
Front exhaust tube SEF209X
2. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 (or terminal 2) and ground. Continuity should not 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 harness for open or short between heated oxygen sensor 2 (rear) and ECM. ©
4
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 4 and engine ground. 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-204
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
SR20DE Component Inspection
5
CHECK HARNESS CONNECTOR
Check heated oxygen sensor 2 (rear) harness connector for water. Water should not exist. OK or NG OK
©
GO TO 6.
NG
©
Repair or replace harness connector.
6
CHECK HEATED OXYGEN SENSOR 2 (REAR)
Refer to “Component Inspection”, EC-SR-205. OK or NG OK
©
GO TO 7.
NG
©
Replace heated oxygen sensor 2 (rear).
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
Component Inspection REAR HEATED OXYGEN SENSOR
x0.01V
SEF662Y
NCEC0179 NCEC0179S01
With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.48V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.43V 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. (Reference data)
The voltage should be above 0.48V at least one time.
The voltage should be below 0.43V at least one time. SEF989R
EC-205
DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)
SR20DE
Component Inspection (Cont’d)
SEF032X
Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) 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 0.48V at least once. If the voltage is above 0.48V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or 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 (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be below 0.43V at least once. 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-206
DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER
SR20DE Description
Description
NCEC0180
SYSTEM DESCRIPTION
NCEC0180S01
Sensor
ECM function
Input Signal to ECM
Camshaft position sensor
Actuator
Heated oxygen sensor Heated oxygen sensor 2 (rear) 2 (rear) heater heater control
Engine speed
The ECM performs ON/OFF control of the heated oxygen sensor 2 (rear) heater corresponding to the engine speed.
OPERATION
NCEC0180S02
Engine condition
Heated oxygen sensor 2 (rear) heater
Engine stopped
OFF
Engine is running below 3,600 rpm. [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]
ON
CONSULT-II Reference Value in Data Monitor Mode
NCEC0181
Specification data are reference values. MONITOR ITEM
HO2S2 HTR (B1)
CONDITION
SPECIFICATION
I Engine speed: Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]
ON
I Ignition switch ON (Engine stopped)
OFF
ECM Terminals and Reference Value
NCEC0182
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERWIRE MINAL COLOR NO.
3
W/R
ITEM
Heated oxygen sensor 2 (rear) heater
CONDITION
DATA (DC Voltage)
[Engine is running] I Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]
Approximately 0.7V
[Ignition switch “ON”] I Engine stopped
BATTERY VOLTAGE (11 - 14V)
On Board Diagnosis Logic DTC No. P0141 0141
Malfunction is detected when ... I The current amperage in the heated oxygen sensor 2 (rear) heater circuit is out of the normal range. (An improper voltage drop signal is sent to ECM through the heated oxygen sensor 2 (rear) heater.)
EC-207
NCEC0183
Check Items (Possible Cause) I Harness or connectors (The heated oxygen sensor 2 (rear) heater circuit is open or shorted.) I Heated oxygen sensor 2 (rear) heater
DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER
SR20DE
DTC Confirmation Procedure
DTC Confirmation Procedure
NCEC0184
NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is in between 10.5V and 16V at idle.
With CONSULT-II Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-210. With GST 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 4) Select “MODE 3” with GST. 5) If DTC is detected, go to “Diagnostic Procedure”, EC-SR-210. When using GST, “DTC Confirmation Procedure ” should be performed twice as much as when using CONSULT-II or ECM (Diagnostic Test Mode II) because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II or ECM (Diagnostic Test Mode II) is recommended. 1)
NEF103A
EC-208
DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER
SR20DE Wiring Diagram
Wiring Diagram
NCEC0185
YEC087A
EC-209
DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0186
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 2 (rear) harness connector. Heated oxygen sensor 2 (rear) harness connector
Heated oxygen sensor 2 (rear)
Front exhaust tube
SEF209X
3. Turn ignition switch “ON”. 4. Check voltage between terminal 4 and ground.
SEF047X
Voltage: Battery voltage OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104 (M81, F115 for CVT models) I Harness for open or short between heated oxygen sensor 2 (rear) and fuse ©
3
Repair harness or connectors.
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 1 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 5.
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the harness for open or short between heated oxygen sensor 2 (rear) heater and ECM. ©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-210
DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER
SR20DE
Component Inspection
5
CHECK HEATED OXYGEN SENSOR 2 (REAR) HEATER
Refer to “Component Inspection”, EC-SR-211. OK or NG OK
©
GO TO 6.
NG
©
Replace heated oxygen sensor 2 (rear).
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©
INSPECTION END
Component Inspection
NCEC0187
HEATED OXYGEN SENSOR 2 (REAR) HEATER
NCEC0187S01
Check the following. 1. Check resistance between terminals 1 and 4. Resistance: 2.3 - 4.3Ω at 25°C (77°F) 2. Check continuity. Terminal No.
Continuity
2 and 1, 3, 4 No 3 and 1, 2, 4
If NG, replace the heated oxygen sensor 2 (rear). 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.
SEF048X
EC-211
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
SR20DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0188
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 (front). 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
P0171 0171
Fuel injection & mixture ratio control
Density of oxygen in exhaust gas (Mixture ratio feedback signal)
Heated oxygen sensor 1 (front)
DTC No.
ECM function
Input Signal to ECM
Malfunction is detected when ... I Fuel injection system does not operate properly. I The amount of mixture ratio compensation is too large. (The mixture ratio is too lean.)
Actuator
Injectors
Check Items (Possible Cause) I I I I I I I
Intake air leaks Heated oxygen sensor 1 (front) Injectors Exhaust gas leaks Incorrect fuel pressure Lack of fuel Mass air flow sensor
DTC Confirmation Procedure
SEF652Y
SEF058Y
Mass air flow sensor harness connector
Air cleaner
NCEC0189
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 4) Clear the self-learning control coefficient by touching “CLEAR”. 5) Select “DATA MONITOR” mode with CONSULT-II. 6) 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 “Diagnostic Procedure”, EC-SR214. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-SR-214. If engine does not start, visually check for exhaust and intake air leak. With GST Follow the procedure “With CONSULT-II” above.
SEF203X
EC-212
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
SR20DE Wiring Diagram
Wiring Diagram
NCEC0190
YEC088A
EC-213
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0191
CHECK EXHAUST AIR LEAK
1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.
SEF099P
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 mass air flow sensor. OK or NG OK
©
GO TO 3.
NG
©
Repair or replace.
3
CHECK HEATED OXYGEN SENSOR 1 (FRONT) CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector.
Heated oxygen sensor 1 (front) harness connector
Heated oxygen sensor 1 (front) SEF207X
3. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not 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-214
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
SR20DE
Diagnostic Procedure (Cont’d)
4
CHECK FUEL PRESSURE
1. Release fuel pressure to zero. Refer to EC-SR-31. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi) OK or NG OK
©
GO TO 6.
NG
©
GO TO 5.
5
DETECT MALFUNCTIONING PART
Check the following. I Fuel pump and circuit Refer to EC-SR-316. I Fuel pressure regulator Refer to EC-SR-32. I Fuel lines Refer to “ENGINE MAINTENANCE” in MA section. I Fuel filter for clogging
©
6
Repair or replace.
CHECK MASS AIR FLOW SENSOR
With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec OK or NG OK
©
GO TO 7.
NG
©
Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-SR-120.
EC-215
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
SR20DE
Diagnostic Procedure (Cont’d)
7
CHECK FUNCTION OF INJECTORS
With CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.
NEF105A
4. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Listen to each injector operating sound.
At idle
Suitable tool
MEC703B
Clicking noise should be heard. OK or NG OK
©
GO TO 8.
NG
©
Perform trouble diagnosis for “INJECTORS”, EC-SR-304.
8
REMOVE INJECTOR
1. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 2. Turn ignition switch “OFF”. 3. Remove injector with fuel tube assembly. Refer to EC-SR-32. Keep fuel hose and all injectors connected to injector gallery. The injector harness connectors should remain connected.
©
GO TO 9.
EC-216
DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)
SR20DE
Diagnostic Procedure (Cont’d)
9
CHECK INJECTOR
1. Disconnect all ignition coil harness connectors. 2. Place pans or saucers under each injector. 3. Crank engine for about 3 seconds. Make sure that fuel sprays out from injectors.
SEF595Q
Fuel should be sprayed evenly for each cylinder. OK or NG OK
©
GO TO 10.
NG
©
Replace injectors from which fuel does not spray out. Always replace O-ring with new one.
10
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-217
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
SR20DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0192
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 (front). 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 a fuel injection system malfunction and lights up the MI (2 trip detection logic). Sensor
Heated oxygen sensor 1 (front)
DTC No. P0172 0172
ECM function
Input Signal to ECM
Fuel injection & mixture ratio control
Density of oxygen in exhaust gas (Mixture ratio feedback signal)
Malfunction is detected when ... I Fuel injection system does not operate properly. I The amount of mixture ratio compensation is too large. (The mixture ratio is too rich.)
Actuator
Injectors
Check Items (Possible Cause) I I I I I
Heated oxygen sensor 1 (front) Injectors Exhaust gas leaks Incorrect fuel pressure Mass air flow sensor
DTC Confirmation Procedure
SEF652Y
SEF058Y
NCEC0193
NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 4) Clear the self-learning control coefficient by touching “CLEAR”. 5) Select “DATA MONITOR” mode with CONSULT-II. 6) 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 “Diagnostic Procedure”, EC-SR221. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-SR-221. If engine does not start, remove ignition plugs and check for fouling, etc.
EC-218
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
SR20DE
DTC Confirmation Procedure (Cont’d)
With GST Follow the procedure “With CONSULT-II” above.
Mass air flow sensor harness connector
Air cleaner
SEF203X
EC-219
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0194
YEC088A
EC-220
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0195
CHECK FOR EXHAUST AIR LEAK
1. Start engine and run it at idle. 2. Listen for an exhaust air leak before the three way catalyst.
SEF099P
OK or NG OK
©
GO TO 2.
NG
©
Repair or replace.
2
CHECK HEATED OXYGEN SENSOR 1 (FRONT) CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector.
Heated oxygen sensor 1 (front) harness connector
Heated oxygen sensor 1 (front) SEF207X
3. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not 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 PRESSURE
1. Release fuel pressure to zero. Refer to EC-SR-31. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. Approximately 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. Approximately 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi) OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
EC-221
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
SR20DE
Diagnostic Procedure (Cont’d)
4
DETECT MALFUNCTIONING PART
Check the following. I Fuel pump and circuit (Refer to EC-SR-316.) I Fuel pressure regulator (Refer to EC-SR-32.) ©
5
Repair or replace.
CHECK MASS AIR FLOW SENSOR
With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec OK or NG OK
©
GO TO 6.
NG
©
Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-SR-123.
6
CHECK FUNCTION OF INJECTORS
With CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.
NEF105A
4. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Listen to each injector operating sound.
MEC703B
Clicking noise should be heard. OK or NG OK
©
GO TO 7.
NG
©
Perform trouble diagnosis for “INJECTORS”, EC-SR-304.
EC-222
DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)
SR20DE
Diagnostic Procedure (Cont’d)
7
REMOVE INJECTOR
1. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 2. Turn ignition switch “OFF”. 3. Remove injector assembly. Refer to EC-SR-32. Keep fuel hose and all injectors connected to injector gallery.
©
8 1. 2. 3. 4.
GO TO 8.
CHECK INJECTOR Disconnect all injector harness connectors. Disconnect all ignition coil harness connectors. Prepare pans or saucers under each injectors. Crank engine for about 3 seconds. Make sure fuel does not drip from injector. OK or NG
OK (Does not drip)
©
GO TO 9.
NG (Drips)
©
Replace the injectors from which fuel is dripping. Always replace O-ring with new one.
9
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-223
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
SR20DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0202
If a misfire occurs, the engine speed will fluctuate. If the fluctuation is detected by the crankshaft position sensor (OBD), the misfire is diagnosed. Sensor
Input Signal to ECM
Crankshaft position sensor (OBD)
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 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 exhaust 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. P0300 0300 P0301 0301 P0302 0302 P0303 0303 P0304 0304
Malfunction is detected when ... I Multiple cylinders misfire. I No. 1 cylinder misfires. I No. 2 cylinder misfires. I No. 3 cylinder misfires.
I I I I I I I I I I I
I No. 4 cylinder misfires.
Check Items (Possible Cause) Improper spark plug Insufficient compression Incorrect fuel pressure The injector circuit is open or shorted Injectors Intake air leak The ignition secondary circuit is open or shorted Lack of fuel Heated oxygen sensor 1 (front) Drive plate/Flywheel Incorrect distributor rotor
DTC Confirmation Procedure
NEF068A
NCEC0203
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 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). With CONSULT-II 1) Turn ignition switch “ON”, and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and warm it up to normal operating temperature. 3) Turn ignition switch “OFF” and wait at least 9 seconds. 4) Start engine again and drive at 1,500 - 3,000 rpm for at least 3 minutes. Hold the accelerator pedal as steady as possible. NOTE: Refer to the freeze frame data for the test driving conditions. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-SR-225. With GST Follow the procedure “With CONSULT-II” above.
EC-224
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0204
CHECK FOR INTAKE AIR LEAK
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.
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 it.
3
PERFORM POWER BALANCE TEST
With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode.
NEF105A
2. Is there any cylinder which does not produce a momentary engine speed drop? Without CONSULT-II When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop? Remove to test other injectors
Injector harness connector (for No. 2 cylinder)
Yes or No Yes
©
GO TO 5.
No
©
GO TO 8.
EC-225
SEF233X
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
SR20DE
Diagnostic Procedure (Cont’d)
4
CHECK INJECTOR
Does each injector make an operating sound at idle?
MEC703B
Yes or No Yes
©
GO TO 6.
No
©
Check injector(s) and circuit(s). Refer to EC-SR-304.
5 1. 2. 3. 4. 5.
CHECK IGNITION SPARK Turn Ignition switch “OFF”. Disconnect ignition wire from spark plug. Connect a known good spark plug to the ignition wire. Place end of spark plug against a suitable ground and crank engine. Check for spark.
Ignition wire
Spark plug
SEF282G
OK or NG OK
©
GO TO 8.
NG
©
GO TO 7.
6
CHECK IGNITION WIRES
Refer to “Component Inspection”, EC-SR-229. OK or NG OK
©
Check distributor rotor head for incorrect parts. Check ignition coil, power transistor and their circuits. Refer to EC-SR-310.
NG
©
Replace.
EC-226
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
SR20DE
Diagnostic Procedure (Cont’d)
7
CHECK SPARK PLUGS
Remove the spark plugs and check for fouling, etc.
SEF156I
OK or NG OK
©
GO TO 9.
NG
©
Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to “ENGINE MAINTENANCE” in MA section.
8
CHECK COMPRESSION PRESSURE
Refer to EM section. I Check compression pressure. Standard: 1,226 kPa (12.26 bar, 12.5 kg/cm2, 178 psi)/300 rpm Minimum: 1,030 kPa (10.30 bar, 10.5 kg/cm2, 149 psi)/300 rpm Difference between each cylinder: 98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)/300 rpm OK or NG OK
©
GO TO 10.
NG
©
Check pistons, piston rings, valves, valve seats and cylinder head gaskets.
9
CHECK FUEL PRESSURE
1. Install any parts removed. 2. Release fuel pressure to zero. Refer to EC-SR-31. 3. Install fuel pressure gauge and check fuel pressure.
Fuel filter
SEF194X
At idle: Approx. 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) OK or NG OK
©
GO TO 12.
NG
©
GO TO 11.
EC-227
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE Diagnostic Procedure (Cont’d)
10
DETECT MALFUNCTIONING PART
Check the following. I Fuel pump and circuit Refer to EC-SR-320. I Fuel pressure regulator Refer to EC-SR-32. I Fuel lines Refer to “ENGINE MAINTENANCE” in MA section. I Fuel filter for clogging
©
11
Repair or replace.
CHECK IGNITION TIMING
Perform “Basic Inspection”, EC-SR-84. OK or NG OK
©
GO TO 13.
NG
©
Adjust ignition timing.
12
CHECK HEATED OXYGEN SENSOR 1 (FRONT)
Refer to “Component Inspection”, EC-SR-154. OK or NG OK
©
GO TO 14.
NG
©
Replace heated oxygen sensor 1 (front).
13
CHECK MASS AIR FLOW SENSOR
With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec OK or NG OK
©
GO TO 16.
NG
©
GO TO 15.
14
CHECK CONNECTORS
Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-SR-120. OK or NG NG
15
©
Repair or replace it.
CHECK SYMPTOM MATRIX CHART
Check items on the rough idle symptom in “Symptom Matrix Chart”, EC-SR-94. OK or NG OK
©
GO TO 17.
NG
©
Repair or replace.
EC-228
SR20DE
DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE
SR20DE Component Inspection
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-SR-56.
©
17
GO TO 18.
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
Component Inspection IGNITION WIRES 1. 2.
SEF174P
NCEC0576 NCEC0576S01
Inspect wires for cracks, damage, burned terminals and for improper fit. Measure the resistance of wires to their distributor cap terminal. Move each wire while testing to check for intermittent breaks. Resistance: 4.5 - 6.7 kΩ/m (1.37 - 2.04 kΩ/ft) at 25°C (77°F) If the resistance exceeds the above specification, inspect ignition wire to distributor cap connection. Clean connection or replace the ignition wire with a new one.
EC-229
SR20DE
DTC P0325 KNOCK SENSOR (KS) Component Description
Component Description
NCEC0206
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. Freeze frame data will not be stored in the ECM for the knock sensor. The MI will not light for knock sensor malfunction. The knock sensor has one trip detection logic. SEF598K
ECM Terminals and Reference Value
NCEC0207
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 81
WIRE COLOR W
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running] I Idle speed
Knock sensor
2.0 - 3.0V
On Board Diagnosis Logic DTC No. P0325 0325
Malfunction is detected when ... I An excessively low or high voltage from the knock sensor is sent to ECM.
Check Items (Possible Cause) I Harness or connectors (The knock sensor circuit is open or shorted.) I Knock sensor
DTC Confirmation Procedure
NEF068A
NCEC0208
NCEC0209
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 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) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 5 seconds at idle speed. 3) If DTC is detected, go to “Diagnostic Procedure”, EC-SR-232. With GST Follow the procedure “With CONSULT-II” above.
EC-230
DTC P0325 KNOCK SENSOR (KS)
SR20DE Wiring Diagram
Wiring Diagram
NCEC0210
YEC089A
EC-231
DTC P0325 KNOCK SENSOR (KS)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0211
RETIGHTEN GROUND SCREWS
Loosen and retighten engine ground screws. Intake manifold collector
Engine ground SEF202X
©
2
GO TO 2.
CHECK INPUT SIGNAL CIRCUIT-1
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and knock sensor harness connector. View from under the vehicle Knock sensor harness connector
Knock sensor
Drive shaft
SEF210X
3. Check harness continuity between knock sensor signal terminal 2 and ECM terminal 81. 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 harness for open or short between knock sensor and ECM.
©
4
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK KNOCK SENSOR
Knock sensor Refer to “Component Inspection”, EC-SR-233. OK or NG OK
©
GO TO 5.
NG
©
Replace knock sensor.
EC-232
DTC P0325 KNOCK SENSOR (KS)
SR20DE Component Inspection
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
Component Inspection KNOCK SENSOR I 1. 2.
NCEC0212 NCEC0212S01
Use an ohmmeter which can measure more than 10 MΩ. Disconnect knock sensor harness connector. Check resistance between terminal 2 and ground. Resistance: 532 - 588 kΩ [at 20°C (68°F)] CAUTION: Discard any knock sensors that have been dropped or physically damaged. Use only new ones.
SEF057X
EC-233
DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) SR20DE Component Description
Component Description Core
Coil Permanent magnet SEF956N
NCEC0577
The crankshaft position sensor (OBD) is located on the transmission housing facing the gear teeth (cogs) of the flywheel or drive plate. It detects the fluctuation of the engine revolution. The sensor consists of a permanent magnet, core and coil. 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. This sensor is not used to control the engine system. It is used only for the on board diagnosis.
Crankshaft position sensor (OBD) harness connector Cooling fan motor (Left side)
SEF226X
ECM Terminals and Reference Value
NCEC0578
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 58
WIRE COLOR
B
ITEM
Sensors’ ground
CONDITION
DATA (AC Voltage)
[Engine is running] I Warm-up condition I Idle speed
Approximately 0V 3 - 5V (AC range)
[Engine is running] I Warm-up condition I Idle speed SEF721W
65
W
Crankshaft position sensor (OBD)
6 - 9V (AC range)
[Engine is running] I Engine speed is 2,000 rpm SEF722W
On Board Diagnosis Logic DTC No. P0335 0335
Malfunction is detected when ...
NCEC0579
Check Items (Possible Cause)
I The proper pulse signal from the crankshaft position sen- I Harness or connectors sor (OBD) is not sent to ECM while the engine is running (The crankshaft position sensor (OBD) circuit is at the specified engine speed. open.) I Crankshaft position sensor (OBD)
EC-234
DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) SR20DE DTC Confirmation Procedure
DTC Confirmation Procedure
NCEC0580
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 10 seconds at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-237. With GST Follow the procedure “With CONSULT-II” above.
EC-235
DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) SR20DE Wiring Diagram
Wiring Diagram
NCEC0581
: Detectable line for DTC : Non-detectable line for DTC : Hyper CVT models CRANKSHAFT POSITION SENSOR (OBD)
TCM (TRANSMISSION CONTROL MODULE)
ECM
YEC839
EC-236
DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0582
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
©
2
GO TO 2.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.
Crankshaft position sensor (OBD) harness connector Cooling fan motor (Left side)
SEF226X
2. Check continuity between ECM terminal 65 and crankshaft position sensor (OBD) harness connector 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 4.
NG
©
GO TO 3.
3
DETECT MALFUNCTIONING PART
Check the harness for open or short between crankshaft position sensor (OBD) and ECM.
©
4
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Reconnect ECM harness connectors. 2. Check harness continuity between crankshaft position sensor harness connector terminal 2 and engine 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 6.
NG
©
GO TO 5.
5
DETECT MALFUNCTIONING PART
Check the following. I Harness for open or short between crankshaft position sensor (OBD) and ECM I Harness for open or short between crankshaft position sensor (OBD) and TCM (Transmission control module)
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-237
DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) SR20DE Component Inspection
6
CHECK IMPROPER INSTALLATION
Loosen and retighten the fixing bolt of the crankshaft position sensor (OBD). Then retest.
Trouble is not fixed.
7
©
GO TO 7.
CHECK CRANKSHAFT POSITION SENSOR (OBD)
Refer to “Component Inspection”, EC-SR-238. OK or NG OK
©
GO TO 8.
NG
©
Replace crankshaft position sensor (OBD).
8
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
Component Inspection CRANKSHAFT POSITION SENSOR (OBD) 1. 2. 3. 4.
Disconnect crankshaft position sensor (OBD) harness connector. Loosen the fixing bolt of the sensor. Remove the sensor. Visually check the sensor for chipping.
SEF960N
5.
NCEC0583 NCEC0583S01
Check resistance as shown in the figure. Resistance: M/T models 166 - 204 Ω [at 20°C (68°F)] CVT models Approx. 285 Ω [at 20°C (68°F)]
SEF231W
EC-238
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)
SR20DE
Component Description Rotor head Sealed cover
Light emitting diode
Photo diode
Ignition coil with power transistor SEF998R
180° signal slit for No. 1 cylinder 1° signal slit 180° signal slit
Component Description
NCEC0220
The camshaft position sensor is a basic component of the engine control system. It monitors engine speed and piston position. These input signals to the engine control system are used to control fuel injection, ignition timing and other functions. The camshaft position sensor has a rotor plate and a wave-forming circuit. The rotor plate has 360 slits for a 1° (POS) signal and 4 slits for a 180° (REF) signal. The wave-forming circuit consists of Light Emitting Diodes (LED) and photo diodes. The rotor plate is positioned between the LED and the photo diode. The LED transmits light to the photo diode. As the rotor plate turns, the slits cut the light to generate rough-shaped pulses. These pulses are converted into on-off signals by the wave-forming circuit and sent to the ECM. The distributor is not repairable and must be replaced as an assembly except distributor cap and rotor head.
SEF853B
Rotor plate
ECM Terminals and Reference Value
NCEC0221
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.
WIRE COLOR
ITEM
CONDITION
DATA (DC Voltage) 0.1 - 0.4V
66*1
[Engine is running] I Warm-up condition I Idle speed
L
SEF006W
Camshaft position sensor (Reference signal)
75
L
0.1 - 0.4V
[Engine is running] I Engine speed is 2,000 rpm
SEF007W
*1: Models before VIN - P11U0548750
EC-239
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)
SR20DE
ECM Terminals and Reference Value (Cont’d) TERMINAL NO.
WIRE COLOR
ITEM
CONDITION
DATA (DC Voltage) Approximately 2.5V
[Engine is running] I Warm-up condition I Idle speed 0.2 ms SEF004W
85
Camshaft position sensor (Position signal)
B/W
Approximately 2.4V
[Engine is running] I Engine speed is 2,000 rpm 0.2 ms SEF005W
On Board Diagnosis Logic DTC No. P0340 0340
Malfunction is detected when ... A)
Either 1° or 180° signal is not sent to ECM for the first few seconds during engine cranking.
B)
Either 1° or 180° signal is not sent to ECM often enough while the engine speed is higher than the specified engine speed.
C)
The relation between 1° and 180° signal is not in the normal range during the specified engine speed.
NCEC0222
Check Items (Possible Cause) I Harness or connectors (The camshaft position sensor circuit is open or shorted.) I Camshaft position sensor I Starter motor (Refer to EL section.) I Starting system circuit (Refer to EL section.) I Dead (Weak) battery
DTC Confirmation Procedure
NCEC0223
Perform “Procedure for malfunction A” first. If DTC cannot be confirmed, perform “Procedure for malfunction B and C”. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V.
PROCEDURE FOR MALFUNCTION A
NCEC0223S01
With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Crank engine for at least 2 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-243. With GST Follow the procedure “With CONSULT-II” above. NEF068A
EC-240
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)
SR20DE
DTC Confirmation Procedure (Cont’d)
PROCEDURE FOR MALFUNCTION B AND C
NCEC0223S02
With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and run it for at least 2 seconds at idle speed. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-243. With GST Follow the procedure “With CONSULT-II” above. NEF068A
EC-241
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0224
YEC090A
EC-242
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0225
CHECK STARTING SYSTEM
Does the engine turn over? (Does the starter motor operate?) Yes or No Yes
©
GO TO 2.
No
©
Check starting system. (Refer to EL section.)
2
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector
Engine ground SEF202X
©
3
GO TO 3.
CHECK POWER SUPPLY
1. Disconnect camshaft position sensor harness connector. Ignition coil harness connector
Camshaft position sensor and power transistor harness connector
Distributor SEF211X
2. Turn ignition switch “ON”. 3. Check voltage between terminal 2 and ground with CONSULT-II or tester.
SEF232W
Voltage: Battery voltage OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
EC-243
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)
SR20DE
Diagnostic Procedure (Cont’d)
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I Harness for open or short between camshaft position sensor and ECM relay I Harness for open or short between camshaft position sensor and ECM
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between sensor terminal 3 and ECM terminal 85, sensor terminal 4 and ECM terminals 66 (Models before VIN-P11U0548750), 75. 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 GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Check harness continuity between sensor terminal 1 and engine 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
©
Repair open circuit or short to ground or short to power in harness or connectors.
7
CHECK CAMSHAFT POSITION SENSOR
Refer to “Component Inspection”, EC-SR-245. OK or NG OK
©
GO TO 8.
NG
©
Replace camshaft position sensor.
8
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-244
SR20DE
DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)
Component Inspection
Component Inspection
NCEC0226
CAMSHAFT POSITION SENSOR
NCEC0226S01
1. 2.
Start engine and warm it up to normal operating temperature. Check voltage between ECM terminals 75, 85 and engine ground under the following conditions. Terminal 66 (or 75) and engine ground
SEF215X
Condition
Idle
2,000 rpm
Voltage
0.1 - 0.4V
0.1 - 0.4V
Pulse signal
SEF007W
SEF006W
Terminal 85 and engine ground Condition
Idle
2,000 rpm
Voltage
Approximately 2.5V
Approximately 2.4V
Pulse signal 0.2 ms
0.2 ms SEF004W
SEF005W
If NG, replace distributor assembly with camshaft position sensor.
EC-245
DTC P0420 THREE WAY CATALYST FUNCTION
SR20DE
On Board Diagnosis Logic
On Board Diagnosis Logic
NCEC0240
The ECM monitors the switching frequency ratio of front and heated oxygen sensor 2 (rear)s. A three way catalyst with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2 (rear). As oxygen storage capacity decreases, the heated oxygen sensor 2 (rear) switching frequency will increase. When the frequency ratio of front and heated oxygen sensor 2 (rear)s approaches a specified limit value, the three way catalyst malfunction is diagnosed. SEF184UD
DTC No. P0420 0420
Malfunction is detected when ... I Three way catalyst does not operate properly. I Three way catalyst does not have enough oxygen storage capacity.
Check Items (Possible Cause) I I I I I I I
Three way catalyst Exhaust tube Intake air leaks Injectors Injector leaks Spark plug Improper ignition timing
DTC Confirmation Procedure
NCEC0241
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 9 seconds before conducting the next test.
WITH CONSULT-II NEF247A
NEF248A
TESTING CONDITION: I Open engine hood before conducting the following procedure. I Do not hold engine speed for more than the specified minutes below. 1) Turn ignition switch “ON”. 2) Select “DTC & SRT CONFIRMATION” then “SRT WORK SUPPORT” mode with CONSULT-II. 3) Start engine. 4) Rev engine up to 3,000±500 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely. 5) Wait 5 seconds at idle. 6) Rev engine up to 2,500±500 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. 7) Select “SELF-DIAG RESULTS” mode with CONSULT-II. 8) Confirm that the 1st trip DTC is not detected. If the 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-SR-247.
SEF560X
EC-246
DTC P0420 THREE WAY CATALYST FUNCTION
SR20DE Overall Function Check
Overall Function Check
SEF074X
Diagnostic Procedure 1
NCEC0242
Use this procedure to check the overall function of the three way catalyst. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeters probes between ECM terminals 62 (Heated oxygen sensor 1 (front) signal), 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Keep engine speed at 2,000 rpm constant under no load. 5) Make sure that the voltage switching frequency (high & low) between ECM terminal 63 and engine ground is much less than that of ECM terminal 62 and engine ground. Switching frequency ratio = A/B A: Heated oxygen sensor 2 (rear) voltage switching frequency B: Heated oxygen sensor 1 (front) 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. NOTE: If the voltage at terminal 62 does not switch periodically more than 5 times within 10 seconds at step 4, perform trouble diagnosis for DTC P0133 first. (See EC-SR-163.)
CHECK EXHAUST SYSTEM
Visually check exhaust tubes and muffler for dent. OK or NG OK
©
GO TO 2.
NG
©
Repair or replace.
EC-247
NCEC0243
DTC P0420 THREE WAY CATALYST FUNCTION
SR20DE
Diagnostic Procedure (Cont’d)
2
CHECK EXHAUST AIR LEAK
1. Start engine and run it at idle. 2. Listen for an exhaust air leak before the three way catalyst.
SEF099P
OK or NG OK
©
GO TO 3.
NG
©
Repair or replace.
3
CHECK INTAKE AIR LEAK
Listen for an intake air leak after the mass air flow sensor. OK or NG OK
©
GO TO 4.
NG
©
Repair or replace.
4
CHECK IGNITION TIMING
Check for ignition timing. Refer to TROUBLE DIAGNOSIS — “BASIC INSPECTION”, EC-SR-84. OK or NG OK
©
GO TO 5.
NG
©
Adjust ignition timing.
5
CHECK INJECTORS
1. Refer to Wiring Diagram for Injectors, EC-SR-304. 2. Stop engine and then turn ignition switch “ON”. 3. Check voltage between ECM terminals 101, 103, 105 and 107 and ground with CONSULT-II or tester.
SEF075X
Battery voltage should exist. OK or NG OK
©
GO TO 6.
NG
©
Perform “Diagnostic Procedure” INJECTOR, EC-SR-304.
EC-248
DTC P0420 THREE WAY CATALYST FUNCTION
SR20DE
Diagnostic Procedure (Cont’d)
6 1. 2. 3. 4.
CHECK IGNITION SPARK Disconnect ignition wire from spark plug. Connect a known good spark plug to the ignition wire. Place end of spark plug against a suitable ground and crank engine. Check for spark.
Ignition wire
Spark plug
SEF282G
OK or NG OK
©
GO TO 8.
NG
©
GO TO 7.
7
CHECK IGNITION WIRES
Refer to “Component Inspection”, EC-SR-310. OK or NG OK
©
Check ignition coil, power transistor and their circuits. Refer to EC-SR-310.
NG
©
Replace.
8
CHECK INJECTOR
1. Turn ignition switch “OFF”. 2. Remove injector assembly. Refer to EC-SR-32. Keep fuel hose and all injectors connected to injector gallery. 3. Disconnect camshaft position sensor harness connector. 4. Turn ignition switch “ON”. Make sure fuel does not drip from injector. OK or NG OK (Does not drip)
©
GO TO 9.
NG (Drips)
©
Replace the injector(s) from which fuel is dripping.
9
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
Trouble is fixed
©
INSPECTION END
Trouble is not fixed
©
Replace three way catalyst.
EC-249
DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)
SR20DE
Description
Description
NCEC0248
SYSTEM DESCRIPTION Sensor
Input Signal to ECM
Crankshaft position sensor (POS)
Engine speed
Mass air flow sensor
Amount of intake air
Engine coolant temperature sensor
Engine coolant temperature
Battery
Battery voltage
Ignition switch
Start signal
Closed throttle position switch
Closed throttle position
Throttle position sensor
Throttle position
Heated oxygen sensor 1 (front)
Density of oxygen in exhaust gas (Mixture ratio feedback signal)
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
NCEC0248S01
ECM function
EVAP canister purge control
Actuator
EVAP canister purge volume control solenoid valve
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
NCEC0248S02
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
NCEC0249
MONITOR ITEM PURG VOL C/V
CONDITION I Engine: Running
SPECIFICATION
Vehicle stopped
0%
Vehicle running
—
EC-250
DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)
SR20DE
ECM Terminals and Reference Value
ECM Terminals and Reference Value
NCEC0250
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.
WIRE COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running] I Warm-up condition I Idle speed
BATTERY VOLTAGE (11 - 14V) 5 - 12V
14
P/B
EVAP canister purge volume control solenoid valve (ON/OFF duty)
[Engine is running] I Warm-up condition I 2,000 rpm SEF975W
On Board Diagnosis Logic DTC No. P0443 0443
Malfunction is detected when ... I An improper voltage signal is sent to ECM through the valve.
NCEC0251
Check Items (Possible Cause) I Harness or connectors (The valve circuit is open or shorted.) I EVAP canister purge volume control solenoid valve
DTC Confirmation Procedure
NCEC0252
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V. With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 5 seconds. If 1st trip DTC is detected, go to “DIAGNOSTIC PROCEDURE”, EC-SR-253. With GST 1) Start engine and let it idle for at least 5 seconds. 2) Select “MODE 7” with GST. 3) If 1st trip DTC is detected, go to “DIAGNOSTIC PROCEDURE”, EC-SR-253. 1) 2) 3) 4)
SEF058Y
EC-251
DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0253
IGNITION SWITCH ON or START FUSE BLOCK (J/B)
Refer to EL-POWER.
: Detectable line for DTC : Non-detectable line for DTC : Hyper CVT models : M/T models
EVAP CANISTER PURGE CONTROL SOLENOID VALVE
.
ECM
REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)
YEC843
EC-252
DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0254
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector. Harness connector
EVAP canister purge volume control solenoid valve
Oil filler cap
SEF219X
3. Turn ignition switch “ON”. 4. Check voltage between terminals 2 and engine ground with CONSULT-II or tester.
DISCONNECT
SEF077X
Voltage: Battery voltage OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the harness connectors M50, F104 (M81, F115 for CVT models).
©
3
Repair harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 14 and 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.
EC-253
DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)
SR20DE
Component Inspection
4
CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to “Component Inspection” EC-SR-254. OK or NG OK
©
GO TO 5.
NG
©
Replace EVAP canister purge volume control solenoid valve.
5
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
Component Inspection
NCEC0255
EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
NEF111A
NCEC0255S01
With CONSULT-II 1) Start engine. 2) Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. If OK, inspection end. If NG, go to following step. 3) Check air passage continuity. Condition PURG VOL CONT/V value
Air passage continuity between A and B
100.0%
Yes
0.0%
No
If NG, replace the EVAP canister purge volume control solenoid valve. Without CONSULT-II Check air passage continuity. SEF079X
Condition
Air passage continuity between A and B
12V direct current supply between terminals
Yes
No supply
No
If NG or operation takes more than 1 second, replace solenoid valve.
EC-254
SR20DE
DTC P0500 VEHICLE SPEED SENSOR (VSS)
Component Description
Component Description
NCEC0272
MODELS WITH VEHICLE SPEED SENSOR The vehicle speed sensor is installed in the transaxle. It contains a pulse generator which provides a vehicle speed signal to the speedometer. The speedometer then sends a signal to the ECM.
MODELS WITHOUT VEHICLE SPEED SENSOR The ABS actuator and electric unit (control unit) provides a vehicle speed signal to the speedometer. The speedometer then sends a signal to the ECM. SEF080X
ECM Terminals and Reference Value
NCEC0273
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.
WIRE COLOR
ITEM
CONDITION
DATA (DC Voltage) Approximately 2.5V
86
OR/W
[Engine is running] Vehicle speed sensor or I Lift up the vehicle ABS actuator and electric I In 2nd gear position unit (control unit) I Vehicle speed is 40 km/h (25 MPH) SEF976W
On Board Diagnosis Logic DTC No. P0500 0500
Malfunction is detected when ... I The almost 0 km/h (0 MPH) signal from vehicle speed sensor or ABS actuator and electric unit (control unit) is sent to ECM even when vehicle is being driven.
NCEC0274
Check Items (Possible Cause) Models with vehicle speed sensor I Harness or connector (The vehicle speed sensor circuit is open or shorted.) I Vehicle speed sensor Models without vehicle speed sensor I Harness or connector (The ABS actuator and electric unit (control unit) is open or shorted.) I ABS actuator and electric unit (control unit)
DTC Confirmation Procedure
NCEC0275
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 9 seconds before conducting the next test. TESTING CONDITION: This procedure 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.
EC-255
DTC P0500 VEHICLE SPEED SENSOR (VSS)
SR20DE
DTC Confirmation Procedure (Cont’d)
1) 2)
3)
NEF112A
4) 5) 6)
With CONSULT-II Start engine Read vehicle speed sensor signal in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULT-II should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. If NG, go to “Diagnostic Procedure”, EC-SR-260. 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 10 consecutive seconds.
ENG SPEED
2,000 - 3,000 rpm (CVT) 2,700 - 3,000 rpm (M/T)
COOLAN TEMP/S
More than 70°C (158°F)
B/FUEL SCHDL
5 - 8.5 msec (CVT) 5 - 14.5 msec (M/T)
Selector lever
Suitable position
PW/ST SIGNAL
OFF
7)
If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-260. With GST Follow the procedure “With CONSULT-II” above.
EC-256
SR20DE
DTC P0500 VEHICLE SPEED SENSOR (VSS)
Wiring Diagram
Wiring Diagram
NCEC0277
MODELS BEFORE VIN - P11U0548750 IGNITION SWITCH ON or START
BATTERY
: Detectable line for DTC FUSE BLOCK (J/B)
Refer to EL-POWER.
: Non-detectable line for DTC : Hyper CVT models : M/T models
COMBINATION METER (SPEEDOMETER)
VEHICLE SPEED SENSOR
ECM
REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)
YEC844
EC-257
DTC P0500 VEHICLE SPEED SENSOR (VSS)
SR20DE
Wiring Diagram (Cont’d)
MT MODELS WITH ABS AFTER VIN - P11U0548750
YEC091A
EC-258
DTC P0500 VEHICLE SPEED SENSOR (VSS)
SR20DE Wiring Diagram (Cont’d)
EXCEPT MT MODELS WITH ABS AFTER VIN - P11U0548750
YEC092A
EC-259
DTC P0500 VEHICLE SPEED SENSOR (VSS)
SR20DE
Diagnostic Procedure
Diagnostic Procedure
NCEC0278
MODELS BEFORE VIN - P11U0548750 1
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 9. 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
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F104, M50 (CVT: F115, M81) I Harness for open or short between ECM and combination meter
©
3
Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power power. Refer to EL section.
CHECK SPEEDOMETER FUNCTION
Make sure that speedometer functions properly. OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104 and M52, F103 (CVT: M81, F115 and M80, F114) I Harness for open or short between combination meter and vehicle speed sensor
©
5
Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL section.
CHECK INTERMITTENT INCIDENT
Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-260
DTC P0500 VEHICLE SPEED SENSOR (VSS)
SR20DE
Diagnostic Procedure (Cont’d)
MT MODELS WITH ABS AFTER VIN - P11U0548750 1
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 4. 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
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F104, M50 (CVT: F115, M81) I Harness for open or short between ECM and combination meter
©
3
Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power. Refer to EL section.
CHECK SPEEDOMETER FUNCTION
Make sure that speedometer functions properly. OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104 I Harness for open or short between combination meter and vehicle speed sensor
©
5
Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL section.
CHECK INTERMITTENT INCIDENT
Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-261
DTC P0500 VEHICLE SPEED SENSOR (VSS)
SR20DE
Diagnostic Procedure (Cont’d)
EXCEPT MT MODELS WITH ABS AFTER VIN - P11U0548750 1
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 4. 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
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F104, M50 (CVT: F115, M81) I Harness for open or short between ECM and combination meter
©
3
Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power power. Refer to EL section.
CHECK SPEEDOMETER FUNCTION
Make sure that speedometer functions properly. OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M80, F114 and M81, F115 I Harness for open or short between combination meter and vehicle speed sensor
©
5
Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL section.
CHECK INTERMITTENT INCIDENT
Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-262
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
SR20DE Description
Description
NCEC0279
SYSTEM DESCRIPTION Sensor
Input Signal to ECM
Camshaft position sensor
Engine speed
Engine coolant temperature sensor
Engine coolant temperature
Ignition switch
Start signal
Throttle position sensor
Throttle position
PNP switch
Park/Neutral position
Air conditioner switch
Air conditioner operation
Power steering oil pressure switch
Power steering load signal
Battery
Battery voltage
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Cooling fan
Cooling fan operation
Electrical load
Electrical load signal
NCEC0279S01
ECM function
ECM
Actuator
IACV-AAC valve
This system automatically controls engine idle speed to a specified level. Idle speed is controlled through fine adjustment of the amount of air which by-passes the throttle valve via IACV-AAC valve. The IACV-AAC valve changes the opening of the air by-pass passage to control the amount of auxiliary air. This valve is actuated by a step motor built into the valve, which moves the valve in the axial direction in steps corresponding to the ECM output signals. One step of IACV-AAC valve movement causes the respective opening of the air by-pass passage. (i.e. when the step advances, the opening is enlarged.) The opening of the valve is varied to allow for optimum control of the engine idling speed. The crankshaft position sensor (POS) detects the actual engine speed and sends a signal to the ECM. The ECM then controls the step position of the IACV-AAC valve so that engine speed coincides with the target value memorized in ECM. The target engine speed is the lowest speed at which the engine can operate steadily. The optimum value stored in the ECM is determined by taking into consideration various engine conditions, such as during warm up, deceleration, and engine load (air conditioner, power steering, cooling fan operation and electrical load).
COMPONENT DESCRIPTION
NCEC0279S02
The IACV-AAC valve is operated by a step motor for centralized control of auxiliary air supply. This motor has four winding phases and is actuated by the output signals of ECM which turns ON and OFF two windings each in sequence. Each time the IACV-AAC valve opens or closes to change the auxiliary air quantity, the ECM sends a pulse signal to the step motor. When no change in the auxiliary air quantity is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening. SEF937W
EC-263
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
SR20DE
CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0280
MONITOR ITEM
CONDITION I I I I
IACV-AAC/V
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” or “P” No-load
SPECIFICATION
Idle
5 - 20 steps
2,000 rpm
—
ECM Terminals and Reference Value
NCEC0281
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 6 7 15 16
WIRE COLOR BR Y/B P OR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running] I Warm-up condition I Idle speed
IACV-AAC valve
0 - 14V
On Board Diagnosis Logic DTC No. P0505 0505
Malfunction is detected when ... I An improper voltage signal is sent to ECM through the valve.
Check Items (Possible Cause) I Harness or connectors (The IACV-AAC valve circuit is open.) I IACV-AAC valve
DTC Confirmation Procedure
NEF085A
NCEC0282
NCEC0283
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. If the target idle speed is out of the specified value, perform “Idle Air Volume Learning” EC-SR-46, before conducting “DTC Confirmation Procedure”. For the target idle speed, refer to the “Service Data and Specifications (SDS)”, EC-SR-330. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and warm it up to normal operating temperature. 4) Rev engine from idle to more than 2,000 rpm 20 times. If 1st trip DTC is detected, go to “DIAGNOSTIC PROCEDURE”, EC-SR-266. With GST Follow the procedure “With CONSULT-II” above.
EC-264
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
SR20DE Wiring Diagram
Wiring Diagram
NCEC0284
BATTERY : Detectable line for DTC : Non-detectable line for DTC
Refer to EL-POWER.
IACV-AAC VALVE
ECM RELAY
ECM
YEC845
EC-265
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0285
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect IACV-AAC valve harness connector.
IACV-AAC valve harness connector
SEF221X
3. Turn ignition switch “ON”. 4. Check voltage between terminal 2, 5 and ground with CONSULT-II or tester.
SEF352QA
Voltage: Battery voltage OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F73, E90 I Harness for open or short between IACV-AAC and ECM relay I 10A fuse
©
3
Repair harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 6 and terminal 1, ECM terminal 7 and terminal 4, ECM terminal 15 and terminal 3, ECM terminal 16 and 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 4.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-266
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
SR20DE
Diagnostic Procedure (Cont’d)
4 1. 2. 3. 4.
CHECK AIR CONTROL VALVE (POWER STEERING) OPERATION-I Reconnect the ECM harness connector and IACV-AAC valve harness connector. Disconnect vacuum hose connected to air control valve (Power steering) at intake air duct. Start and let it idle. Check vacuum hose for vacuum existence.
SEF969X
Vacuum slightly exists or does not exist. OK or NG OK
©
GO TO 5.
NG
©
Replace air control valve (Power steering).
5
CHECK AIR CONTROL VALVE (POWER STEERING) OPERATION-II
Check the vacuum hose for vacuum existence when steering wheel is turned.
SEF969X
Vacuum should exist. OK or NG OK
©
GO TO 8.
NG
©
GO TO 6.
EC-267
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
SR20DE
Diagnostic Procedure (Cont’d)
6 1. 2. 3. 4.
CHECK VACUUM PORT Stop engine. Disconnect vacuum hose connected to air control valve (Power steering) at the vacuum port. Blow air into vacuum port. Check that air flows freely.
SEF970X
OK or NG OK
©
GO TO 7.
NG
©
Repair or clean vacuum port.
7
CHECK VACUUM HOSES AND TUBES
1. Disconnect vacuum hoses between air control valve (Power steering) and vacuum port, air control valve (Power steering) and intake air duct. 2. Check hoses and tubes for cracks, clogging, improper connection or disconnection.
SEF109L
OK or NG OK
©
GO TO 8.
NG
©
Repair hoses or tubes.
EC-268
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
SR20DE
Diagnostic Procedure (Cont’d)
8
CHECK IACV-AAC VALVE
Refer to “Component Inspection”, EC-SR-270. OK or NG OK
©
GO TO 9.
NG
©
Replace IACV-AAC valve.
9
REPLACE IACV-AAC VALVE
1. Replace IACV-AAC valve assembly. 2. Perform “Idle Air Volume Learning”, EC-46. Is the result CMPLT or INCMP? CMPLT or INCMP CMPLT
©
INSPECTION END
INCMP
©
Follow the construction of “Idle Air Volume Learning”.
10
CHECK TARGET IDLE SPEED
1. Turn ignition switch “OFF”. 2. Reconnect all harness connectors and vacuum hoses. 3. Start engine and warm it up to normal operating temperature. 4. Also warm up transmission to normal operating temperature I For CVT models with CONSULT-II, drive vehicle until “FLUID TEMP SE” in “DATA MONITOR” mode of “CVT” system indicates less than 0.9V. I For CVT models without CONSULT-II and M/T models, drive vehicle for 10 minutes. 5. Stop vehicle with engine running. 6. Check target idle speed. M/T: 750±50 rpm A/T: 750±50 rpm (in “P” or “N” position) OK or NG OK
©
GO TO 11.
NG
©
Perform “Idle Air Volume Learning”, EC-45.
11
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-269
DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE
SR20DE
Component Inspection
Component Inspection
NCEC0286
IACV-AAC VALVE 1) 2)
NCEC0286S01
Disconnect IACV-AAC valve harness connector. Check IACV-AAC valve resistance. Condition
Resistance
Terminal 2 and terminals 1, 3 20 - 24Ω [at 20°C (68°F)] Terminal 5 and terminals 4, 6
3) 4)
5)
Reconnect IACV-AAC valve harness connector. Remove idle air adjusting unit assembly (IACV-AAC valve is built-in) from engine. (The IACV-AAC valve harness connector should remain connected.) Turn ignition switch “ON” and “OFF”, and ensure the IACVAAC valve shaft smoothly moves forward and backward, according to the ignition switch position. If NG, replace the IACV-AAC valve.
SEF353QA
SEF089X
EC-270
DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)
SR20DE
Component Description
Component Description
Throttle position switch built into throttle position sensor
NCEC0287
A closed throttle position switch and wide open throttle position switch are built into the throttle position sensor unit. The wide open throttle position switch is used only for CVT control. When the throttle valve is in the closed position, the closed throttle position switch sends a voltage signal to the ECM. The ECM only uses this signal to open or close the EVAP canister purge control valve when the throttle position sensor is malfunctioning.
Throttle position switch connector
Throttle position sensor connector
SEF505V
CONSULT-II Reference Value in Data Monitor Mode
NFEC0257
Specification data are reference values. MONITOR ITEM CLSD THL/P SE
CONDITION I Engine: Idle
SPECIFICATION
Throttle valve: Idle position
ON
Throttle valve: Slightly open
OFF
ECM Terminals and Reference Value
NCEC0288
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERWIRE MINAL COLOR NO.
40
Y
ITEM
Throttle position switch (Closed position)
CONDITION
DATA (DC Voltage)
[Engine is running] I Accelerator pedal released
BATTERY VOLTAGE (11 - 14V)
[Ignition switch “ON”] I Accelerator pedal depressed
Approximately 0V
On Board Diagnosis Logic DTC No. P0510 0510
Malfunction is detected when ...
Check Items (Possible Cause)
I Battery voltage from the closed throttle position switch is I Harness or connectors sent to ECM with the throttle valve opened. (The closed throttle position switch circuit is shorted.) I Closed throttle position switch I Throttle position sensor
EC-271
NCEC0289
DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)
SR20DE
DTC Confirmation Procedure
DTC Confirmation Procedure
SEF092X
NCEC0290
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 9 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Check ignition switch “OFF”, wait at least 9 seconds and then start engine. 3) Select “CLSD THL/P SW” in “DATA MONITOR” mode. If “CLSD THL/P SW” is not available, go to step 5. 4) Check the signal under the following conditions. Condition
Signal indication
Throttle valve: Idle position
ON
Throttle valve: Slightly open
OFF
PEF329U
5) 6)
If the result is NG, go to “Diagnostic Procedure”, EC-SR-274. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Drive the vehicle for at least 5 consecutive seconds under the following condition.
THRTL POS SEN
More than 2.3V
VHCL SPEED SE
More than 4 km/h (2 MPH)
Selector lever
Suitable position
Driving pattern
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 “Diagnostic Procedure”, ECSR-274.
Overall Function Check
CONNECT
NCEC0291
Use this procedure to check the overall function of the closed throttle position switch circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Check the voltage between ECM terminal 40 (Closed throttle position switch signal) and ground under the following conditions. Condition
SEF090X
Voltage
At idle
Battery voltage
At 2,000 rpm
Approximately 0V
3)
If NG, go to “Diagnostic Procedure”, EC-SR-274.
EC-272
DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)
SR20DE Wiring Diagram
Wiring Diagram
NCEC0292
BATTERY : Detectable line for DTC : Non-detectable line for DTC
Refer to EL-POWER.
ECM RELAY
WIDE OPEN
OFF
CLOSED
THROTTLE POSITION SWITCH (CLOSED THROTTLE POSITION SWITCH AND WIDE OPEN THROTTLE POSITION SWITCH
OFF
ECM
YEC846
EC-273
DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0293
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect throttle position switch harness connector. Throttle position sensor harness connector
Throttle body
Closed throttle position switch harness connector
SEF197X
3. Turn ignition switch “ON”. 4. Check voltage between terminal 5 and engine ground with CONSULT-II or tester.
SEF250W
Voltage: Battery voltage OK or NG OK
©
GO TO 3.
NG
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F73, E90 I Harness for open or short between throttle position switch and ECM relay I 10A fuse
©
3
Repair harness or connectors.
CHECK INPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 40 and terminal 4. 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
©
GO TO 4.
EC-274
DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)
SR20DE
Diagnostic Procedure (Cont’d)
4
DETECT MALFUNCTIONING PART
Check the following. I Harness for open or short between throttle position switch and ECM I Harness for open or short between throttle position switch and TCM (Transmission control module)
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
ADJUST THROTTLE POSITION SWITCH IDLE POSITION
Perform Basic Inspection, EC-SR-84.
©
6
GO TO 6.
CHECK CLOSED THROTTLE POSITION SWITCH
Refer to “Component Inspection”, EC-SR-276. OK or NG OK
©
GO TO 7.
NG
©
Replace throttle position switch.
7
CHECK THROTTLE POSITION SENSOR
Refer to “Component Inspection”, EC-SR-142. OK or NG OK
©
GO TO 8.
NG
©
Replace throttle position sensor.
8
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-275
DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)
SR20DE
Component Inspection
Component Inspection
NCEC0294
CLOSED THROTTLE POSITION SWITCH
NCEC0294S01
With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and turn ignition switch “ON”. 3) Select “DATA MONITOR” mode with CONSULT-II. 4) Check indication of “CLSD THL/P SW” under the following conditions. NOTE: Measurement must be made with closed throttle position switch installed in vehicle. Throttle valve conditions
CLSD THL/P SW
Completely closed
ON
Partially open or completely open
OFF
If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-SR-84. 5) If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF”. 3) Disconnect throttle position switch harness connector. 4) Check continuity between terminals 4 and 5 under the following conditions. Refer to wiring diagram. NOTE: Continuity measurement must be made with closed throttle position switch installed in vehicle. Throttle valve conditions
Continuity
Completely closed
Yes
Partially open or completely open
No
5)
If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-SR-84. If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch.
EC-276
SR20DE
DTC P0605 ECM
Component Description
Component Description
NCEC0295
The ECM consists of a microcomputer, diagnostic test mode selector, and connectors for signal input and output and for power supply. The ECM controls the engine.
SEF093X
On Board Diagnosis Logic DTC No. P0605 0605
Malfunction is detected when ... I ECM calculation function is malfunctioning.
Check Items (Possible Cause) I ECM
DTC Confirmation Procedure
NEF068A
NCEC0296
NCEC0297
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine. 4) Run engine for at least 1 second at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-278. With GST Follow the procedure “With CONSULT-II” above.
EC-277
DTC P0605 ECM
SR20DE
Diagnostic Procedure
Diagnostic Procedure 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 previous page. 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4.
With GST Turn ignition switch “ON”. Select MODE 4 with GST. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See previous page. 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4.
Yes or No Yes
©
Replace ECM.
No
©
INSPECTION END
EC-278
=NCEC0298
SR20DE
DTC P1217 OVERHEAT (COOLING SYSTEM)
System Description
System Description
NCEC0433
COOLING FAN CONTROL
NCEC0433S01
Sensor
Input Signal to ECM
ECM function
Actuator
Vehicle speed sensor or ABS actuator and Vehicle speed electric unit (control unit) Engine coolant temperature sensor
Engine coolant temperature
Air conditioner switch
Air conditioner “ON” signal
Ignition switch
Start signal
Refrigerant pressure sensor
Refrigerant pressure
ECM
Cooling fan relay(s)
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 ON-OFF control. The refrigerant pressure sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The transducer is installed in the liquid tank of the air conditioner system.
SEF099X
OPERATION
NCEC0433S02
Engine coolant temperature °C (°F)
Refrigerant pressure is less than 1.76 Mpa. 105 (221) 100 (212) 95 (203)
Engine coolant temperature °C (°F)
Engine coolant temperature °C (°F)
20 (12) 80 (50) Vehicle speed km/h (MPH) Refrigerant pressure is above 2.06 Mpa. Refrigerant pressure is between 1.76 Mpa and 2.06 Mpa. 105 (221) 100 (212) 95 (203)
105 (221) Cooling fans operate at “High” speed.
100 (212) 95 (203)
Cooling fans operate at “Low” speed. Cooling fans do no operate 20 (12) 80 (50) Vehicle speed km/h (MPH)
20 (12) 80 (50) Vehicle speed km/h (MPH)
EC-279
SEF198X
SR20DE
DTC P1217 OVERHEAT (COOLING SYSTEM) CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0486
Specification data are reference values. MONITOR ITEM
CONDITION I Engine: After warming up, idle the engine
AIR COND SIG
I After warming up engine, idle the engine. I Air conditioner switch: OFF
COOLING FAN
SPECIFICATION
Air conditioner switch: OFF
OFF
Air conditioner switch: ON (Compressor operates)
ON
Engine coolant temperature is 94°C (201°F) or less
OFF
Engine coolant temperature is between 95°C (203°F) and 104°C (219°F)
LOW
Engine coolant temperature is 105°C (221°F) or more
HIGH
ECM Terminals and Reference Value
NCEC0487
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.
13
23
74
WIRE COLOR
LG/R
—
R/L
ITEM
Cooling fan relay
Air conditioner switch
Refrigerant pressure sensor
CONDITION
DATA (DC Voltage)
[Engine is running] I Cooling fan is not operating
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Cooling fan is operating
Approximately 0V
[Engine is running] I Both air conditioner switch and blower switch are “ON” (Compressor operates)
Approximately 0V
[Engine is running] I Air conditioner switch is “OFF”
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Warm-up condition I Idle speed I Air conditioner is “ON”
More than 1.5V
On Board Diagnosis Logic
NCE0488
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. DTC No. P1217 1217
Malfunction is detected when ...
Check Items (Possible Cause)
I Cooling fan does not operate properly (Overheat). I Harness or connectors I Cooling fan system does not operate properly (Overheat). (The cooling fan circuit is open or shorted). I Engine coolant was not added to the system using the I Cooling fan I Radiator hose proper filling method. I Radiator I Radiator cap I Water pump I Thermostat For more information, refer to “MAIN 12 CAUSES OF OVERHEATING”, EC-SR-288.
CAUTION: When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Also, replace the 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 section (“Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED FLUIDS AND LUBRICANTS”). 2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.
EC-280
DTC P1217 OVERHEAT (COOLING SYSTEM)
SR20DE Overall Function Check
Overall Function Check
SEF621WA
SEF111X
SEC163BA
NCEC0489
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 when the engine is hot. Serious burns could be caused by high pressure fluid escaping from 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) 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 “Diagnostic Procedure”, EC-SR-284. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-SR-284. 3) Turn ignition switch “ON”. 4) Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. 5) If the results are NG, go to “Diagnostic Procedure”, EC-SR284. Without CONSULT-II 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 “Diagnostic Procedure”, EC-SR-284. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-SR-284. 3) Start engine. Be careful not to overheat engine. 4) Set temperature control lever 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. Be careful not to overheat engine. 8) Make sure that cooling fan operates. If NG, go to “Diagnostic Procedure”, EC-SR-284.
EC-281
DTC P1217 OVERHEAT (COOLING SYSTEM)
SR20DE
Wiring Diagram
Wiring Diagram IGNITION SWITCH ON or START
NCEC0490
BATTERY Detectable line for DTC Non-detectable line for DTC
FUSE BLOCK (J/B)
Refer to EL-POWER.
COOLING FAN RELAY
COOLING FAN MOTOR-1
COOLING FAN MOTOR-2
REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)
YEC847
EC-282
SR20DE
DTC P1217 OVERHEAT (COOLING SYSTEM)
Wiring Diagram (Cont’d)
: Detectable line for DTC REFRIGERANT SENSOR
: Non-detectable line for DTC : Hyper CVT models
TCM (TRANSMISSION CONTROL MODULE)
ECM
YEC848
EC-283
DTC P1217 OVERHEAT (COOLING SYSTEM)
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1 1. 2. 3. 4. 5.
NCEC0491
CHECK COOLING FAN OPERATION Start engine and let it idle. Set temperature lever at full cold position. Turn air conditioner switch “ON”. Turn blower fan switch “ON”. Make sure that cooling fans-1 and -2 operate.
SEC163BA
OK or NG OK
©
GO TO 11.
NG
©
GO TO 2.
2
CHECK AIR CONDITIONER OPERATION
Is air conditioner operating? (Check operation of compressor and blower motor.) OK or NG OK
©
GO TO 3.
NG
©
Check for failure of air conditioner to operate. Refer to HA section.
3 1. 2. 3. 4.
CHECK POWER SUPPLY Turn ignition switch “OFF”. Disconnect cooling fan relay. Turn ignition switch “ON”. Check voltage between terminals 2, 3 and ground with CONSULT-II or tester.
SEF112X
Voltage: Battery voltage OK or NG OK
©
GO TO 5.
NG
©
GO TO 4.
EC-284
DTC P1217 OVERHEAT (COOLING SYSTEM)
SR20DE
Diagnostic Procedure (Cont’d)
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M70, E125 I 10A fuse I 40A fusible link I Harness for open or short between cooling fan relay and fuse
©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect cooling fan motor-1 harness connector and cooling fan motor-2 harness connector. Right side (View from under the vehicle)
Left side
Cooling fan motor harness connector
SEF225X
3. Check harness continuity between relay terminal 5 and motor-1 terminal 1, motor-1 terminal 2 and body ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. 5. Check harness continuity between relay terminal 5 and motor-2 terminal 1, motor-2 terminal 2 and body ground. Refer to wiring diagram. Continuity should exist. 6. 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 OUTPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 13 and relay 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 8.
NG
©
GO TO 7.
7
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E42, F4 I Harness for open or short between cooling fan relay and ECM
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-285
DTC P1217 OVERHEAT (COOLING SYSTEM)
SR20DE
Diagnostic Procedure (Cont’d)
8
CHECK COOLING FAN RELAY
Refer to “Component Inspection”, EC-SR-289. OK or NG OK
©
GO TO 9.
NG
©
Replace cooling fan relay.
9
CHECK COOLING FAN MOTORS-1 AND -2
Refer to “Component Inspection”, EC-SR-289. OK or NG OK
©
GO TO 10.
NG
©
Replace cooling fan motors.
10
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
11
INSPECTION END
CHECK COOLING SYSTEM FOR LEAK
Apply pressure to the cooling system with a tester, and check if the pressure drops. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage.
SLC754A
Pressure should not drop. OK or NG OK
©
GO TO 12.
NG
©
Check the following for leak I Hose I Radiator I Water pump Refer to LC section (“Water Pump”).
EC-286
DTC P1217 OVERHEAT (COOLING SYSTEM)
SR20DE
Diagnostic Procedure (Cont’d)
12
CHECK RADIATOR CAP
Apply pressure to cap with a tester.
SLC755A
Radiator cap relief pressure: 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi) OK or NG OK
©
GO TO 13.
NG
©
Replace radiator cap.
13
CHECK THERMOSTAT
1. Check valve seating condition at normal room temperatures. It should seat tightly. 2. Check valve opening temperature and valve lift.
SLC343
Valve opening temperature: 76.5°C (170°F) [standard] Valve lift: More than 8 mm/90°C (0.31 in/194°F) 3. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to LC section (“Thermostat”). OK or NG OK
©
GO TO 14.
NG
©
Replace thermostat
14
CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to “COMPONENT INSPECTION”, EC-SR-136. OK or NG OK
©
GO TO 15.
NG
©
Replace engine coolant temperature sensor.
15
CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-SR-288. ©
INSPECTION END
EC-287
SR20DE
DTC P1217 OVERHEAT (COOLING SYSTEM) Main 12 Causes of Overheating
Main 12 Causes of Overheating Engine
Step
Inspection item
OFF
1
I I I I
2
Equipment
Standard
NCEC0492
Reference page
I Visual
No blocking
I Coolant mixture
I Coolant tester
50 - 50% coolant mixture
3
I Coolant level
I Visual
Coolant up to MAX level in See “Changing Engine reservoir tank and radiator Coolant”, “ENGINE filler neck MAINTENANCE” in MA section.
4
I Radiator cap
I Pressure tester
59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 14 psi) (Limit)
See “System Check”, “ENGINE COOLING SYSTEM” in LC section.
ON*2
5
I Coolant leaks
I Visual
No leaks
See “System Check”, “ENGINE COOLING SYSTEM” in LC section.
ON*2
6
I Thermostat
I Touch the upper and lower radiator hoses
Both hoses should be hot
See “Thermostat” and “Radiator”, “ENGINE COOLING SYSTEM” in LC section.
ON*1
7
I Cooling fan
I CONSULT-II
Operating
See “TROUBLE DIAGNOSIS FOR OVERHEAT” (EC-SR-279).
OFF
8
I Combustion gas leak
I Color checker chemical tester 4 Gas analyzer
Negative
—
ON*3
9
I Coolant temperature gauge
I Visual
Gauge less than 3/4 when driving
—
I Coolant overflow to reservoir tank
I Visual
No overflow during driving and idling
See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA section.
Blocked Blocked Blocked Blocked
radiator condenser radiator grille bumper
—
See “RECOMMENDED FLUIDS AND LUBRICANTS” in MA section.
OFF*4
10
I Coolant return from reservoir tank to radiator
I Visual
Should be initial level in reservoir tank
See “ENGINE MAINTENANCE” in MA section.
OFF
11
I Cylinder head
I Straight gauge feeler gauge
0.1 mm (0.004 in) Maximum distortion (warping)
See “Inspection”, “CYLINDER HEAD” in EM section.
12
I Cylinder block and pistons
I Visual
No scuffing on cylinder walls or piston
See “Inspection”, “CYLINDER BLOCK” in EM section.
*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. For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.
EC-288
SR20DE
DTC P1217 OVERHEAT (COOLING SYSTEM)
Component Inspection
Component Inspection
NCEC0493
COOLING FAN RELAYS
NCEC0493S01
Check continuity between terminals 3 and 5.
SEF511P
Conditions
Continuity
12V direct current supply between terminals 1 and 2
Yes
No current supply
No
If NG, replace relay.
COOLING FAN MOTORS-1 AND -2 1. 2.
NCEC0493S02
Disconnect cooling fan motor harness connectors. Supply cooling fan motor terminals with battery voltage and check operation. Terminals
Cooling fan motor SEF721Q
(+)
(−)
1
2
Cooling fan motor should operate. If NG, replace cooling fan motor.
REFRIGERANT PRESSURE SENSOR
NCEC0493S03
With the refrigerant pressure sensor installed on the vehicle, start the engine and while idling, read the voltage at refrigerant pressure sensor terminals 1 and 2. (Refer to wiring diagram.) Air conditioner condition
Voltage V
OFF
More than approx. 0.3V
ON
More than approx. 1.5
ON to OFF
Decreasing gradually
If results are NG, check for 5V between refrigerant sensor terminal 3 and ground. If there is 5V, replace sensor.
EC-289
DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)
SR20DE
Component Description
Component Description Core
Coil Permanent magnet SEF956N
NCEC0327
The crankshaft position sensor (OBD) is located on the transmission housing facing the gear teeth (cogs) of the flywheel or drive plate. It detects the fluctuation of the engine revolution. The sensor consists of a permanent magnet, core and coil. 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. This sensor is not used to control the engine system. It is used only for the on board diagnosis.
Crankshaft position sensor (OBD) harness connector Cooling fan motor (Left side)
SEF226X
ECM Terminals and Reference Value
NCEC0328
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 58
WIRE COLOR
B
ITEM
Sensors’ ground
CONDITION
DATA (AC Voltage)
[Engine is running] I Warm-up condition I Idle speed
Approximately 0V 3 - 5V (AC range)
[Engine is running] I Warm-up condition I Idle speed 0.2 ms SEF721W
65
W
Crankshaft position sensor (OBD)
6 - 9V (AC range)
[Engine is running] I Engine speed is 2,000 rpm 0.2 ms SEF722W
On Board Diagnosis Logic DTC No. P1336 1336
Malfunction is detected when ...
Check Items (Possible Cause)
I A chipping of the flywheel or drive plate gear tooth (cog) I Harness or connectors is detected by the ECM. I Crankshaft position sensor (OBD) I Drive plate/Flywheel
EC-290
NCEC0329
DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)
SR20DE
DTC Confirmation Procedure
DTC Confirmation Procedure
NEF068A
NCEC0330
NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 4 minutes at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-293. With GST Follow the procedure “With CONSULT-II” above.
EC-291
DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0331
: Detectable line for DTC : Non-detectable line for DTC : Hyper CVT models CRANKSHAFT POSITION SENSOR (OBD)
TCM (TRANSMISSION CONTROL MODULE)
ECM
YEC839
EC-292
DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0332
RETIGHTEN GROUND SCREWS
1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.
©
2
GO TO 2.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.
Crankshaft position sensor (OBD) harness connector Cooling fan motor (Left side)
SEF226X
2. Check continuity between ECM terminal 65 and crankshaft position sensor (OBD) harness connector 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 4.
NG
©
GO TO 3.
3
DETECT MALFUNCTIONING PART
Check the harness for open or short between crankshaft position sensor (OBD) and ECM.
©
4
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK GROUND CIRCUIT
1. Reconnect ECM harness connectors. 2. Check harness continuity between crankshaft position sensor harness connector terminal 2 and engine 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 6.
NG
©
GO TO 5.
5
DETECT MALFUNCTIONING PART
Check the following. I Harness for open or short between crankshaft position sensor (OBD) and ECM I Harness for open or short between crankshaft position sensor (OBD) and TCM (Transmission control module)
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-293
DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)
SR20DE
Component Inspection
6
CHECK IMPROPER INSTALLATION
Loosen and retighten the fixing bolt of the crankshaft position sensor (OBD). Then retest.
Trouble is not fixed.
7
©
GO TO 7.
CHECK CRANKSHAFT POSITION SENSOR (OBD)
Refer to “Component Inspection”, EC-SR-294. OK or NG OK
©
GO TO 8.
NG
©
Replace crankshaft position sensor (OBD).
8
CHECK GEAR TOOTH
Visually check for chipping flywheel or drive plate gear tooth (cog). OK or NG OK
©
GO TO 9.
NG
©
Replace the flywheel or drive plate.
9
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
Component Inspection CRANKSHAFT POSITION SENSOR (OBD) 1. 2. 3. 4.
NCEC0333S01
Disconnect crankshaft position sensor (OBD) harness connector. Loosen the fixing bolt of the sensor. Remove the sensor. Visually check the sensor for chipping.
SEF960N
5.
NCEC0333
Check resistance as shown in the figure. Resistance: M/T models 166 - 204 Ω [at 20°C (68°F)] CVT models Approx. 285 Ω [at 20°C (68°F)]
SEF231W
EC-294
SR20DE
DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE
System Description
System Description
NCEC0560
The malfunction information related to CVT is transferred through the line (circuit) from TCM (Transmission Control Module) to ECM. Therefore, be sure to erase the malfunction information such as DTC not only in TCM (Transmission Control Module) but also ECM after the CVT related repair.
ECM Terminals and Reference Value
NCEC0561
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 91
WIRE COLOR PU/Y
ITEM
CONDITION
CVT check signal
DATA (DC Voltage)
[Ignition switch “ON”] [Engine is running]
0 - Approximately 5V
On Board Diagnosis Logic DTC No. P1605 1605
Malfunction is detected when ... I An incorrect signal from TCM (Transmission Control Module) is sent to ECM.
Check Items (Possible Cause) I Harness or connectors [The communication line circuit between ECM and TCM (Transmission Control Module) is open or shorted.] I Dead (Weak) battery I TCM (Transmission Control Module)
DTC Confirmation Procedure
NEF068A
NCEC0562
NCEC0563
NOTE: If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and let it idle for at least 40 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-297. With GST Follow the procedure “With CONSULT-II” above.
EC-295
DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE
SR20DE
Wiring Diagram
Wiring Diagram
TCM (TRANSMISSION CONTROL MODULE)
.
NCEC0564
: Detectable line for DTC : Non-detectable line for DTC
ATCK
ECM F101
YEC850
EC-296
DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE
SR20DE Diagnostic Procedure
Diagnostic Procedure 1 1. 2. 3. 4.
CHECK INPUT SIGNAL CIRCUIT Turn ignition switch “OFF”. Disconnect ECM harness connector and TCM harness connector. Refer to A/T section for TCM location. Check harness continuity between ECM terminal 91 and TCM terminal 15. Refer to wiring diagram. 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 INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-297
NCEC0565
DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH
SR20DE
Component Description
Component Description
NCEC0424
When the gear position is “P” (CVT models only) or “N”, park/ neutral position (PNP) switch is “ON”. ECM detects the park/neutral position when continuity with ground exists.
SEF740W
CONSULT-II Reference Value in Data Monitor Mode
NCEC0425
Specification data are reference values. MONITOR ITEM
CONDITION I Ignition switch: ON
P/N POSI SW
SPECIFICATION
Shift lever: “P” or “N”
ON
Except above
OFF
ECM Terminals and Reference Value
NCEC0426
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.
42
WIRE COLOR
G/OR
ITEM
PNP switch
CONDITION
DATA (DC Voltage)
[Ignition switch “ON”] I Gear position is “Neutral position” (M/T models) I Gear position is “N” or “P” (CVT models)
Approximately 0V
[Ignition switch “ON”] I Except the above gear position
BATTERY VOLTAGE (11 - 14V)
On Board Diagnosis Logic DTC No. P1706 1706
Malfunction is detected when ... I The signal of the PNP switch is not changed in the process of engine starting and driving.
NCEC0427
Check Items (Possible Cause) I Harness or connectors (The PNP switch circuit is open or shorted.) I PNP switch
DTC Confirmation Procedure
NCEC0428
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 9 seconds before conducting the next test.
EC-298
DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH
SR20DE
DTC Confirmation Procedure (Cont’d)
1) 2) 3) 4)
NEF118A
With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Maintain the following conditions for at least 50 consecutive seconds.
ENG SPEED
1,500 - 3,400 rpm
COOLAN TEMP/S
More than 70°C (158°F)
B/FUEL SCHDL
2.4 - 12.0 msec
VHCL SPEED SE
64 - 130 km/h (40 - 81 MPH)
Selector lever
Suitable position
5)
If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-301.
Overall Function Check
NCEC0429
Use this procedure to check the overall function of the park/neutral position switch circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Turn ignition switch “ON”. 2) Check voltage between ECM terminal 42 (PNP switch signal) and body ground under the following conditions. Condition (Gear position)
SEF137X
“P” (CVT only) and “N” position Except the above position
3)
Voltage (V) (Known good data) Approx. 0 BATTERY VOLTAGE (11 - 14V)
If NG, go to “Diagnostic Procedure”, EC-SR-301.
EC-299
DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0430
ECM : Detectable line for DTC : Non-detectable line for DTC : Hyper CVT models : M/T models
NEUTRAL
NEUTRAL POSITION SWITCH
P
Ds R
OTHERS
N
D
PARK/NEUTRAL POSITION SWITCH
YEC851
EC-300
DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0431
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect PNP switch harness connector.
SEF740W
3. Check harness continuity between PNP switch harness connector terminal 2 and body ground. 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
©
GO TO 2.
2
DETECT MALFUNCTIONING PART
Check the harness for open or short between PNP switch and body ground. ©
3
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 42 and PNP switch harness connector 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 5.
NG
©
GO TO 4.
4
DETECT MALFUNCTIONING PART
Check the harness for open or short between ECM and PNP switch. ©
5
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK PNP SWITCH
Refer to MT section or AT section. OK or NG OK
©
GO TO 6.
NG
©
Replace PNP switch.
6
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©
INSPECTION END
EC-301
SR20DE
INJECTOR Component Description
Component Description
NCEC0435
The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the injector circuit, the coil in the injector is energized. The energized coil pulls the needle valve back and allows fuel to flow through the injector into the intake manifold. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the injector remains open. The ECM controls the injection pulse duration based on engine fuel needs. SEF138X
CONSULT-II Reference Value in Data Monitor Mode
NCEC0436
MONITOR ITEM
INJ PULSE -B1
B/FUEL SCHDL
CONDITION
SPECIFICATION
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
2.4 - 3.2 msec
2,000 rpm
1.9 - 2.8 msec
I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
Idle
2.4 - 3.2 msec
2,000 rpm
1.4 - 2.8 msec
ECM Terminals and Reference Value
NCEC0437
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Warm-up condition I Idle speed
101 103 105 107
R/B Y/B G/B L/B
Injector Injector Injector Injector
No. No. No. No.
1 2 3 4
SEF011W
BATTERY VOLTAGE (11 - 14V)
[Engine is running] I Warm-up condition I Engine speed is 2,000 rpm
SEF012W
EC-302
SR20DE
INJECTOR
Wiring Diagram
Wiring Diagram
NCEC0434
IGNITION SWITCH ON or START FUSE BLOCK (J/B)
Refer to EL-POWER.
Detectable line for DTC Non-detectable line for DTC Hyper CVT models M/T models
INJECTOR No.1
INJECTOR No.2
INJECTOR No.3
INJECTOR No.4
ECM
REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)
YEC251
EC-303
INJECTOR
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0438
CHECK OVERALL FUNCTION
With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.
NEF105A
3. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Start engine. 2. Listen to each injector operating sound.
MEC703B
Clicking noise should be heard. OK or NG OK
©
INSPECTION END
NG
©
GO TO 2.
2 1. 2. 3. 4.
CHECK POWER SUPPLY Stop engine. Disconnect injector harness connector. Turn ignition switch “ON”. Check voltage between terminal 2 and ground with CONSULT-II or tester.
SEF986W
Voltage: Battery voltage OK or NG OK
©
GO TO 4.
NG
©
GO TO 3.
EC-304
SR20DE
INJECTOR
Component Inspection
3
DETECT MALFUNCTIONING PART
Check the following. I 10A fuse I Harness connectors F13, F60 I Harness connectors M50, F104 (CVT: M81, F115) I Harness for open or short between injector and fuse ©
4
Repair harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between injector harness connector terminal 1 and ECM terminals 101, 103, 105, 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. I Harness connectors F13, F60 I Harness for open or short between ECM and injector ©
6
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK INJECTOR
Refer to “Component Inspection”, EC-SR-305. OK or NG OK
©
GO TO 7.
NG
©
Replace injector.
7
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©
INSPECTION END
Component Inspection INJECTOR 1. 2.
NCEC0439 NCEC0439S01
Disconnect injector harness connector. Check resistance between terminals as shown in the figure. Resistance: 13.5 - 17.5Ω [at 25°C (77°F)] If NG, replace injector.
SEF139X
EC-305
SR20DE
IGNITION SIGNAL Component Description
Component Description
Ignition coil harness connector
Camshaft position sensor and power transistor harness connector
NCEC0566
IGNITION COIL & POWER TRANSISTOR (BUILT INTO DISTRIBUTOR) NCEC0566S01
Distributor SEF211X
The ignition coil is built into distributor. The ignition signal from the ECM is sent to the power transistor. The power transistor switches on and off the ignition coil primary circuit. As the primary circuit is turned on and off, the proper high voltage is induced in the coil secondary circuit. The distributor is not repairable and must be replaced as an assembly except distributor cap and rotor head.
CONSULT-II Reference Value in Data Monitor Mode
NCEC0567
MONITOR ITEM
IGN TIMING
CONDITION I I I I
Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load
SPECIFICATION
Idle
15° BTDC
2,000 rpm
Approx. 40° BTDC
ECM Terminals and Reference Value
NCEC0568
Specification data are reference values and are measured between each terminal and 43 (ECM ground). TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) Approximately 0.3V
[Engine is running] I Warm-up condition I Idle speed
SEF996V
35
W/L
Ignition signal Approximately 0.8V
[Engine is running] I Engine speed is 2,000 rpm
SEF997V
EC-306
SR20DE
IGNITION SIGNAL
ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage) Approximately 13V
[Engine is running] I Warm-up condition I Idle speed
SEF998V
36*1
G
Ignition check
Approximately 12V
[Engine is running] I Engine speed is 2,000 rpm
SEF999V
*1: If so equipped
EC-307
SR20DE
IGNITION SIGNAL Wiring Diagram
Wiring Diagram
NCEC0571
BATTERY
Refer to EL-POWER.
ECM RELAY
CONDENSER RESISTOR
IGNITION COIL
POWER TRANSISTOR
DISTRIBUTOR
SPARK PLUG
YEC852
EC-308
IGNITION SIGNAL
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
NCEC0572
CHECK ENGINE START
Turn ignition switch “OFF”, and restart engine. Is engine running? Yes or No Yes
©
GO TO 7.
No
©
GO TO 2.
2
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect ignition coil harness connector. Ignition coil harness connector
Camshaft position sensor and power transistor harness connector
Distributor SEF211X
3. Turn ignition switch “ON”. 4. Check voltage between terminal 8 and ground with CONSULT-II or tester.
SEF257W
Voltage: Battery voltage OK or NG OK
©
GO TO 4.
NG
©
GO TO 3.
3
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors E90, F73 I Harness for open or short between ignition coil and ignition switch ©
4
Repair harness or connectors.
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect power transistor harness connector. 3. Check harness continuity between terminal 5 and engine ground. 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-309
IGNITION SIGNAL
SR20DE
Component Inspection
5
CHECK INPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 35 and power transistor terminal 6. 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 6.
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
6
CHECK IGNITION COIL, POWER TRANSISTOR
Refer to “Component Inspection”, EC-SR-310. OK or NG OK
©
GO TO 7.
NG
©
Replace malfunctioning component(s).
7
CHECK INPUT SIGNAL CIRCUIT (If so equipped)
1. 2. 3. 4.
Stop engine. Disconnect ignition coil harness connector. Disconnect ECM harness connector. Check harness continuity between ignition coil terminal 7 and ECM terminal 36. 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
©
Repair open circuit or short to ground or short to power in harness or connectors.
8
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©
INSPECTION END
Component Inspection
NCEC0573
IGNITION COIL
Coil tower metal tip
Disconnect distributor harness connector. Check continuity between terminal 7 and 8 on distributor. Continuity should exist. If NG, replace distributor.
3. 4.
For checking secondary coil, remove distributor cap. Check resistance between ignition coil harness connector terminal 7 and coil tower metal tip 9 (secondary terminal) on the distributor head.
SEF237X
Terminal 7 - 8 (Primary coil) 8 - secondary terminal on distributor head (Secondary coil) Coil tower metal tip
NCEC0573S01
1. 2.
SEF238X
If NG, replace distributor.
EC-310
Resistance [at 25°C (77°F)] Approximately 0.5 - 1.0Ω Approximately 25 kΩ
SR20DE
IGNITION SIGNAL
Component Inspection (Cont’d)
POWER TRANSISTOR 1. 2.
Distributor
NCEC0573S02
Disconnect power transistor harness connector. Check power transistor resistance between terminals 5 and 7. Terminals
Resistance
Result
Except 0Ω
OK
0Ω
NG
5 and 7
If NG, replace distributor. SEF239X
EC-311
SR20DE
START SIGNAL CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0441
Specification data are reference values. MONITOR ITEM START SIGNAL
CONDITION
SPECIFICATION
I Ignition switch: ON , START , ON
OFF , ON , OFF
ECM Terminals and Reference Value
NCEC0442
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 41
WIRE COLOR
B/Y
ITEM
CONDITION
DATA (DC Voltage)
[Ignition switch “ON”]
Approximately 0V
[Ignition switch “START”]
9 - 12V
Start signal
EC-312
SR20DE
START SIGNAL
Wiring Diagram
Wiring Diagram
NCEC0440
BATTERY
Refer to EL-POWER.
Detectable line for DTC Non-detectable line for DTC Hyper CVT models OFF
ST
IGNITION SWITCH
M/T models
ACC ON
FUSE BLOCK (J/B)
ECM
.
REFER TO THE FOLLOWING M1 FUSE BLOCK Junction Box (J/B) E104 FUSE BLOCK Junction Box (J/B)
YEC252
EC-313
SR20DE
START SIGNAL Diagnostic Procedure
Diagnostic Procedure 1
=NCEC0443
INSPECTION START
Do you have CONSULT-II? Yes or No Yes
©
GO TO 2.
No
©
GO TO 3.
2
CHECK OVERALL FUNCTION
With CONSULT-II 1. Turn ignition switch “ON”. 2. Check “START SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.
PEF111P Condition
“START SIGNAL”
IGN “ON”
OFF
IGN “START”
ON MTBL0140
OK or NG OK
©
INSPECTION END
NG
©
GO TO 4.
3
CHECK OVERALL FUNCTION
Without CONSULT-II 1. Turn ignition switch to “START”. 2. Check voltage between ECM terminal 41 and ground under the following conditions. CONNECT
SEF142X Condition
Voltage
Ignition switch “START” Except above
Battery voltage Approximately 0V
MTBL0143
OK or NG OK
©
INSPECTION END
NG
©
GO TO 4.
EC-314
START SIGNAL
SR20DE Diagnostic Procedure (Cont’d)
4
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104 (CVT: M81, F115) I 10A fuse I Harness for open or short between ECM and ignition switch 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
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.
©
INSPECTION END
EC-315
SR20DE
FUEL PUMP System Description
System Description Sensor
Input Signal to ECM
Camshaft position sensor (REF)
Engine speed
Ignition switch
Start signal
NCEC0444
ECM function ECM
Actuator
Fuel pump relay
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 180° signal from the camshaft position sensor, it knows that the engine is rotating, and causes the pump to perform. If the 180° 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 2 seconds
Engine running and cranking
Operates
When engine is stopped
Stops in 1.5 seconds
Except as shown above
Stops
Component Description
NCEC0501
A turbine type design fuel pump is used in the fuel tank.
AEC801
CONSULT-II Reference Value in Data Monitor Mode
NCEC0445
MONITOR ITEM
FUEL PUMP RLY
CONDITION
SPECIFICATION
I Ignition switch is turned to ON (Operates for 2 seconds) I Engine running and cranking I When engine is stopped (stops in 1.5 seconds)
ON
I Except as shown above
OFF
ECM Terminals and Reference Value
NCEC0446
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.
21
WIRE COLOR
B/P
ITEM
CONDITION
DATA (DC Voltage)
[Ignition switch “ON”] I For 2 seconds after turning ignition switch “ON” [Engine is running]
0 - 1V
[Ignition switch “ON”] I More than 1 second after turning ignition switch “ON”
BATTERY VOLTAGE (11 - 14V)
Fuel pump relay
EC-316
SR20DE
FUEL PUMP
Wiring Diagram
Wiring Diagram
NCEC0447
IGNITION SWITCH ON or START
FUSE BLOCK (J/B)
Refer to EL-POWER.
Detectable line for DTC Non-detectable line for DTC Hyper CVT models
FUEL PUMP RELAY
M/T models
FUEL PUMP
ECM
.
REFER TO THE FOLLOWING M1 FUSE BLOCK Junction Box (J/B) B8 FUSE BLOCK Junction Box (J/B)
YEC253
EC-317
FUEL PUMP
SR20DE
Diagnostic Procedure
Diagnostic Procedure 1
NCEC0448
CHECK OVERALL FUNCTION
1. Turn ignition switch “ON”. 2. Pinch fuel feed hose with fingers.
Fuel filter
Pinch
SEF241X
Fuel pressure pulsation should be felt on the fuel feed hose for 1 second after ignition switch is turned “ON”. OK or NG OK
©
INSPECTION END
NG
©
GO TO 2.
2
CHECK POWER SUPPLY
1. Turn ignition switch “OFF”. 2. Disconnect fuel pump relay located on the fuse block.
SEF071X
3. Turn ignition switch “ON”. 4. Check voltage between terminals 1, 3 and ground with CONSULT-II or tester.
SEF144X
Voltage: Battery voltage OK or NG OK
©
GO TO 4.
NG
©
GO TO 3.
EC-318
FUEL PUMP
SR20DE Diagnostic Procedure (Cont’d)
3
DETECT MALFUNCTIONING PART
Check the following. I 15A fuse I Harness for open or short between fuse and fuel pump relay ©
4
Repair harness or connectors.
CHECK POWER GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect fuel pump harness connector.
SEF299W
3. Check harness continuity between fuel pump harness connector terminal 2 and body ground, terminal 1 and fuel pump relay connector terminal 9J. 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. I Harness for open or short between fuel pump and body ground I Harness for open or short between fuel pump and fuel pump relay ©
6
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK OUTPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 21 and fuel pump relay connector terminal 19C. 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 8.
NG
©
GO TO 7.
7
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors M50, F104 (CVT: M81, F115) I Harness for open or short between ECM and fuel pump relay
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
EC-319
FUEL PUMP
SR20DE
Component Inspection
8
CHECK FUEL PUMP RELAY
Refer to “Component Inspection”, EC-SR-320. OK or NG OK
©
GO TO 9.
NG
©
Replace fuel pump relay.
9
CHECK FUEL PUMP
Refer to “Component Inspection”, EC-SR-320. OK or NG OK
©
GO TO 10.
NG
©
Replace fuel pump.
10
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©
INSPECTION END
Component Inspection
NCEC0449
FUEL PUMP RELAY
NCEC0449S01
Check continuity between terminals 3 and 5. Conditions
Continuity
12V direct current supply between terminals 1 and 2
Yes
No current supply
No
If NG, replace relay. SEF145X
FUEL PUMP 1. 2.
Disconnect fuel pump harness connector. Check resistance between terminals 1 and 2. Resistance: 0.2 - 5.0Ω [at 25°C (77°F)] If NG, replace fuel pump.
SEF326W
EC-320
NCEC0449S02
SR20DE
POWER STEERING OIL PRESSURE SWITCH
Component Description
Component Description
Power steering oil pressure switch
NCEC0451
The power steering oil pressure switch is attached to the power steering high-pressure tube and detects a power steering load. When a power steering load is detected, it signals the ECM. The ECM adjusts the IACV-AAC valve to increase the idle speed and adjust for the increased load.
NEF124A
CONSULT-II Reference Value in Data Monitor Mode
NCEC0452
Specification data are reference values. MONITOR ITEM
PW/ST SIGNAL
CONDITION I Engine: After warming up, idle the engine
SPECIFICATION
Steering wheel in neutral position (forward direction)
OFF
The steering wheel is fully turned
ON
ECM Terminals and Reference Value
NCEC0453
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.
46
WIRE COLOR
PU/W
ITEM
CONDITION
[Engine is running] Power steering oil pressure I Steering wheel is fully turned switch [Engine is running] I Steering wheel is not turned
EC-321
DATA (DC Voltage)
Approximately 0V Approximately 5V
POWER STEERING OIL PRESSURE SWITCH
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0450
YEC254
EC-322
POWER STEERING OIL PRESSURE SWITCH
SR20DE Diagnostic Procedure
Diagnostic Procedure 1
=NCEC0454
INSPECTION START
Do you have CONSULT-II? Yes or No Yes
©
GO TO 2.
No
©
GO TO 3. CONNECT
2
CHECK OVERALL FUNCTION
With CONSULT-II 1. Start engine. 2. Check “PW/ST SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.
PEF591I Steering is in neutral position
OFF
Steering is turned
ON MTBL0141
OK or NG OK
©
INSPECTION END
NG
©
GO TO 4.
3
CHECK OVERALL FUNCTION
Without CONSULT-II 1. Start engine. 2. Check voltage between ECM terminal 46 and ground under the following conditions.
SEF148X Condition
Voltage
When steering wheel is turned quickly
Approximately 0V
Except above
Approximately 5V MTBL0142
OK or NG OK
©
INSPECTION END
NG
©
GO TO 4.
EC-323
SR20DE
POWER STEERING OIL PRESSURE SWITCH Component Inspection
4
CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”. 2. Disconnect power steering oil pressure switch harness connector. 3. Check harness continuity between power steering oil pressure switch harness terminal 2 and engine ground. 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 INPUT SIGNAL CIRCUIT
1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 46 and power steering oil pressure switch harness 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 7.
NG
©
GO TO 6.
6
DETECT MALFUNCTIONING PART
Check the following. I Harness connectors F4, E42 I Harness for open or short between ECM and power steering oil pressure switch ©
7
Repair open circuit or short to ground or short to power in harness or connectors.
CHECK POWER STEERING OIL PRESSURE SWITCH
Refer to “Component Inspection”, EC-SR-324. OK or NG OK
©
GO TO 8.
NG
©
Replace power steering oil pressure switch.
8
CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©
INSPECTION END
Component Inspection
NCEC0455
POWER STEERING OIL PRESSURE SWITCH 1. 2.
NCEC0455S01
Disconnect power steering oil pressure switch harness connector then start engine. Check continuity between terminals 1 and 2. Refer to wiring diagram. Conditions
Continuity
Steering wheel is being turned
Yes
Steering wheel is not being turned
No
If NG, replace power steering oil pressure switch.
EC-324
SR20DE
ELECTRICAL LOAD SIGNAL
CONSULT-II Reference Value in Data Monitor Mode
CONSULT-II Reference Value in Data Monitor Mode
NCEC0548
Specification data are reference values. MONITOR ITEM
LOAD SIGNAL
HEATER FAN SW
CONDITION
I Engine: running
I Ignition switch: ON
SPECIFICATION
Rear window defogger or headlamp “ON”
ON
Except the above
OFF
Heater fan switch: ON
ON
Heater fan switch: OFF
OFF
ECM Terminals and Reference Value
NCEC0549
Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 50
51
WIRE COLOR
R
LG/B
ITEM
Electric load signal
Blower fan SW
CONDITION
DATA (DC Voltage)
[Engine is running] I Headlamp switch or rear window defogger switch is “ON”
BATTERY VOLTAGE (11 - 14V)
[Ignition switch “ON”] I Blower fan switch is “ON”
Approximately 0V
[Ignition switch “ON”] I Blower fan switch is “OFF”
Approximately 5V
EC-325
ELECTRICAL LOAD SIGNAL
SR20DE
Wiring Diagram
Wiring Diagram
NCEC0550
YEC255
EC-326
SR20DE
ELECTRICAL LOAD SIGNAL
Wiring Diagram (Cont’d)
DIODE TYPE - 1
To EL-DEF
: Detectable line for DTC
FUSE BLOCK (J/B)
: Non-detectable line for DTC Refer to EL-POWER.
TIME CONTROL UNIT
: With XENON headlamp or daytime light system : Except
HD
: Hyper CVT models : M/T models
To EL-H/LAMP
OFF
2ND
1ST PASS
COMBINATION SWITCH (LIGHTING SWITCH)
With XENON headlamp . . . R/W Except XENON headlamp . . . G With daytime light system . . . 1 Without daytime light system . . . 2 With daytime light system . . . 2 Without daytime light system . . . 1
With daytime light system and with XENON headlamp. . . R/l
LOW HIGH
With daytime light system and without XENON headlamp. . . P/B Without daytime light system . . . OR/L
Headlamp relay LH
DIODE
To EL-LAMP
ECM
REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)
: This connector is not shown in “HARNESS LAYOUT” of EL section.
YEC853
EC-327
ELECTRICAL LOAD SIGNAL
SR20DE
Wiring Diagram (Cont’d)
DIODE TYPE - 2
YEC095A
EC-328
MI & DATA LINK CONNECTORS
SR20DE Wiring Diagram
Wiring Diagram
NCEC0466
YEC096A
EC-329
SERVICE DATA AND SPECIFICATIONS (SDS) Fuel Pressure Regulator
Fuel Pressure Regulator Fuel pressure at idling kPa (bar, kg/cm2, psi)
NCEC0467
Vacuum hose is connected
Approximately 235 (2.35, 2.4, 34)
Vacuum hose is disconnected
Approximately 294 (2.94, 3.0, 43)
Idle Speed and Ignition Timing
NCEC0468
Target idle speed*1
rpm
No-load*3 (in “P” or “N” position)
Air conditioner: ON
rpm
In “P” or “N” position
825 or more
In “P” or “N” position
15°±2° BTDC
Ignition timing*2 Throttle position sensor idle position
*1: *2: *3: I I I
750±50
V
0.35 - 0.65
Throttle position sensor harness connector connected Throttle position sensor harness connector disconnected Under the following conditions: Air conditioner switch: OFF Electrical load: OFF (Lights, heater fan & rear window defogger) Steering wheel: Kept in straight-ahead position
Ignition Coil Primary voltage
V
NCEC0574
Battery voltage (11 - 14)
Primary resistance [at 25°C (77°F)]
kΩ
Secondary resistance [at 25°C (77°F)]
2.2 kΩ
Approximately 17
Mass Air Flow Sensor
NCEC0470
Supply voltage (Heater)
V
Battery voltage (11 - 14)
Supply voltage (Sensor)
V
Approximately 5
Output voltage
V
1.3 - 1.7*
Mass air flow (Using CONSULT-II or GST)
2.5 - 5.0 at idle* 7.1 - 12.5 at 2,500 rpm*
g⋅m/sec
*: Engine is warmed up to normal operating temperature and idling under no-load.
Engine Coolant Temperature Sensor Temperature
°C (°F)
Resistance
kΩ
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
Fuel Pump Resistance [at 25°C (77°F)] Ω
NCEC0471
NCEC0473
0.2 - 5.0
IACV-AAC Valve Resistance [at 20°C (68°F)] Ω Between terminals 1 - 2, 2 - 3, 4 - 5 and 5 - 6
NCEC0474
20 - 24
Injector Resistance [at 25°C (77°F)] Ω
NCEC0475
13.5 - 17.5
EC-330
SERVICE DATA AND SPECIFICATIONS (SDS) Throttle Position Sensor
Throttle Position Sensor Throttle valve conditions
NCEC0477
Resistance [at 25°C (77°F)]
Completely closed
Approximately 0.6 kΩ
Partially open
0.6 - 4.0 kΩ
Completely open
Approximately 4.0 kΩ
Heated Oxygen Sensor 1 (Front) Heater Resistance [at 25°C (77°F)] Ω
NCEC0478
2.3 - 4.3
Intake Air Temperature Sensor Temperature
°C (°F)
Resistance
NCEC0480
kΩ
20 (68)
2.2 - 2.6
80 (176)
0.31 - 0.37
EVAP Canister Purge Volume Control Valve Resistance [at 20°C (68°F)] Ω
NCEC0481
31 - 35
Heated Oxygen Sensor 1 (Rear) Heater Resistance [at 25°C (77°F)] Ω
NCEC0483
2.3 - 4.3
Crankshaft Position Sensor (OBD) Resistance [at 25°C (77°F)] Ω
166 - 204
EC-331
NCEC0575
SERVICE DATA AND SPECIFICATIONS (SDS) NOTE
EC-332
ENGINE CONTROL SYSTEM SECTION
EC EC
CONTENTS CD20T PRECAUTIONS AND PREPARATION.......................... 3 Special Service Tools ................................................ 3 Engine Fuel & Emission Control System .................. 5 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 6 Precautions for On Board Diagnostic (OBD) System of Engine ...................................................... 6 Precautions ................................................................ 7 ENGINE AND EMISSION CONTROL OVERALL SYSTEM......................................................................... 9 Engine Control Module Component Parts Location ..................................................................... 9 Circuit Diagram .........................................................11 System Diagram ...................................................... 12 Vacuum Hose Drawing ............................................ 13 System Chart ........................................................... 14 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ............................................. 15 Glow Control System............................................... 15 Fuel Injection System .............................................. 15 Fuel Injection Timing System .................................. 18 Air Conditioning Cut Control.................................... 20 Cooling Fan Control................................................. 20 CRANKCASE VENTILATION SYSTEM...................... 21 Description ............................................................... 21 Blow-by Control Valve ............................................. 21 Ventilation Hose....................................................... 21 INJECTION NOZZLE................................................... 22 Removal and Installation ......................................... 22 Test and Adjustment ................................................ 22 ELECTRONIC FUEL INJECTION PUMP.................... 24 Removal................................................................... 24 Installation................................................................ 25
Disassembly and Assembly..................................... 26 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ............................................................. 27 CONSULT-II ............................................................. 27 TROUBLE DIAGNOSIS - INTRODUCTION................ 33 Introduction .............................................................. 33 Diagnostic Worksheet.............................................. 34 TROUBLE DIAGNOSIS - WORK FLOW .................... 35 Work Flow................................................................ 35 Description for Work Flow ....................................... 36 TROUBLE DIAGNOSIS - BASIC INSPECTION......... 37 Basic Inspection....................................................... 37 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ............................................................. 39 Diagnostic Trouble Chart ......................................... 39 Symptom Matrix Chart............................................. 47 CONSULT-II Reference Value in Data Monitor Mode ........................................................................ 50 Major Sensor Reference Graph in Data Monitor Mode ........................................................................ 51 ECM Terminals and Reference Value ..................... 52 TROUBLE DIAGNOSIS FOR POWER SUPPLY........ 59 Main Power Supply and Ground Circuit.................. 59 TROUBLE DIAGNOSIS 1............................................ 62 Mass Air Flow Sensor (MAFS) ................................ 62 TROUBLE DIAGNOSIS 2............................................ 66 Engine Coolant Temperature (ECT) Sensor ........... 66 TROUBLE DIAGNOSIS 3............................................ 70 Vehicle Speed Sensor (VSS) .................................. 70 TROUBLE DIAGNOSIS 4............................................ 74 Control Sleeve Position Sensor (CSPS) ................. 74 TROUBLE DIAGNOSIS 5............................................ 78 Electric Governor ..................................................... 78 TROUBLE DIAGNOSIS 6............................................ 82
Injection Timing Control Valve ................................. 82 TROUBLE DIAGNOSIS 7............................................ 86 Engine Control Module (ECM) ................................ 86 TROUBLE DIAGNOSIS 8............................................ 87 Cooling Fan (Overheat) ........................................... 87 TROUBLE DIAGNOSIS 9............................................ 97 Needle Lift Sensor (NLS) ........................................ 97 TROUBLE DIAGNOSIS 10........................................ 100 Fuel Cut Solenoid Valve ........................................ 100 TROUBLE DIAGNOSIS 11........................................ 104 Fuel Temperature Sensor (FTS)............................ 104 TROUBLE DIAGNOSIS 12........................................ 108 Accelerator Position Sensor & Switch................... 108 TROUBLE DIAGNOSIS 13.........................................114 Crankshaft Position Sensor (TDC) .........................114 TROUBLE DIAGNOSES 14 .......................................118 Glow Control System..............................................118
TROUBLE DIAGNOSES 15 ...................................... 126 Air Conditioner Cut Control ................................... 126 TROUBLE DIAGNOSES 16 ...................................... 129 EGRC-Solenoid Valve ........................................... 129 TROUBLE DIAGNOSES 17 ...................................... 136 Brake Switch.......................................................... 136 TROUBLE DIAGNOSES 18 ...................................... 140 ECM Relay............................................................. 140 TROUBLE DIAGNOSES 19 ...................................... 141 MI & Data Link Connectors ................................... 141 TROUBLE DIAGNOSES 20 ...................................... 145 Start Signal ............................................................ 145 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 147 General Specifications........................................... 147 Injection Nozzle ..................................................... 147 Inspection and Adjustment .................................... 147
When you read wiring diagrams: ● Read GI section, “HOW TO READ WIRING DIAGRAMS”. ● See EL section, “POWER SUPPLY ROUTING” for power distribution circuit. ● See EL section for NATS information and wiring diagram. When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”. For clarification of system component abbreviations and terminology read GI section “SAE J1930 TERMINOLOGY LIST”.
EC-2
PRECAUTIONS AND PREPARATION Special Service Tools Tool number Tool name
Description
KV11289004 Nozzle cleaning kit 1 KV11290012 p Box 2 KV11290110 p Brush 3 KV11290122 p Nozzle oil sump scraper 4 KV11290140 p Nozzle needle tip cleaner 5 KV11290150 p Nozzle seat scraper 6 KV11290210 p Nozzle holder 7 KV11290220 p Nozzle hole cleaning needle NT296
KV109E0010 Break-out box
NT825
KV109E0050 Y-cable adapter
NT826
KV11292010 Nozzle centering device
NT293
KV11100300 No. 2-4 injection nozzle holder socket
NT563
EC-3
CD20T
PRECAUTIONS AND PREPARATION Special Service Tools (Cont’d) Tool number Tool name
Description
KV119E0030 No. 1 injection nozzle holder socket
NT648
EC-4
CD20T
PRECAUTIONS AND PREPARATION
CD20T
Engine Fuel & Emission Control System
ECM (ECCS-D control module) ● Do not disassemble ECM. ● If a battery terminal 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 problem. Do not replace parts because of a slight variation. ● When ECM is removed for inspection, make sure to ground the ECM mainframe.
WIRELESS EQUIPMENT ● When installing C.B. ham radio or a mobile
1) 2)
3)
BATTERY ● Always use a 12 volt battery as power
4)
source.
phone, be sure to observe the following as it may adversely affect electronic control systems depending on its installation location. Keep the antenna as far as possible away from the ECM. Keep the antenna feeder line more than 20 cm (7.9 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 standing-wave ratio can be kept small. Be sure to ground the radio to vehicle body.
● Do not attempt to disconnect battery cables
while engine is running.
ELECTRONIC FUEL INJECTOR PUMP
ECM mainframe
● Do not disconnect pump harness connectors
with engine running. ● Do not disassemble or adjust electronic fuel
injection pump, except for the following parts. Camshaft position sensor (pump) Injection timing control valve Fuel cut solenoid valve
ECM PARTS HANDLING ● 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. ● Do not disassemble No. 1 injection nozzle (builtin needle lift sensor). ● Even a slight leak in the air intake system can cause serious problems. ● Do not shock or jar the camshaft position sensor (TDC).
WHEN STARTING ● 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.
ECM HARNESS HANDLING ● Connect ECM harness connectors securely.
A poor connection can cause an extremely high (surge) voltage to develop in coil and condenser, thus resulting in damage to ICs. ● Keep ECM harness at least 10 cm (3.9 in) away from adjacent harnesses, to prevent an ECM system malfunction due to receiving external noise, degraded operation of ICs, etc. ● Keep ECM parts and harnesses dry. ● Before removing parts, turn off ignition switch and then disconnect battery ground cable.
NEF390
EC-5
PRECAUTIONS AND PREPARATION
CD20T
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” NCEC0002
The Supplemental Restraint System “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information necessary to service the system safely is included in the RS 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 dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors).
Precautions for On Board Diagnostic (OBD) System of Engine NCEC0003
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 terminal before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. ● 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 EL section, “Description”, “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 EGR system or fuel injection system, etc. ● Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before returning the vehicle to the customer.
EC-6
PRECAUTIONS AND PREPARATION
CD20T
Precautions ●
Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned off.
●
When connecting ECM harness connectors, push in both sides of the connector until you hear a click. Maneuver the lever until you hear the three connectors on the inside click. Refer to the figure at left.
●
Before replacing ECM, perform Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-CD-52.
●
If MI illuminates or blinks irregularly during engine running, water may have accumulated in fuel filter. Drain water from fuel filter. If this does not correct the problem, perform specified trouble diagnostic procedures. After performing each TROUBLE DIAGNOSIS, perform “OVERALL FUNCTION CHECK” or “DTC (Diagnostic Trouble Code) CONFIRMATION PROCEDURE”. 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.
SEF289H
SEF881Y
MEF040D
●
SAT652J
EC-7
PRECAUTIONS AND PREPARATION Precautions (Cont’d) ●
CD20T
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.
SEF348N
EC-8
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
CD20T
Engine Control Module Component Parts Location
YEC133A
EC-9
CD20T ENGINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Module Component Parts Location (Cont’d)
YEC134A
EC-10
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
CD20T
Circuit Diagram
YEC099A
EC-11
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
CD20T
System Diagram
YEC125A
EC-12
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
CD20T
Vacuum Hose Drawing
YEC131A 1 p 2 p 3 p
EGRC-solenoid valves A and B to EGR valve EGRC-solenoid valves A and B to air duct EGRC-solenoid valve A to vacuum pump
Refer to “System Diagram” on previous page for vacuum control system.
EC-13
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
CD20T
System Chart Crankshaft position sensor (TDC)
E
Control sleeve position sensor
E
Fuel temperature sensor
E
Mass air flow sensor
E
Engine coolant temperature sensor
E
Needle lift sensor
E
Accelerator position sensor
E
ECM Accelerator position switch
E
Air conditioner switch
E
Ignition switch (ON & ST POS.)
E
Battery voltage
E
Vehicle speed sensor or ABS actuator and electric unit (control unit)
E
Brake switch
E
Atmospheric pressure sensor
E
Fuel injection control
E
Electric governor
E
Fuel injection timing control
E
Injection timing control valve
E
Fuel cut control
E
Fuel cut solenoid valve
E
Glow control system
E
Glow relay & glow lamp
E
On board diagnostic system
E
Malfunction indicator (On the instrument panel)
E
EGR valve control
E
EGRC-solenoid valve A & B
E
Cooling fan control
E
Cooling fan relays
E
Air conditioning cut control
E
Air conditioner relay
E
Cooling fan motor control
E
Cooling fan relay
E
EC-14
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
CD20T
Glow Control System SYSTEM DESCRIPTION Crankshaft position sensor (TDC)
Engine speed E
E
Glow relay
E
Glow lamp
E
Glow plugs
ECM Engine coolant temperature sensor
Engine coolant temperature E
When coolant temperature is lower than 75°C (167°F): ● Ignition switch ON After the ignition switch has been turned to ON, the glow relay turns ON for a period of time depending on the engine coolant temperature, allowing current to flow through the glow plugs. ● Starting After starting the engine, current will flow through the glow plugs for 300 seconds, or until the coolant temperature exceeds 50°C (122°F).
Fuel Injection System SYSTEM DESCRIPTION Three types of fuel injection control are provided to accommodate the engine operating conditions; normal control, idle control and start control. The ECM determines the appropriate fuel injection control. Under each control, the amount of fuel injected is compensated to improve engine performance. The ECM performs duty cycle control on the electric governor (built into the fuel injection pump) according to sensor signals to compensate the amount of fuel injected to the preset value.
START CONTROL Input/output signal line Engine coolant temperature sensor Crankshaft position sensor (TDC)
Fuel injection volume
Control sleeve position sensor
Engine coolant temperature Engine speed Control sleeve position
E
E
ECM
E
Electric governor
E
When starting, the ECM adapts the fuel injection system for the start control. The amount of fuel injected at engine starting is a preset program value in the ECM. The program is determined by the engine speed and engine coolant temperature. For better startability under cool engine conditions, the lower the coolant temperature becomes, the greater the amount of fuel injected. The ECM ends the start control when the engine speed reaches a coolant temperature dependent value.
Coolant temperature getting lower
Engine rpm SEF648S
EC-15
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injection System (Cont’d)
CD20T
IDLE CONTROL Input/output signal line Engine coolant temperature
Engine coolant temperature sensor
Engine speed
Crankshaft position sensor (TDC)
Air conditioner operation
Air conditioner switch
Control sleeve position
Control sleeve position sensor
Idle position
Accelerator position switch Vehicle speed sensor or ABS actuator and electric unit (control unit)
E
E
E
ECM E
E
Electric governor
E
Vehicle speed
E
When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the engine to keep engine speed constant. During the first 270s after a cold start, the ECM also provides the system with a fast idle control in response to the engine coolant temperature.
NORMAL CONTROL Input/output signal line Engine speed
Crankshaft position sensor (TDC)
Control sleeve position
Control sleeve position sensor
Accelerator position
Accelerator position sensor
Fuel injection volume
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Accelerator opening larger
Engine rpm
E
E
ECM E
E
Electric governor
E
The amount of fuel injected under normal driving conditions is determined according to sensor signals. The crankshaft position sensor (TDC) detects engine speed and the accelerator position sensor detects accelerator position. These sensors send signals to the ECM. The fuel injection data, predetermined by correlation between various engine speeds and accelerator positions, are stored in the ECM memory, forming a map. The ECM determines the optimal amount of fuel to be injected using the sensor signals in comparison with the map.
SEF649S
EC-16
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injection System (Cont’d)
CD20T
FUEL TEMPERATURE COMPENSATION Input/output signal line Fuel temperature sensor Crankshaft position sensor (TDC) Control sleeve position sensor
Fuel temperature Engine speed Control sleeve position
E
E
ECM
E
Electric governor
E
The amount of fuel leaking at or around high-pressure parts inside the fuel injection pump varies with fuel temperature and engine speed. This will result in a difference between the target amount of fuel injected and the actual amount. The ECM compensates for the actual amount depending on the signal from the fuel temperature sensor, the control sleeve position sensor and the crankshaft position sensor.
DECELERATION CONTROL Input/output signal line Accelerator sensor Camshaft position sensor (PUMP)
Accelerator position Engine speed
E
ECM
E
Electric governor
E
The ECM cuts power supply delivery to the electric governor during deceleration for better fuel efficiency. The ECM determines the time of deceleration according to signals from the accelerator sensor and camshaft position sensor (PUMP).
EC-17
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
CD20T
Fuel Injection Timing System SYSTEM DESCRIPTION The fuel injection timing system determines the optimal fuel injection timing, based on engine speed, injection quantity, engine coolant temperature and atmospheric pressure. The timing is formed by a basic value (Basic Control) and two correction values. By performing a duty cycle signal on the timing control valve, the ECM allows the valve to provide optimal injection timing. The ECM also performs feedback control on the timing control valve using the signal from the needle lift sensor which detects the actual fuel injection timing.
BASIC CONTROL Input/output signal line Crankshaft position sensor (TDC)
Injection timing
Needle lift sensor Control sleeve position sensor
Fuel injection timing
BTDC (degree)
Engine speed
Control sleeve position
E
E
ECM
E
Injection timing control valve
E
The optimal fuel injection timing data, predetermined in proportion to engine speeds and amount of fuel injected, are stored in the ECM memory. The ECM uses the data to control the fuel injection timing.
Fuel injection volume Large
Small
Engine rpm SEF650S
HIGH ALTITUDE COMPENSATION Crankshaft position sensor Control sleeve position sensor Atmospheric pressure sensor
Engine speed Control sleeve position Atmospheric pressure Injection timing
Needle lift sensor Fuel temperature sensor
Fuel temperature
E
E
E
ECM
E
Injection timing control valve
E
E
Fuel injection timing compensation
For better drivability in high altitude areas, the fuel injection timing is advanced and the fuel quantity is reduced according to the atmospheric pressure. Normal
High altitude Engine rpm NEF771
EC-18
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injection Timing System (Cont’d)
CD20T
ENGINE COOLANT TEMPERATURE COMPENSATION (During driving) Input/output signal line Crankshaft position sensor (TDC) Engine coolant temperature sensor
Engine speed Engine coolant temperature
E
E
ECM Injection timing
Needle lift sensor
Fuel injection timing compensation
Control sleeve position sensor
Control sleeve position
E
E
Injection timing control valve
E
For better exhaust efficiency under cool engine conditions, the fuel injection timing is controlled within a compensation range depending on the engine speed, engine coolant temperature and amount of fuel injected.
Engine coolant temperature Low
High Engine rpm SEF652S
ENGINE COOLANT TEMPERATURE COMPENSATION (When starting) Input/output signal line Crankshaft position sensor (TDC) Engine coolant temperature sensor
Engine coolant temperature Ignition timing
Needle lift sensor
Fuel injection timing compensation
Engine speed
E
E
ECM
E
Injection timing control valve
E
For better startability under cool engine conditions, the fuel injection timing is compensated according to the engine coolant temperature.
Engine coolant temperature
High
Low Engine rpm SEF651S
EC-19
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
CD20T
Air Conditioning Cut Control INPUT/OUTPUT SIGNAL LINE Air conditioner switch or ABS actuator and electric unit (control unit)
Air conditioner “ON” signal
E
Accelerator valve opening angle
Accelerator position sensor
E
Vehicle speed
Vehicle speed sensor
E
Air conditioner relay
E
Engine coolant temperature
Engine coolant temperature sensor
ECM
E
SYSTEM DESCRIPTION This system improves acceleration when the air conditioner is used. When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds. When engine coolant temperature becomes excessively high, the air conditioner is turned off. This continues until the coolant temperature returns to normal.
Cooling Fan Control INPUT/OUTPUT SIGNAL LINE Vehicle speed sensor or ABS actuator and electric unit (control unit)
Vehicle speed
Engine coolant temperature sensor
Engine coolant temperature
Air conditioner switch
Air conditioner “ON” signal
E
E
ECM
Cooling fan relay(s)
E
E
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, and air conditioner ON signal. The control system has 3-step control [OFF/LOW/HIGH].
Operation Air conditioner is ON Engine coolant temperature °C (°F)
Engine coolant temperature °C (°F)
Air conditioner is OFF
.
102 (216) .
96 (205) .
.
102 (216) .
96 (205)
.
20 80 (12) (50) Vehicle speed km/h (mph) Cooling fans do not operate
.
20 (12)
.
80 (50)
Vehicle speed km/h (mph)
Cooling fans operate at low speed
EC-20
Cooling fans operate at high speed
NEF772
CRANKCASE VENTILATION SYSTEM Blow-by control valve
CD20T
Description ●
In this system blow-by gas is sucked into the air inlet pipe through the control valve after oil separation by the oil separator in the rocker cover.
Baffle plate
FRESH AIR BLOW BY GAS SEF851S
Blow-by Control Valve ●
Blow-by control valve
Check control valve for clogging and abnormalities.
Intake manifold
Rocker cover SEC586B
Ventilation Hose 1. Check hoses and hose connections for leaks. 2. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.
SEC692
EC-21
INJECTION NOZZLE
CD20T
CAUTION: ● Do not disassemble injection nozzle assembly. Entrust disassembly or adjustment to BOSCH service shop. ● Plug flare nut with a cap or rag so that no dust enters the nozzle.
Nozzle side
Combustion chamber side
NEF396 No. 1 injection nozzle
Removal and Installation 1. Remove fuel injection tube and spill tube. 2. Remove injection nozzle assembly. Also remove gasket from nozzle end. 3. Install injection nozzle in the reverse order of removal. Injection nozzle to engine: : 59 - 69 N·m (6.0 - 7.0 kg-m, 43 - 51 ft-lb) Injection nozzle to tube: : 22 - 25 N·m (2.2 - 2.5 kg-m, 16 - 18 ft-lb) Spill tube: : 39 - 49 N·m (4.0 - 5.0 kg-m, 29 - 36 ft-lb) a. Always clean the nozzle holes. b. Always use new injection nozzle gasket. c. Note that small washer should be installed in specified direction. d. Bleed air from fuel system.
NEF774
Test and Adjustment WARNING: When using nozzle tester, be careful not to allow diesel fuel sprayed from nozzle to contact your hands or body, and make sure your eyes are properly protected with goggles.
INJECTION PRESSURE TEST 1. Install nozzle to injection nozzle tester and bleed air from flare nut.
EF791A
EC-22
INJECTION NOZZLE Test and Adjustment (Cont’d)
SEF672A
CD20T
2. Pump the tester handle slowly (one time per second) and watch the pressure gauge. 3. Read the pressure gauge when the injection pressure just starts dropping. Initial injection pressure: Used 14,423 - 15,651 kPa (144.2 - 156.5 bar, 148 - 159 kg/cm2, 2,091 - 2,269 psi) New 15,000 - 16,000 kPa (150.0 - 160.0 bar, 153 - 163 kg/cm2, 2,175 - 2,320 psi) Always check initial injection pressure using a new nozzle. If the pressure is not correct, replace nozzle assembly.
LEAKAGE TEST 1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6 bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection pressure. 2. Check that there is no dripping from the nozzle tip or around the body. 3. If there is leakage, replace nozzle. Good
Faulty SEF674A
SPRAY PATTERN TEST 1. Check spray pattern by pumping tester handle one full stroke per second. a. If main spray angle is within 30 degrees as shown, injection nozzle is good. b. It is still normal even if a thin stream of spray deviates from the main spray (pattern B). 2. Test again and if spray pattern is not corrected, replace nozzle. SEF079S
EC-23
CD20T
ELECTRONIC FUEL INJECTION PUMP
6.3 - 8.2 (0.64 - 0.84, 55.6 - 72.9) 16 - 21 (1.6 - 2.1, 12 - 15)
13 - 18 (1.3 - 1.8, 9 - 13) Front of engine 16 - 21 (1.6 - 2.1, 12 - 15)
31 - 37 (3.2 - 3.8, 23 - 27) 59 - 69 (6.0 - 7.0, 43 - 51)
49 - 59 (5.0 - 6.0, 36 - 43)
24 - 27 (2.4 - 2.8, 17 - 20)
: N·m (kg-m, in-lb)
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8) 24 - 27 (2.4 - 2.8, 17 - 20)
: N·m (kg-m, ft-lb) 1 p 2 p 3 p
Rear back cover Injection pump sprocket Injection pump bracket
4 p 5 p 6 p
Water connector Bracket Bracket
7 p 8 p
NEF777
Electronic fuel injection pump Key
Removal 1. Remove battery. Disconnect electronic injection pump harness connectors.
2. Set No. 1 piston at TDC on its compression stroke. TDC: Crankshaft pulley notch without painted mark 3. Remove fuel hoses (supply, return and spill) and injection tubes. 4. Remove air duct and injection pump timing belt cover. 5. Remove injection pump timing belt. Refer to EM section (“Injection Pump Timing Belt”).
Injection timing mark (Yellow painted mark)
TDC (Without painted mark)
SEF655S
6. Remove injection pump sprocket with Tool. ● Remove key from injection pump shaft and store safely.
SEF656S
EC-24
ELECTRONIC FUEL INJECTION PUMP Removal (Cont’d)
CD20T
7. Remove injection pump assembly.
SEF657S Injection pump sprocket Key
Alignment mark
Installation 1. Install key on injection pump shaft, then install injection pump sprocket. 2. Install injection pump timing belt. Refer to EM section (“Injection Pump Timing Belt”). 3. Adjust injection timing. Refer to “Basic Inspection”, EC-CD-37. 4. Install all parts removed.
NEF866
Fuel cut solenoid valve 20 - 25 (2.0 - 2.5, 14 - 18)
O-ring
Washer 20 - 25 (2.0 - 2.5, 14 - 18)
: Do not reuse : N·m (kg-m, in-lb)
7 - 10 (0.7 - 1.0, 61 - 87)
: N·m (kg-m, ft-lb) NEF778
EC-25
ELECTRONIC FUEL INJECTION PUMP
CD20T
Disassembly and Assembly CAUTION: ● Do not disassemble the parts not shown in the illustration above. ● Before installing injection timing control valve, apply a coat of diesel fuel to O-ring and its mating area. Insert injection timing control valve straight into bore in fuel pump body. After properly positioning injection timing control valve, visually check for fuel leaks. ● After assembling the parts, erase Diagnostic Trouble Code (DTC), and perform DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK).
EC-26
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CD20T
CONSULT-II Fuse box
CONSULT-II INSPECTION PROCEDURE 1. Turn off ignition switch. 2. Connect “CONSULT-II” to data link connector for CONSULTII. (Data link connector for CONSULT-II is located behind the fuse box cover.)
Data link connector for CONSULT-II
NEF225A
3. 4. 5. 6.
Turn on ignition switch. Touch “START”. Touch “ENGINE”. Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual.
PEF895K
PEF216U
EC-27
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)
CD20T
ENGINE CONTROL MODULE COMPONENT PARTS/CONTROL SYSTEMS APPLICATION DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS
ENGINE CONTROL MODULE COMPONENT PARTS
Item
INPUT
OUTPUT
DATA MONITOR
Camshaft position sensor (PUMP) *1
X *2
X
Mass air flow sensor
X
X
Engine coolant temperature sensor
X
X
Control sleeve position sensor
X
X
Fuel temperature sensor
X
X
Vehicle speed sensor or ABS actuator and electric unit (control unit)
X
X
Accelerator position sensor
X
X
Accelerator position switch
ACTIVE TEST
X
X
Brake lamp switch
X *2
X
Crankshaft position sensor (TDC)
X
X
Needle lift sensor
X
X
Ignition switch (start signal)
X
Ignition switch (ON signal)
X
Air conditioner switch
X
Brake switch
X
Battery voltage
X
Injection timing control valve
X
X
X
Fuel cut solenoid valve
X
X
X
Air conditioner relay
X
Glow relay
X
X
EGRC-solenoid valve
X
X
Cooling fan relay
X
X
X: Applicable *1: Imaginary sensor, which produces secondary engine revolution signal using needle lift sensor pulse. *2: CONSULT-II may not display, but self-diagnostic results are available with MI.
EC-28
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)
CD20T
SELF-DIAGNOSTIC MODE Regarding items detected in “SELF-DIAG RESULTS” mode, refer to “Diagnostic Trouble chart”.
DATA MONITOR MODE Monitored item [Unit]
ECM Main input signals signals
Description
CKPS⋅RPM (TDC) [rpm]
q q
●
The engine speed computed from the crankshaft position sensor (TDC) signal is displayed.
CMPS⋅RPM PUMP [rpm]
q q
●
The engine speed computed from the camshaft position sensor (PUMP) signal is displayed.
●
The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed.
●
The vehicle speed computed from the vehicle speed sensor signal or ABS actuator and electric unit (control unit) signal is displayed.
●
The fuel temperature (determined by the signal voltage of the fuel temperature sensor) is displayed.
●
The accelerator position sensor signal voltage is displayed.
●
Indicates [ON/OFF] condition from the accelerator position switch signal.
●
The control sleeve position sensor signal voltage is displayed.
●
The power supply voltage of ECM is displayed.
●
Indicates [ON/OFF] condition from the starter signal.
●
Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal.
●
Indicates [ON/OFF] condition of the stio lamp switch.
●
Indicates [ON/OFF] condition of the stio lamp switch 2.
●
Indicates [ON/OFF] condition from ignition switch.
●
The signal voltage of the mass air flow sensor is displayed.
●
The actual injection timing angle determined by the ECM (an approximate average angle between injection start and end from TDC) is displayed.
●
The target fuel injection quantity (determined by the ECM according to the input signal) is indicated.
COOLAN TEMP/S [°C] or [°F]
VHCL SPEED SE [km/h] or [mph]
q q q q
FUEL TEMP SEN [°C] or [°F]
q q
ACCEL POS SEN [V]
q q q q q
OFF ACCEL POS [ON/OFF] C/SLEEV POS/S [V] BATTERY VOLT [V] START SIGNAL [ON/OFF]
q q q q q
AIR COND SIG [ON/OFF]
q q
BRAKE SW [ON/OFF]
q q q q q q
BRAKE SW2 [ON/OFF] IGN SW [ON/OFF] MAS AIR/FL SE [V] ACT INJ TIMG [°]
TARGET F/INJ [mm3/STROKE]
q q
Remarks
●
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 starting the engine, [OFF] is displayed regardless of the starter signal.
●
When the engine is stopped, a certain value is indicated.
NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
EC-29
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Monitored item [Unit]
ECM Main input signals signals
FUEL CUT S/V [ON/OFF]
Description ●
●
AIR COND RLY [ON/OFF] GLOW RLY [ON/OFF] COOLING FAN [LOW/HI/OFF]
EGRC SOL/V A [ON/OFF]
The control condition of the fuel cut solenoid valve (determined by ECM according to the input signal) is indicated. OFF ... Fuel cut solenoid valve is not operating. ON ... Fuel cut solenoid valve is operating.
q
●
The air conditioner relay control condition (determined by ECM according to the input signal) is indicated.
q
●
The glow relay control condition (determined by ECM according to the input signal) is displayed.
●
Indicates the control condition of the cooling fans (determined by ECM according to the input signal). LOW ... Operates at low speed. HI ... Operates at high speed. OFF ... Stopped.
q
●
●
●
The control condition of the EGRCsolenoid valve (determined by ECM according to the input signal) is indicated. OFF ... EGRC-solenoid valve is not operating. ON ... EGRC-solenoid valve is operating.
EC-30
CD20T
Remarks ●
When the fuel cut solenoid valve is not operating, fuel supply is shut off.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)
CD20T
ACTIVE TEST MODE TEST ITEM
CONDITION
TARGET F/INJ
COOLING FAN
FUEL CUT SOL/V
EGRC SOL/V A
GLOW RLY
CHECK ITEM (REMEDY)
If trouble symptom disappears, see CHECK ITEM.
●
Control sleeve position sensor
● ●
Ignition switch: ON Operate the cooling fan at “LOW”, “HI” speed and turn “OFF” using CONSULT-II.
Cooling fan moves at “LOW”, “HI” speed and stops.
● ●
Harness and connector Cooling fan motor
● ●
Ignition switch: ON Turn solenoid valve “ON” and “OFF” with the CONSULT-II and listen to operating sound.
Solenoid valve makes an operating sound.
● ●
Harness and connector Solenoid valve
● ●
Ignition switch: ON Turn solenoid valve “ON” and “OFF” with the CONSULT-II and listen to operating sound.
Solenoid valve makes an operating sound.
● ●
Harness and connector Solenoid valve
●
Ignition switch: ON (Engine stopped) Glow relay makes the operating Turn the glow relay “ON” and sound. “OFF” using CONSULT-II and listen to operating sound.
● ●
Harness and connector Fuel pump relay
Engine: Return to the original trouble condition Retard the injection timing using CONSULT-II.
●
Adjust initial injection timing
●
●
●
INJ TIMING
JUDGEMENT
Engine: Return to the original trouble condition Fix the target injection quantity using CONSULT-II.
●
●
If trouble symptom disappears, see CHECK ITEM.
EC-31
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)
CD20T
REAL TIME DIAGNOSIS IN DATA MONITOR MODE 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 and malfunction item will be displayed at the moment the malfunction is detected by ECM. DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA MONITOR cannot continue any longer after the malfunction detection. 2. “MANU TRIG” (Manual trigger): ● 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. Use these triggers as follows: 1. “AUTO TRIG” ● While trying to detect the malfunction item by performing the “DIAGNOSTIC TROUBLE 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. Inspect the circuit by gently shaking (or twisting) suspicious connectors, components and harness in the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. The moment a malfunction is found the malfunction item will be displayed. (Refer to GI section, “Incident Simulation Tests” in “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.) 2. “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.
“SETTING”
“AUTO TRIG” A malfunction can be displayed on “DATA MONITOR” screen automatically if detected.
“MANU TRIG” A malfunction can not be displayed on “DATA MONITOR” screen automatically even if detected. PEF529Q
EC-32
TROUBLE DIAGNOSIS — Introduction
CD20T
Introduction
SEF858S
SEF233G
The engine has an ECM to control major systems such as fuel injection control, fuel injection timing control, glow control system, etc. The ECM accepts input signals from sensors and instantly drive the electronic fuel injection pump use the data to based on current ambient conditions. It is essential that both input and output signals are correct and stable. At the same time, it is important that there are no problems such as vacuum leaks, or other problems with the engine. It is much more difficult to diagnose a problem that occurs intermittently rather than catastrophically. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspected circuits may help prevent the replacement of good parts. A visual check only may not be sufficient to determine the cause of the problems. A road test with CONSULT-II or a circuit tester connected should be performed. Follow the “Work Flow” on the next page. 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 problems, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “Diagnostic Worksheet” like the example on next page should be used. Start your diagnosis by looking for “conventional” problems first. This will help troubleshoot driveability problems on a vehicle with an electronically controlled engine.
SEF234G
EC-33
CD20T
TROUBLE DIAGNOSIS — Introduction Diagnostic Worksheet KEY POINTS WHAT ..... WHEN ..... WHERE ..... HOW .....
Vehicle & engine model Date, Frequencies Road conditions Operating conditions, Weather conditions, Symptoms
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 problem. It is important to fully understand the symptoms or conditions for a customer complaint. Utilize a diagnostic worksheet like the one shown below in order to organize all the information for troubleshooting.
SEF907L
WORKSHEET SAMPLE Customer name
Model & Year
VIN
Engine #
Trans.
Mileage
Incident Date
Manuf. Date
In Service Date
Symptoms
MR/MS
l Startability
l Impossible to start l No combustion l Partial combustion l Partial combustion when warming-up engine l Partial combustion when cooling down engine l Possible but hard to start l Others [ ]
l Idling
l No fast idle l Others [
l Driveability
l Stumble l Others [
l Engine stall
l At the time of start l While accelerating l Just after stopping
l Unstable l Surge
Incident occurrence
l Just after delivery l In the morning
Frequency
l All the time
Weather conditions
l Not affected
Weather
l Fine [
Temperature
l Hot
Engine conditions
l Knock
l Low idle
l Lack of power ]
l While idling l While decelerating l While loading l Recently l At night l In the daytime
l Under certain conditions
l Raining
l Snowing ]
l Warm
l Cold
l High idle ]
l Cool
l Sometimes
l Others
l Cold
l During warm-up
l Humid
°F
l After warm-up
Engine speed 0
2,000
l In suburbs
4,000
Road conditions
l In town
l Highway
Driving conditions
l Not affected l At starting l While idling l At racing l While accelerating l While cruising l While decelerating l While turning (RH/LH)
6,000
8,000 rpm
l Off road (up/down)
Vehicle speed 0 Malfunction indicator
l Turned on
10
20
30
l Not turned on
EC-34
40
50
60
70
80
90
100 mph
TROUBLE DIAGNOSIS — Work Flow
CD20T
Work Flow CHECK IN H
Listen to customer complaints. (Get symptoms.)
..........................................
STEP I
.....................................
STEP II
H
Check, print out or write down, and erase Diagnostic Trouble (malfunction item). Symptoms collected.
No symptoms, except MI lights up, or Malfunction Code exists at STEP II. H
Verify the symptom by driving in the condition the customer described. Normal Code (at STEP II)
....................................................................................*1 STEP III
Malfunction Code (at STEP II) H
H
Verify the malfunction item by performing the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. H E
..................................... *2
Choose the appropriate action. Malfunction Code (at STEP II or IV)
H
.....................................*1 STEP IV
STEP V
Normal Code (at both STEP II and IV)
BASIC INSPECTION SYMPTOM BASIS (at STEP I or III) ...........................................................E H
Perform inspections according to Symptom Matrix Chart. H
H
STEP VI
TROUBLE DIAGNOSIS FOR SPECIFIC MALFUNCTION ITEM. H
REPAIR/REPLACE H
NG FINAL CHECK Confirm that the incident is completely fixed by performing BASIC INSPECTION and DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK). Then, erase the unnecessary (already fixed) Malfunction Item in ECM.
.....................................
STEP VII
OK H
CHECK OUT *1: If the incident cannot be duplicated, refer to GI section (“Incident Simulation Tests”, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”). *2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to “TROUBLE DIAGNOSIS FOR MAIN POWER SUPPLY AND GROUND CIRCUIT”, EC-CD-59.
EC-35
TROUBLE DIAGNOSIS — Work Flow
CD20T
Description for Work Flow STEP
DESCRIPTION
STEP I
Get detailed information about the conditions and the environment when the incident/symptom occurred using the “DIAGNOSTIC WORKSHEET” as shown on the previous page.
STEP II
Before confirming the concern, check and write down (print out using CONSULT-II) the malfunction item, then erase the code. The malfunction item can be used when duplicating the incident at STEP III & IV. Study the relationship between the cause, specified by malfunction item, and the symptom described by the customer. (The “Symptom Matrix Chart” will be useful. Refer to EC-CD-47.)
STEP III
Try to confirm the symptom and under what conditions the incident occurs. The “DIAGNOSTIC 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. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section. If the malfunction code is detected, skip STEP IV and perform STEP V.
STEP IV
Try to detect the malfunction item by driving in (or performing) the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. Check and read the malfunction item by using CONSULT-II. During the malfunction item verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section. In case the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” is not available, perform the “OVERALL FUNCTION CHECK” instead. The malfunction item cannot be displayed by this check, however, this simplified “check” is an effective alternative. The “NG” result of the “OVERALL FUNCTION CHECK” is the same as the DTC detection.
STEP V
Take the appropriate action based on the results of STEP I through IV. If the malfunction code is indicated, proceed to specific TROUBLE DIAGNOSIS for the malfunction item. If the normal code is indicated, proceed to the BASIC INSPECTION. Refer to EC-CD-37. Then perform inspections according to the Symptom Matrix Chart. Refer to EC-CD-47.
STEP VI
Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) “Harness Layouts”. Gently shake the related connectors, components or wiring harness with CONSULT-II set in “DATA MONITOR (AUTO TRIG)” mode. Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II. Refer to EC-CD-52. The “DIAGNOSTIC PROCEDURE” in EC section contains a description based on open circuit inspection. A short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details, refer to GI section (“Circuit Inspection”, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”). Repair or replace the malfunctioning parts.
STEP VII
Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions and circumstances which resulted in the customer’s initial complaint. Perform the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” and confirm the normal code is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the previous one. Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) malfunction item in ECM.
EC-36
TROUBLE DIAGNOSIS — Basic Inspection
CD20T
Basic Inspection Precaution: Perform Basic Inspection without electrical or mechanical loads applied; ● Headlamp switch is off, ● Air Conditioner switch is off, ● Rear defogger switch is off, ● Steering wheel is in the straight-ahead position, etc. SEF142I
Priming pump
SEF671S
.
Diesel tacho tester
BEFORE STARTING 1. Check service records for any recent repairs that may indicate a related problem, or the current need for scheduled maintenance. 2. Open engine hood and check the following: ● Harness connectors for faulty connections ● Vacuum hoses for splits, kinks, or faulty connections ● Wiring for faulty connections, pinches, or cuts 3. Using priming pump, bleed air from fuel system. Refer to “Fuel Filter Check” in MA section. H
.
Injection tube
CONNECT CONSULT-II TO THE VEHICLE. Connect “CONSULT-II” to the data link connector for CONSULT-II and select “ENGINE” from the menu. Refer to ECCD-27.
SEF689S
H
DOES ENGINE START? Yes
H
Run engine for 10 minutes. H PEF190P
CHECK IDLE SPEED. Read engine idle speed in “DATA MONITOR” mode with CONSULT-II. 825 rpm ± 25 (in N position) ----------------------------------------------------------------- OR ----------------------------------------------------------------Check idle speed using tachometer tester. 825 rpm ± 25 (in N position)
(Go to
A p
H
on next page.)
EC-37
No
E
Turn ignition switch to the “LOCK” position, wait 5 seconds and then start engine. If engine fails to start, check malfunction item.
CD20T
TROUBLE DIAGNOSIS — Basic Inspection Basic Inspection (Cont’d) A p
H
SEF661S
Plunger lift timing mark (Yellow painted mark)
TDC (Without painted mark)
SEF655S
Increase Decrease
CHECK INJECTION TIMING. 1. Set No. 1 piston at TDC on its compression stroke. TDC: Without painted mark 2. Remove injection tubes and air bleeder on the back of injection pump. 3. Set dial gauge so its indicator points to somewhere between 1.0 and 2.0 mm (0.039 and 0.079 in) on the scale. 4. Turn crankshaft 2 turns clockwise and check that dial gauge indicates the same value again. 5. Turn crankshaft counterclockwise about 100 degrees, then turn crankshaft slowly clockwise, and set dial gauge indicator to 0 mm at the position it stops. 6. Turn crankshaft clockwise and set it at plunger lift timing mark using the mark on the crankshaft pulley. plunger lift timing mark: Yellow painted mark 7. Read plunger lift. Plunger lift: 0.89 ± 0.08 mm (0.0350 ± 0.0031 in) at plunger lift timing mark ● When repeating the checking, start with step 5.
OK
E
Bleed air from fuel system. After this inspection, unnecessary diagnostic trouble code No. might be displayed. Erase the stored memory in ECM. Refer to “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”. OK H
INSPECTION END
NG H
SEF662S
SEF657S
Adjusting 1. If plunger lift is not within the specified value, adjust by turning injection pump. ● If indication is smaller than the specified value, turn pump body away from engine. ● If indication is larger than the specified value, turn pump body towards engine. 2. Tighten injection pump securing bolts and nuts. Nut: : 20 - 25 N·m (2.0 - 2.6 kg-m, 15 - 18 ft-lb) Bolt: : 25 - 35 N·m (2.6 - 3.6 kg-m, 18 - 26 ft-lb) 3. Remove dial gauge and install air bleeder with new washer. 4. Install injection tubes. Flare nut: : 14 - 20 N·m (1.4 - 2.0 kg-m, 10 - 15 ft-lb) 5. Bleed air from fuel system. Refer to “Water Draining, Fuel Filter Check and Replacement” of “ENGINE MAINTENANCE” in MA section.
EC-38
E
Go to
TROUBLE DIAGNOSIS — General Description
CD20T
Diagnostic Trouble Chart ENGINE RELATED ITEMS Detected items Malfunction is detected when ... (Screen terms for CONSULT-II, “SELF-DIAG RESULTS” mode) Mass air flow sensor circuit (MASS AIR FLOW SEN)
●
An excessively high or low voltage from the sensor is detected by the ECM.
Engine coolant temperature sensor circuit (COOLANT TEMP SEN)
●
An excessively high or low voltage from the sensor is detected by the ECM.
Vehicle speed sensor circuit or ABS actuator and electric unit (control unit) circuit (VEHICLE SPEED SEN)
●
The almost 0 km/h (0 mph) signal from the sensor is detected by the ECM even when vehicle is being driven.
Control sleeve position sensor circuit (CONT SLEEV POS SEN)
●
An excessively high or low voltage from the sensor is detected by the ECM. An incorrect voltage signal from the sensor is detected by the ECM during engine running.
Fuel injection feedback 2 (F/INJ F/B 2)
●
The fuel injection feedback system (consists of the ECM, electric governor and control sleeve position sensor) does not operate properly.
Fuel injection timing feedback (F/INJ TIMG F/B)
●
The fuel injection timing feedback system (consists of the ECM, fuel injection timing control valve and needle lift sensor) does not operate properly.
●
Abbreviations for Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” IGN: ON : Turning the ignition switch ON is required for checking the function of the sensor, switch, solenoid and circuit. RUNNING : Running engine is required for checking the function of the sensor, switch, solenoid and circuit. LIFTING : Lifting up the vehicle, running engine and spinning wheels are required. DRIVING : Driving the vehicle in the specified pattern is required. Abbreviations for Quick Reference of “OVERALL FUNCTION CHECK” IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists). RUNNING : Running engine is required for the ECM to detect a malfunction (if one exists). LIFTING : Lifting up the vehicle, running engine and spinning wheels are required for the ECM to detect a malfunction (if one exists). DRIVING : Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction (if one exists).
EC-39
TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)
CD20T
—: Not applicable *2
*1 Overall Function Check
Harness or connectors (The sensor circuit is open or shorted.) Mass air flow sensor
IGN: ON
—
—
EC-CD-62
Harness or connectors (The sensor circuit is open or shorted.) Engine coolant temperature sensor
IGN: ON
—
Lighting up
EC-CD-66
—
LIFTING
—
EC-CD-70
Harness or connectors (The sensor circuit is open or shorted.) Control sleeve position sensor
RUNNING
—
Lighting up
EC-CD-74
Main power supply circuit (ECM terminals 23 , 45 ), 68 and fuse Harness or connectors (Electric governor and control sleeve position sensor circuit) Electronic fuel injection pump ECM Electric governor
RUNNING (DRIVING)
—
Lighting up
EC-CD-78
Harness or connectors (Injection timing control valve, Needle lift sensor and Crankshaft position sensor (TDC) circuit] Injection timing control valve Needle lift sensor Crankshaft position sensor Air in fuel line
RUNNING (DRIVING)
—
Lighting up
EC-CD-82
Check Items (Possible Cause)
●
● ●
● ●
●
●
● ●
●
● ● ● ●
● ● ● ●
MI Reference Illumination Page
Confirmation Procedure Quick Ref.
Harness or connectors (The sensor circuit is open or shorted.) Vehicle speed sensor or ABS actuator and electric unit (control unit)
*1:
●
*2:
●
● ●
This is Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. Details are described in each TROUBLE DIAGNOSIS. The “OVERALL FUNCTION CHECK” is a simplified and effective way to inspect a component or circuit. In some cases, the “OVERALL FUNCTION CHECK” is used rather than a “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available, the “NG” result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection. During an “NG” OVERALL FUNCTION CHECK, the malfunction item might not be confirmed. This is Quick Reference of “OVERALL FUNCTION CHECK”. Details are described in each TROUBLE DIAGNOSIS.
EC-40
TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)
CD20T
ENGINE RELATED ITEMS Detected items Malfunction is detected when ...
(Screen terms for CONSULT-II, “SELF-DIAG RESULTS” mode) Cooling fan (OVER HEAT)
●
An excessive high engine coolant temperature sensor signal is detected by the ECM. (Overheat)
ECM2 (ECM2)
●
ECM calculation function is malfunctioning.
Needle lift sensor circuit (NEEDLE LIFT SEN)
●
An incorrect signal from the sensor is detected by the ECM during engine running.
Fuel cut solenoid valve 1 (FUEL CUT S/V 1)
●
Fuel cut solenoid valve circuit is malfunctioning.
Fuel temperature sensor circuit (FUEL TEMP SENSOR)
●
An excessively high or low voltage from the sensor is detected by the ECM.
Accelerator position sensor circuit (ACCEL POS SENSOR)
●
An excessively high or low voltage from the sensor is detected by the ECM.
Crankshaft position sensor (TDC) [CRANK POS SEN (TDC)]
●
An incorrect signal from the sensor is detected by the ECM during engine running and cranking.
No failure (NO SELF DIAGNOSTIC FAILURE INDICATED)
No malfunction is detected by the ECM.
Abbreviations for Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” IGN: ON : Turning the ignition switch ON is required for checking the function of the sensor, switch, solenoid and circuit. RUNNING : Running engine is required for checking the function of the sensor, switch, solenoid and circuit. LIFTING : Lifting up the vehicle, running engine and spinning wheels are required. DRIVING : Driving the vehicle in the specified pattern is required. Abbreviations for Quick Reference of “OVERALL FUNCTION CHECK” IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists). RUNNING : Running engine is required for the ECM to detect a malfunction (if one exists). LIFTING : Lifting up the vehicle, running engine and spinning wheels are required for the ECM to detect a malfunction (if one exists). DRIVING : Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction (if one exists).
EC-41
TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)
CD20T
—: Not applicable *2
*1 Check Items (Possible Cause)
Confirmation Procedure Quick Ref.
Harness or connectors (The cooling fan circuit is open or shorted.) ● Cooling fan ● Radiator hose ● Radiator ● Radiator cap ● Water pump ● Thermostat ● Fan belt ● Engine coolant temperature sensor For more information, refer to “12 MAIN CAUSES OF OVERHEATING”. (EC-CD-95)
Overall Function Check
MI Reference Illumination Page
●
—
IGN: ON (RUNNING)
Lighting up
EC-CD-78
IGN: ON
—
Lighting up
EC-CD-86
●
ECM
●
Harness or connectors (The sensor circuit is open or shorted.) Needle lift sensor Air in fuel line Clogging No. 1 injection nozzle
RUNNING
—
Lighting up
EC-CD-97
Harness or connectors (The solenoid valve circuit is open or shorted.) Fuel cut solenoid valve
RUNNING
—
Lighting up
EC-CD-100
Harness or connectors (The sensor circuit is open or shorted.) Fuel temperature sensor
IGN: ON
—
—
EC-CD-104
Harness or connectors (The sensor circuit is open or shorted.) Accelerator position sensor Accelerator position switch
IGN: ON
—
Lighting up
EC-CD-108
RUNNING
—
Lighting up
EC-CD-114
●
Harness or connectors (The sensor circuit is open or shorted.) Crankshaft position sensor (TDC)
●
No failure —
—
—
—
● ● ● ●
● ●
● ●
● ● ●
*1:
●
*2:
●
● ●
This is Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. Details are described in each specific TROUBLE DIAGNOSIS. The “OVERALL FUNCTION CHECK” is a simplified and effective way to inspect a component or circuit. In some cases, the “OVERALL FUNCTION CHECK” is used rather than a “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available, the “NG” result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection. During an “NG” OVERALL FUNCTION CHECK, the malfunction item might not be confirmed. This is Quick Reference of “OVERALL FUNCTION CHECK”. Details are described in each specific TROUBLE DIAGNOSIS.
EC-42
TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)
CD20T
ENGINE RELATED ITEMS Detected items Malfunction is detected when ...
(Screen terms for CONSULT-II, “SELF-DIAG RESULTS” mode) Atmospheric pressure sensor *5 (—) *3
●
An excessively high or low voltage from the sensor is detected by the ECM.
Glow relay circuit (GLOW RELAY)
●
Glow relay circuit is open or shorted.
ECM (—)*3
●
ECM reference voltage (2.5V) is excessively high or low.
Air conditioner relay circuit (—)*3
●
Air conditioner relay circuit is shorted.
EGRC-solenoid valve A (EGR SYS)
●
EGRC-solenoid valve A is open or shorted.
Brake switch circuits (—)*3
●
Brake switch circuits are open or shorted.
ECM (—)*3
●
ECM version number or switching function is not plausible.
ECCS-D relay circuit (—)*3
●
ECCS-D relay shut-off time is too late.
Ignition switch “ON” signal circuit (—)*3
●
Ignition switch “ON” signal evaluation circuit in ECM is malfunctioning.
Injection timing control valve circuit (INJ TIMING CONT/V)
●
Injection timing control valve circuit is open or shorted.
Camshaft position sensor (PUMP)*4 (—)*3
●
An improper signal is calculated by the ECM.
Abbreviations for Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” IGN: ON : Turning the ignition switch ON is required for checking the function of the sensor, switch, solenoid and circuit. RUNNING : Running engine is required for checking the function of the sensor, switch, solenoid and circuit. LIFTING : Lifting up the vehicle, running engine and spinning wheels are required. DRIVING : Driving the vehicle in the specified pattern is required. Abbreviations for Quick Reference of “OVERALL FUNCTION CHECK” IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists). RUNNING : Running engine is required for the ECM to detect a malfunction (if one exists). LIFTING : Lifting up the vehicle, running engine and spinning wheels are required for the ECM to detect a malfunction (if one exists). DRIVING : Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction (if one exists).
EC-43
TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)
CD20T
—: Not applicable *1 Confirmation Procedure Quick Ref.
Check Items (Possible Cause)
●
*2 Overall Func- MI Reference tion Check Illumination Page
ECM IGN: ON
—
—
EC-CD-86
IGN: ON
—
—
EC-CD-118
IGN: ON
—
—
EC-CD-86
IGN: ON
—
—
EC-CD-126
Harness or connectors (The EGRC-solenoid valve A circuit is open or shorted.) EGRC-solenoid valve
RUNNING
—
Lighting up
EC-CD-129
RUNNING
—
Lighting up
EC-CD-136
●
Harness or connectors (Brake switch circuits are open or shorted.) Brake lamp switch RDNT brake switch
●
ECM
IGN: ON
—
—
EC-CD-86
●
IGN: ON
—
Lighting up
EC-CD-86
●
Harness or connectors (The ECCS-D relay circuit is shorted.) ECCS-D relay ECM
●
ECM IGN: ON
—
Lighting up
EC-CD-86
IGN: ON
—
Lighting up
EC-CD-82
RUNNING
—
Lighting up
EC-CD-97
●
Harness or connectors (The glow relay circuit is open or shorted.) Glow relay
●
ECM
●
Harness or connectors (The air conditioner relay circuit is open or shorted.) Air conditioner relay
●
● ●
● ●
●
●
●
● ● ● ●
*1: *2:
*3: *4: *5:
Harness or connectors (The injection timing control valve circuit is open or shorted.) Injection timing control valve ECM Needle lift sensor Low battery voltage
This is Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. Details are described in each specific TROUBLE DIAGNOSIS. ● The “OVERALL FUNCTION CHECK” is a simplified and effective way to inspect a component or circuit. In some cases, the “OVERALL FUNCTION CHECK” is used rather than a “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available, the “NG” result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection. ● During an “NG” OVERALL FUNCTION CHECK, the malfunction item might not be confirmed. ● This is Quick Reference of “OVERALL FUNCTION CHECK”. Details are described in each specific TROUBLE DIAGNOSIS. CONSULT-II may not detect, but self-diagnostic results are available with MI. Imaginary sensor, which produces secondary engine revolution signal using needle lift sensor pulse. The atmospheric pressure sensor is located inside the ECM and is not replaceable. ●
EC-44
TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)
CD20T
ENGINE RELATED ITEMS Detected items Malfunction is detected when ...
(Screen terms for CONSULT-II, “SELF-DIAG RESULTS” mode) MI (—)*3
●
MI (malfunction indicator) circuit is open or shorted.
GLOW LAMP CIRCUIT (—)*3
●
Glow lamp circuit is open or shorted.
Abbreviations for Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” IGN: ON : Turning the ignition switch ON is required for checking the function of the sensor, switch, solenoid and circuit. RUNNING : Running engine is required for checking the function of the sensor, switch, solenoid and circuit. LIFTING : Lifting up the vehicle, running engine and spinning wheels are required. DRIVING : Driving the vehicle in the specified pattern is required. Abbreviations for Quick Reference of “OVERALL FUNCTION CHECK” IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists). RUNNING : Running engine is required for the ECM to detect a malfunction (if one exists). LIFTING : Lifting up the vehicle, running engine and spinning wheels are required for the ECM to detect a malfunction (if one exists). DRIVING : Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction (if one exists).
EC-45
TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)
CD20T
—: Not applicable *1 Check Items (Possible Cause)
●
● ● ●
●
*1:
Confirmation Procedure Quick Ref.
*2 Overall Func- MI Reference tion Check Illumination Page
Harness or connectors (The MI circuit is open or shorted.) MI lamp ECM
IGN: ON
—
—
EC-CD-141
Harness or connectors (The glow indicator lamp circuit is open or shorted.) Glow lamp
IGN: ON
—
—
EC-CD-118
This is Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. Details are described in each specific TROUBLE DIAGNOSIS. *2: ● The “OVERALL FUNCTION CHECK” is a simplified and effective way to inspect a component or circuit. In some cases, the “OVERALL FUNCTION CHECK” is used rather than a “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available, the “NG” result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection. ● During an “NG” OVERALL FUNCTION CHECK, the malfunction item might not be confirmed. ● This is Quick Reference of “OVERALL FUNCTION CHECK”. Details are described in each specific TROUBLE DIAGNOSIS. *3: CONSULT-II may not detect, but self-diagnostic results are available with MI. ●
EC-46
CD20T
TROUBLE DIAGNOSIS — General Description Symptom Matrix Chart
●
●
q
q q
●
●
q
●
Electric injection pump mainframe
●
●
●
q q q q q
●
Injection nozzle
q q q q q q q
●
Glow system
q q
●
●
●
Engine body
q q
●
●
●
q q q
q q
q q
q q
q
q
●
●
●
●
●
●
q
●
q q q
●
●
●
Air cleaner and ducts
●
●
●
EC-47
Feature of symptom, Check point
Reference page EC-CD-38
●
q
EC-CD-38
q
q q q
—
*1
EC-CD-22
*2
●
EGR system
● ; High Possibility Item q; Low Possibility Item *1: Insufficient or excess amount. Governor malfunction may be the cause. *2: Depends on open-valve pressure and spray pattern. *3: Caused mainly by insufficient compression pressure. *4: Symptom varies depending on off-position of air duct, etc.
HA
q
●
q
DEAD BATTERY (UNDER CHARGE)
ABNORMAL SMOKE COLOR AP
q q q q q
WHITE SMOKE
BLACK SMOKE
EXCESSIVE OIL CONSUMPTION
EXCESSIVE FUEL CONSUMPTION
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
SLOW/NO RETURN TO IDLE
AG AH AJ AK AL AM
●
●
IDLING VIBRATION
ROUGH IDLE/HUNTING
LOW IDLE
HI IDLE
AF
Fuel cut
AE
q q
Injec- Advanced tion timing Retarded
POOR ACCELERATION
LACK OF POWER
SPARK KNOCK/DETONATION
AC AD
Can be detected by CONSULT-II?
AB
HESITATION/SURGING/FLAT SPOT
WHEN DECELERATING
DURING DRIVING
AT IDLE
HARD TO START WHEN ENGINE IS HOT
HARD TO START WHEN ENGINE IS COLD
AA
Malfunction indicator illuminates.
New CT/CS
NO START (without first firing)
NO START (with first firing)
SYSTEM — Basic engine control system
ENGINE STALL
HARD/NO START/RESTART (EXCP. HA)
SYMPTOM
●
EC-CD-118
●
EMsection
*3
EC-CD-129 q
MAsection
*4
HARD TO START WHEN ENGINE IS COLD
Malfunction
SYSTEM — Engine control module system
EC-48
Engine control module
open, short
HARD TO START WHEN ENGINE IS HOT
open, short open, short
Accelerator position sensor circuit
Crankshaft position sensor (TDC) circuit noise
open, short
Fuel temperature sensor circuit
short
open, ground short
open, short
ground short
open, short
short
open, ground short
Control sleeve position sensor circuit
Fuel cut solenoid valve circuit
HESITATION/SURGING/FLAT SPOT
open, short
q
q
q q q
q q q q
q
q
q
q
q q
q q q
q q
q q q
q q q
LACK OF POWER
Vehicle speed sensor circuit or ABS actuator and electric unit (control unit) circuit
HI IDLE q
q
ROUGH IDLE/HUNTING
Needle lift sensor circuit
WHEN DECELERATING q
IDLING VIBRATION
q q
q q
q q
q
q
q
q
HA q
q
q q
q q
q q
q
q q q
q q q
q q
q q
q q
q q
q q q
q q q
q
q q
Malfunction indicator illuminates.
Injection timing control valve circuit
NO START (without first firing) AP
Fuel cut
Electric governor circuit
AT IDLE q
SLOW/NO RETURN TO IDLE
q
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
open, short
EXCESSIVE FUEL CONSUMPTION
AG AH AJ AK AL AM
BLACK SMOKE
NO START (with first firing) q
LOW IDLE
AF
EXCESSIVE OIL CONSUMPTION
short
POOR ACCELERATION
AE
WHITE SMOKE
q q
ABNORMAL SMOKE COLOR
q
EC-CD-114
EC-CD-108
Compensation for amount fuel injected according EC-CD-104 of to fuel temperature does not function.
EC-CD-100 Engine runs on after turning ignition switch OFF.
EC-CD-97
Injection timing cannot be EC-CD-82 controlled.
EC-CD-78
EC-CD-74
EC-CD-70
Compensation according to EC-CD-66 engine coolant temperature does not function.
EC-CD-62
Feature of symptom Check point
Engine coolant temperature sensor circuit
SPARK KNOCK/DETONATION
AC AD
Can be detected by CONSULT-II?
Mass air flow sensor circuit
HARD/NO START/ RESTART (EXCP. HA) DURING DRIVING AB
Reference page
open, ground short
DEAD BATTERY (UNDER CHARGE)
AA
ENGINE STALL
New CT/CS
SYMPTOM
TROUBLE DIAGNOSIS — General Description Symptom Matrix Chart (Cont’d) CD20T
SYSTEM — Engine control module system
EC-49
Engine control module
ECM, Connector circuit
Brake switch circuits
Malfunction open short open, short
short
open
NO START (with first firing)
Air conditioner relay circuit
NO START (without first firing)
short
HARD TO START WHEN ENGINE IS COLD
Engine control module relay (Selfshutoff) circuit
HARD TO START WHEN ENGINE IS HOT q q q
q
q q q q q q q q q q q q q
q q q q
HESITATION/SURGING/FLAT SPOT
Glow relay circuit
LACK OF POWER
EGRC-solenoid valve circuit
HI IDLE
Power supply for ECM circuit
ROUGH IDLE/HUNTING
q q q
IDLING VIBRATION
q
SLOW/NO RETURN TO IDLE
q
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
q q
EXCESSIVE FUEL CONSUMPTION
q
BLACK SMOKE
open short open short open, short ground short open short open
WHEN DECELERATING q
WHITE SMOKE HA
q q q q q q
q q
q q EC-CD-108 Accelerator position sensor NG signal is output.
EC-CD-145 Start control does not function. Air conditioner does not stop EC-CD-126 operating. Air conditioner does not work.
EC-CD-59 Engine does not stop. q q EC-CD-59 q q EC-CD-129 q q Does not stop operating. q q Glow lamp does not turn on. EC-CD-118 q Glow lamp does not turn off. q EC-CD-59 Ground short makes engine q q q unable to stop. Air conditioner does not operate. EC-CD-126 Air conditioner does not stop q operating. q EC-CD-136 q q q q q q q q q q q q q EC-CD-86
AP
Fuel cut
Ignition switch circuit (ON signal)
AT IDLE q
EXCESSIVE OIL CONSUMPTION
AG AH AJ AK AL AM
ABNORMAL SMOKE COLOR
short
LOW IDLE
AF
Malfunction indicator illuminates.
Accelerator position switch (Idle) circuit
POOR ACCELERATION
AE
Can be detected by CONSULT-II?
short open, ground short
SPARK KNOCK/DETONATION
AC AD
Reference page
Air conditioner switch circuit
DURING DRIVING AB
DEAD BATTERY (UNDER CHARGE)
AA q q
Feature of symptom Check point
open, ground short
HARD/NO START/ RESTART (EXCP. HA)
open, short
ENGINE STALL
New CT/CS Start signal circuit
SYMPTOM
TROUBLE DIAGNOSIS — General Description Symptom Matrix Chart (Cont’d) CD20T
TROUBLE DIAGNOSIS — General Description
CD20T
CONSULT-II Reference Value in Data Monitor Mode 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
CKPS⋅RPM (TDC)
●
CKPS⋅RPM-PUMP
●
Tachometer: Connect Almost the same speed as the CONRun engine and compare tachometer indication with the CONSULT-II value. SULT-II value.
COOLAN TEMP/S
●
Engine: After warming up
More than 70°C (158°F)
●
Turn drive wheels and compare speedometer indication with the CONSULT-II value
Almost the same speed as the CONSULT-II value
●
Engine: After warming up
More than 40°C (104 °F)
●
Ignition switch: ON (Engine stopped)
Accelerator pedal: release
Approx. 0.40V
Accelerator pedal: depress
Approx. 3.3V
Ignition switch: ON (Engine stopped)
Accelerator pedal: release
ON
Accelerator pedal: slightly open
OFF
VHCL SPEED SE FUEL TEMP SEN ACCEL POS SEN
OFF ACCEL POS
●
C/SLEEV POS/S
●
Engine: After warming up
BATTERY VOLT
●
Ignition switch: ON (Engine stopped)
11 - 14V
START SIGNAL
●
Ignition switch: ON , START , ON
OFF , ON , OFF
●
Engine: After warming up, idle the engine
AIR COND SIG IGN SW
MAS AIR/FL SE
●
Ignition switch: ON , OFF
●
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load
● ● ● ● ●
ACT INJ TIMG
● ● ●
●
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load At sea level
●
Ignition switch: ON
● ●
TARGET F/INJ
● ●
BRAKE SW
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load At sea level
Approx. 2.5V
Air conditioner switch: “OFF”
OFF
Air conditioner switch: “ON” (Compressor operates.)
ON ON , OFF
Idle
0.8 - 2.7V
2,000 rpm
2.2 - 2.8V
Idle
-0.5 to -1.5°
2,000 rpm
+2.5° to +3.5°
Idle
8.0 - 8.8 mm3/stroke
2,000 rpm
Approx. 7.6 mm3/stroke
Brake pedal: released
OFF
Brake pedal: depressed
ON
Brake pedal: released
OFF
BRAKE SW 2
●
Ignition switch: ON
FUEL CUT S/V
●
Ignition switch: ON , OFF
ON , OFF
AIR COND RLY
●
Air conditioner switch: OFF , ON
OFF , ON
GLOW RLY
●
Refer to EC-CD-124.
●
When cooling fan is stopped.
OFF
●
When cooling fan operates at low speed.
LOW
●
When cooling fan operates at high speed.
HI
●
Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load At sea level
COOLING FAN
●
EGRC SOL/V A
● ● ●
Brake pedal: depressed
ON
Idle
OFF
2,800 rpm
ON
EC-50
TROUBLE DIAGNOSIS — General Description
CD20T
Major Sensor Reference Graph in Data Monitor Mode The following are the major sensor reference graphs in “DATA MONITOR” mode. (Select “HI SPEED” in “DATA MONITOR” with CONSULT-II.)
ACCEL POS SEN, C/SLEEV POS/S, ACT INJ TIMG
-00”09 +04”95
Below is the data for “ACCEL POS SEN”, “C/SLEEV POS/S” and “ACT INJ TIMG” when revving engine quickly up to 3,000 rpm under no load after warming up engine sufficiently. Each value is for reference, the exact value may vary.
x0.1V
● “ACCEL POS SEN” should increase
-00”09 +04”95
16:06
while depressing the accelerator pedal and should decrease while releasing it.
x0.1V
● “C/SLEEV POS/S” should increase
-00”09 +04”95
16:06
when depressing the accelerator pedal and should decrease when the pedal is released.
● “ACT INJ TIMG” should increase
ACT INJ TIMG 13:22
when depressing the accelerator pedal and should decrease when the pedal is released.
NEF780
EC-51
TROUBLE DIAGNOSIS — General Description
CD20T
ECM Terminals and Reference Value PREPARATION The ECM is located beneath the heater unit. To access the ECM, remove the center console under cover at the passenger side. Perform all voltage measurements with all connectors connected. Since the ECM harness connector cannot be accessed from the backside, voltages should be measured by connecting a break out box (SST) between ECM and ECM harness connector. SEF883Y
When measuring: ● Use extreme care not to touch 2 pins at the same time. ● Note that the data is for comparison and may not be exact. ● Be sure ECM unit is properly grounded before checking.
ECM
Y-adapter
Breakout box
To ECM harness connector Y-adapter
NEF162A
EC-52
CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)
ECM INSPECTION TABLE 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. TERWIRE MINAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage and Pulse Signal) qApproximately 10.5V
Engine is running. (Warm-up condition) Idle speed
101 102 103
SEF562S
B/L
Electric governor ground Approximately 10.5
Engine is running. (Warm-up condition) Engine speed is 2,000 rpm
SEF563S
104 105 106
B
107 108 109
R
Engine is running. ECM ground Idle speed
Power supply for ECM
Ignition switch “ON”
Engine ground (Probe this terminal with @ tester probe when measuring.) BATTERY VOLTAGE (11 - 14V) Approximately 9V
Engine is running. (Warm-up condition) Idle speed
202
B/W
SEF564S
Injection timing control valve
Approximately 8V
Engine is running. (Warm-up condition) Engine speed is 2,000 rpm
SEF565S
EC-53
CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)
TERWIRE MINAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage and Pulse Signal)
Engine is running.
204
L/W
Air conditioner relay
Both A/C switch and blower switch are “ON” Engine is running. A/C switch is “OFF” Engine is running. (Warm-up condition) Idle speed
208
P
Approximately 0.4V
BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V)
EGRC-solenoid valve A Engine is running. (Warm-up condition) Approximately 0.3V Engine speed is 2,800 rpm
214
215
W/R
OR/L
Glow relay
Malfunction indicator
Refer to “Glow control System”. Ignition switch “ON”
Approximately 1.0V
Engine is running.
BATTERY VOLTAGE (11 - 14V)
Idle speed 218
OR
Mass air flow sensor ground
Engine is running. Approximately 0V Idle speed Engine is running.
219
LG/R
Cooling fan relay (Low speed)
Cooling fan is not operating.
BATTERY VOLTAGE (11 - 14V)
Engine is running. Approximately 0.4V Cooling fan is operating. Engine is running.
220
LG
Cooling fan relay (High speed)
Cooling fan is not operating. Cooling fan is operating at low speed.
BATTERY VOLTAGE (11 - 14V)
Engine is running. Approximately 0.5V Cooling fan is operating at high speed. Ignition switch “ON” Approximately 1.0V Glow lamp is “ON”. 221
P/L
Glow lamp Ignition switch “ON” Glow lamp is “OFF”
223
W/L
Mass air flow sensor power supply
Ignition switch “ON”
BATTERY VOLTAGE (11 - 14V) Approximately 5V
Engine is running. (Warm-up condition) 1.9 - 2.3V Idle speed 224
L/W
Mass air flow sensor Engine is running. (Warm-up condition) 2.5 - 2.9V Engine speed is 2,000 rpm
EC-54
CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)
TERWIRE MINAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage and Pulse Signal) Approximately 2.6V
320
W
Control sleeve position sensor power supply
Engine is running. Idle speed
SEF559S
Approximately 2.6V
321
B
Control sleeve position sensor ground
Engine is running. Idle speed
SEF560S
Approximately 2.6V
322
R
Control sleeve position sensor (Reference signal)
Engine is running. (Warm-up condition) Idle speed
SEF561S
Engine is running. Ignition switch “LOCK” 325
W/G
Engine control module relay (Self-shutoff)
0 - 1V
For a few seconds after turning ignition switch to the “LOCK” position Ignition switch “LOCK” Following a few seconds delay after turning ignition switch to the “LOCK” position
331
OR
Crankshaft position sensor (TDC) ground
333
B
Needle lift sensor ground
334 335 436
B
Sensors’ ground
BATTERY VOLTAGE (11 - 14V)
Engine is running. Approximately 0V Idle speed Ignition switch “ON”
Approximately 0V
Engine is running. Approximately 0V Idle speed
EC-55
CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)
TERWIRE MINAL COLOR NO.
ITEM
CONDITION
DATA (DC Voltage and Pulse Signal) Approximately 0V
Engine is running. (Warm-up condition) Idle speed
344
W
NEF867
Crankshaft position sensor (TDC) (Signal)
Approximately 0V
Engine is running. Engine speed is 2,000 rpm
NEF868
Approximately 3.8 - 4.0V
Engine is running. (Warm-up condition) Idle speed
NEF869
345
W
Needle lift sensor Approximately 3.8 - 4.0V
Engine is running. (Warm-up condition) Engine speed is 2,000 rpm
NEF870
347
L/B
Engine coolant temperature sensor
348 411
R/Y
Fuel temperature sensor
349
SB
Engine is running.
0.6 - 4.8V Output voltage varies with engine coolant temperature.
Engine is running.
0.6 - 4.8V Output voltage varies with fuel temperature.
Ignition switch “LOCK”
Approximately 0V
Ignition switch “ON”
BATTERY VOLTAGE (11 - 14V)
Fuel cut solenoid valve
EC-56
CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)
TERWIRE MINAL COLOR NO.
ITEM
DATA (DC Voltage and Pulse Signal)
CONDITION
Engine is running.
403
GY
Air conditioner switch
Both air conditioner switch and blower switch are “ON” (Compressor operates) Engine is running. Air conditioner switch is “OFF”
Approximately 0V
BATTERY VOLTAGE (11 - 14V)
Ignition switch “ON” 0V Brake pedal released 405
R/G
Stop lamp switch Ignition switch “ON” Brake pedal depressed
410
OR
Immobilizer communication
Ignition switch “ON” Ignition switch “ON” Brake pedal released
416
R/B
Battery voltage (11 - 14V) BATTERY VOLTAGE (4 - 14V) Battery voltage (11 -14V)
Brake switch 2 Ignition switch “ON” 0V Brake pedal depressed 0 - Approximately 4.2V
417
OR/W
Vehicle speed sensor or ABS actuator and electric unit (control unit)
Engine is running. Lift up the vehicle. In 2nd gear position Vehicle speed is 40 km/h (25 mph)
SEF552S
420
BR/W
415
G/R
425
BR
433
LG/W
Engine is running. Data link connector for CONSULT-II
Accelerator position sensor ground Accelerator position sensor power supply
Idle speed (CONSULT-II is connected and turned on)
Approximately 4 - 9V Approximately 0V
Engine is running. Approximately 0V Idle speed Ignition switch “ON”
Approximately 5V
Ignition switch “ON” 0.4 - 0.6V 434
W/PU
Accelerator position sensor
Accelerator pedal released Ignition switch “ON” Approximately 4.0V Accelerator pedal fully depressed
EC-57
CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)
TERWIRE MINAL COLOR NO.
ITEM
DATA (DC Voltage and Pulse Signal)
CONDITION
Ignition switch “ON” Approximately 0V 435
GY/R
Accelerator position switch (Idle)
Accelerator pedal released Ignition switch “ON” Approximately 2.7V Accelerator pedal depressed
442
B/Y
Ignition switch “ON”
Approximately 0V
Ignition switch “START”
BATTERY VOLTAGE (11 - 14V)
Start signal
Approximately 1.1 - 1.5V
Engine is running. (Warm-up condition) Idle speed
SEF550S
439
L/OR
Tachometer Approximately 1.1 - 1.5V
Engine is running. Engine speed is 2,000 rpm
SEF551S
507
BR/Y
Ignition switch “LOCK”
0V
Ignition switch “ON”
BATTERY VOLTAGE (11 - 14V)
Ignition switch
EC-58
TROUBLE DIAGNOSIS FOR POWER SUPPLY
CD20T
Main Power Supply and Ground Circuit
YEC100A
EC-59
CD20T TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d) INSPECTION START
H
No
Start engine. Is engine running?
E
Yes
NEF863
H
1. Stop engine. 2. Disconnect ECM harness connector. 3. Turn ignition switch to “ON” position.
ECM relay
YEC327
CHECK POWER SUPPLY-I. 1. Disconnect ECM harness connector. 2. Turn ignition switch to “ON” position. 3. Check voltage between ECM connector terminal 507 and ground Voltage: Battery voltage If NG, check the following: ● 10A fuse ● Harness connectors M52 , F103 ● Harness for open or short-circuit between ECM and ignition switch. If NG, replace 10A fuse or repair harness or connectors. OK
F H
CHECK POWER SUPPLY-II. 1. Short between ECM connector terminal 325 and engine ground with a jump wire. 2. Check voltage between ECM terminals 107 , 108 , 109 and ground. Voltage: Battery voltage
OK E
“CHECK Go to GROUND CIRCUIT” on page EC-CD-61.
E
Check the following: ● Harness connectors M89 , F96 ● Harness for open or short-circuit between ECM relay and ECM. If NG, repair harness or connectors.
NG H NEF186A
CHECK HARNESS CONTINUITY BETWEEN ENGINE CONTROL MODULE RELAY AND ECM Check harness continuity between ECM connector terminals 107 , 108 , 109 and ECM relay connector terminal p 5 . Continuity should exist. If OK, check harness for short. H OK
A p
NEF187A
ECM relay connector
NEF188A
EC-60
NG
CD20T TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d) A p
ECM relay connector
H
CHECK VOLTAGE BETWEEN ENGINE CONTROL MODULE RELAY AND GROUND. Check voltage between ECM relay connector terminals p 2 , p 3 and ground with CONSULT-II or tester. Voltage: Battery voltage
NG E
Check the following: ● 15A fuse ● Harness for open or short-circuit between ECM relay and battery. If NG, replace fuse or repair harness or connectors.
E
Check harness connectors E43 , F2 Repair harness or connectors.
E
Replace ECM relay.
E
Repair harness or connectors.
YEC352
OK H
CHECK OUTPUT SIGNAL CIRCUIT. Check harness continuity between ECM connector terminal 325 and ECM relay connector terminal p 1 . Continuity should exist. If OK, check harness for short-circuit.
ECM relay connector
NG
●
OK H NEF189A
ECM relay connector
CHECK ECM RELAY. 1. Apply 12V direct current between ECM relay connector terminals p 1 and p 2 . 2. Check continuity between engine control module relay connector terminals p 3 and 5 . p 12V (p 1 -p 2 ) applied: Continuity exists. No voltage applied: No continuity
NG
OK H
YEC354
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Check harness continuity between ECM connector terminals 104 , 105 , 106 and engine ground. Continuity should exist. If resistance is too high, loosen, clean and retighten engine ground. If OK, check harness for short-circuit. H
OK
Check ECM pin terminals for damage and check the connection of ECM harness connector. NEF190A
H
INSPECTION END
Engine ground NEF399
EC-61
NG
CD20T
TROUBLE DIAGNOSIS 1 Mass Air Flow Sensor (MAFS)
The mass air flow sensor measures the amount of intake air by analysing a part of the entire flow. When intake air flows into the intake manifold, heat is withdrawn from the hot film. By regulating the electrical current that flows through the hot film, the ECM maintains the hot film temperature on a constant level. The amount of electric current that is needed to keep the hot film on a constant temperature level is proportional to the mass of air that flows into the engine. NEF663
Check Items (Possible Cause)
Malfunction is detected when . . . ●
An excessively high or low voltage from the sensor is entered to ECM.
●
●
Harness or connectors (The sensor circuit is open or shorted.) Mass air flow sensor
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)
Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait for at least 20 seconds.
EC-62
CD20T TROUBLE DIAGNOSIS 1 Mass Air Flow Sensor (MAFS) (Cont’d) BATTERY : Detectable line for DTC : Non-detectable line for DTC
Refer to EL-POWER.
ENGINE CONTROL MODULE RELAY
MASS AIR FLOW SENSOR
ECM
YEC799
EC-63
CD20T TROUBLE DIAGNOSIS 1 Mass Air Flow Sensor (MAFS) (Cont’d) Mass air flow sensor harness connector
DIAGNOSTIC PROCEDURE INSPECTION START
H
NEF788
CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect mass air flow sensor harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between mass air flow sensor connector terminal p 2 and ground. Voltage: Battery positive voltage
NG E
Repair harness or connectors.
E
Repair harness or connectors.
E
Repair harness or connectors.
E
Replace mass air flow sensor.
OK Mass air flow sensor connector
NEF789
H
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between mass air flow sensor connector terminal p 3 and ECM connector terminal 218 . Continuity should exist. If OK, check harness for short-circuit.
NG
OK H
Mass air flow sensor connector
CHECK INPUT SIGNAL CIRCUIT. Check harness continuity between mass air flow sensor connector terminal p 4 and ECM connector terminal 223 , mass air flow sensor connector terminal p 5 and ECM connector terminal 224 . Continuity should exist. If OK, check harness for short.
NG
OK NEF191A H
Mass air flow sensor connector
CHECK COMPONENT (Mass air flow sensor). Refer to “COMPONENT INSPECTION” on next page. OK H
Disconnect and reconnect harness connectors in the circuits. Then retest. Trouble is not fixed. NEF192A
H
Check ECM pin terminals for damage or the connection of ECM harness connector.
H
INSPECTION END
EC-64
NG
CD20T TROUBLE DIAGNOSIS 1 Mass Air Flow Sensor (MAFS) (Cont’d)
COMPONENT INSPECTION Mass air flow sensor
Mass air flow sensor connector
1. Turn ignition switch to “ON” position. 2. Start engine and warm it up sufficiently. 3. Check voltage between mass air flow sensor connector terminal p 5 and ground. Conditions Ignition switch “ON” position (Engine stopped.) NEF792
Idle (Engine is warmed-up sufficiently.)
Voltage V Approximately 1.0 1.9 - 2.3
4. If NG, remove mass air flow sensor from air duct. Check hot film for damage or dust.
NEF669
EC-65
CD20T
TROUBLE DIAGNOSIS 2
Engine Coolant Temperature (ECT) Sensor 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)
Voltage (V)
Resistance (kΩ)
−10 (14)
4.4
7.0 - 11.4
20 (68)
3.5
2.1 - 2.9
50 (122)
2.3
0.68 - 1.00
90 (194)
1.0
0.236 - 0.260
SEF012P
Check Items (Possible Cause)
Malfunction is detected when ... ●
An excessively high or low voltage from the sensor is entered to ECM.
●
●
Harness or connectors (The sensor circuit is open or shorted.) Engine coolant temperature sensor
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)
Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds.
EC-66
CD20T TROUBLE DIAGNOSIS 2 Engine Coolant Temperature (ECT) Sensor (Cont’d)
ENGINE COOLANT TEMPERATURE SENSOR
: Detectable line for DTC : Non-detectable line for DTC
ECM
YEC800
EC-67
CD20T TROUBLE DIAGNOSIS 2 Engine Coolant Temperature (ECT) Sensor (Cont’d) .
DIAGNOSTIC PROCEDURE
RH strut tower
INSPECTION START
H .
Engine coolant temperature sensor harness connector
NEF401
Engine coolant temperature sensor connector
CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect engine coolant temperature sensor harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between engine coolant temperature sensor connector terminal p 2 and ground with CONSULT-II or tester. Voltage: Approximately 4.9V
NG
E
Repair harness or connectors.
E
Repair harness or connectors.
E
Replace engine coolant temperature sensor.
OK H NEF193A
Engine coolant temperature sensor connector
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Check harness continuity between engine coolant temperature sensor connector terminal p 1 and engine ground. Continuity should exist. If OK, check harness for short-circuit.
NG
OK H SEF542P
CHECK COMPONENT (Engine coolant temperature sensor). Refer to “COMPONENT INSPECTION” on next page. OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed. H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest.
H
INSPECTION END
EC-68
NG
CD20T TROUBLE DIAGNOSIS 2 Engine Coolant Temperature (ECT) Sensor (Cont’d)
COMPONENT INSPECTION Engine coolant temperature sensor Check resistance as shown in the figure.
SEF152P
Temperature °C (°F)
Resistance kΩ
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.0
90 (194)
0.236 - 0.260
If NG, replace engine coolant temperature sensor.
SEF012P
EC-69
CD20T
TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor (VSS)
Models with vehicle speed sensor The vehicle speed sensor is installed in the transaxle. It contains a pulse generator which provides a vehicle speed signal to the speedometer. The speedometer then sends a signal to the ECM.
Vehicle speed sensor
Models without vehicle speed sensor The ABS actuator and electric unit (control unit) provides a vehicle speed signal to the speedometer. The speedometer than sends a signal to the ECM. AEC110
Check Items (Possible Cause)
Malfunction is detected when .... ●
The almost 0 km/h (0 mph) signal from vehicle speed sen- Models with vehicle speed sensor sor or ABS actuator and electric unit (control unit) is sent ● Harness or connector to ECM even when vehicle is being driven. (The vehicle speed sensor circuit is open or shorted.) ● Vehicle speed sensor Models without vehicle speed sensor ● Harness or connector (The ABS actuator and electric unit (control unit) is open or shorted.) ● ABS actuator and electric unit (control unit)
OVERALL FUNCTION CHECK
PEF651U
Use this procedure to check the overall function of the vehicle speed sensor circuit. During this check, a DTC might not be confirmed. 1) Jack up drive wheels. 2) Start engine. 3) Read vehicle speed sensor signal in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULT-II should be able to exceed 10 km/h (6 mph) when rotating wheels with suitable gear position. ------------------------------------------------------------------------------------------------------------------------------- OR ------------------------------------------------------------------------------------------------------------------------------1) Jack up drive wheels. 2) Start engine. 3) Rotate drive wheel by hand. 4) Check voltage between ECM connector terminal 417 and ground with voltage tester. Voltage should vary between approx. 0 - 0.6V.
NEF194A
EC-70
TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor (VSS) (Cont’d)
CD20T
MODELS BEFORE VIN - P11U0583350 BATTERY
IGNITION SWITCH ON or START
FUSE BLOCK (J/B)
Refer to EL-POWER.
: Dectable line for DTC : Non-detectable line for DTC
COMBINATION METER (SPEEDOMETER)
VEHICLE SPEED SENSOR
ECM
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YEC801
EC-71
TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor (VSS) (Cont’d)
CD20T
MODELS AFTER VIN - P11U0583350
YEC101A
EC-72
TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor (VSS) (Cont’d)
CD20T
DIAGNOSTIC PROCEDURE INSPECTION START
H
CHECK INPUT SIGNAL CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM connector terminal 417 and combination meter connector terminal p 9 or p 4 . Continuity should exist. If OK, check harness for short-circuit.
NG
E
Check the following: ● Harness connectors M50 , F104 ● Harness for open or short-circuit between ECM and combination meter. If NG, repair harness or connectors.
OK YEC124A
H
CHECK SPEEDOMETER FUNCTION. Make sure that speedometer functions correctly. OK
H
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed. H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest.
H
INSPECTION END
EC-73
NG
E
Check the following: ● Harness connectors M50 , F104 ● Harness for open or short-circuit between combination meter and vehicle speed sensor or ABS actuator and electric unit (control unit). If NG, repair harness or connectors. Check vehicle speed sensor or ABS actuator and electric unit (control unit) and its circuit. Refer to EL section.
CD20T
TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor (CSPS)
The control sleeve position sensor is installed on the electric governor. It senses the position of control sleeve (rotor angle) while the control sleeve is being driven by the electric governor, and feeds it back to the ECM.
Shaft
Sensor coil SEF641S
Check Items (Possible cause)
Malfunction is detected when .... An excessively high or low voltage from the sensor is detected by ECM. ............................................................................................... ● An incorrect voltage signal from the sensor is detected by ECM during engine running. ●
.
●
●
Harness or connectors (The control sleeve position sensor circuit is open or shorted.) Control sleeve position sensor
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE
Electronic injection pump harness connector (control sleeve position sensor)
1) 2)
Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 2 seconds at idle speed.
NEF796
EC-74
CD20T TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor (CSPS) (Cont’d) INJECTION PUMP (CONTROL SLEEVE POSITION SENSOR)
: Detectable line for DTC : Non-detectable line for DTC
ECM
YEC802
EC-75
CD20T TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor (CSPS) (Cont’d)
DIAGNOSTIC PROCEDURE Control sleeve position sensor connector
INSPECTION START
H
NEF196A
Control sleeve position sensor connector
CHECK POWER SUPPLY CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector and electronic injection pump harness connector. 3. Check harness continuity between control sleeve position sensor connector terminal 3 and ECM connector terminal 320 . p Continuity should exist. If OK, check harness for short-circuit.
NG E
Repair harness or connectors.
E
Repair harness or connectors.
E
Repair harness or connectors.
E
Have the injection pump assembly serviced by an authorised service representative.
OK H
NEF197A
CHECK INPUT SIGNAL CIRCUIT. Check harness continuity between control sleeve position sensor connector terminal 2 and ECM terminal 321 . p Continuity should exist. If OK, check harness for short-circuit.
NG
OK H Control sleeve position sensor connector
CHECK REFERENCE SIGNAL CIRCUIT. Check harness continuity between control sleeve position sensor connector terminal 1 and ECM connector terminal 322 . p Continuity should exist. If OK, check harness for short-circuit.
NG
OK H NEF198A
CHECK COMPONENT (Control sleeve position sensor). Refer to “COMPONENT INSPECTION” on next page. H
OK
Disconnect and reconnect harness connectors in the circuit. Then retest. H
Trouble is not fixed.
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-76
NG
CD20T TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor (CSPS) (Cont’d)
COMPONENT INSPECTION Control sleeve position sensor, electric governor & fuel temperature sensor connector
Control sleeve position sensor 1. Disconnect electronic injection pump harness connector. 1 and p 3 , p 2 and 2. Check continuity between terminals p 3 . p Resistance: Approximately 6.0Ω [at 25°C (77°F)] If NG, take proper action.
NEF680
EC-77
CD20T
TROUBLE DIAGNOSIS 5 Electric Governor Return spring
Coil Rotor
Core Shaft Ball pin
The electric governor is built into the fuel injection pump. It moves the control sleeve to increase or decrease the amount of fuel injected. When current flows through the coil, a magnetic force is produced, rotating the rotor. The rotor shaft is installed to the control sleeve via a ball pin which is eccentrically situated in relation to the rotor shaft. With this arrangement, the control sleeve can be moved in relation to rotor rotation. The rotor’s rotating angle is determined by a balanced condition of magnetic force (generated by current flow regulated by means of the ECM) and tension of return spring (installed to rotor). The larger the current flow through the coil, the greater the rotor’s rotating angle. This means that the control sleeve moves to the right, increasing the amount of fuel injected. The ECM regulates the current flow through the coil by changing the duty cycle ratio which controls the ON-OFF operation of the electric governor grounding circuit.
Decrease Increase Control sleeve SEF632S Magnet
Core
Rotor Coil SEF633S
Check Items (Possible cause)
Malfunction is detected when .... ●
Fuel injection feedback system does not operate properly. [This system consists essentially of ECM, electric governor and control sleeve position sensor.]
●
●
● ●
Main power supply circuit (ECM connector terminals 107 , 108 , 109 ) and fuse Harness or connectors (Electric governor and control sleeve position sensor circuit) Electric governor ECM
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)
Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. Start engine above 1,200 rpm. Run it for 2 seconds above 1,200 rpm. Return engine speed to idle.
NOTE: If malfunction occurs intermittently, conduct suitable driving pattern for 10 minutes. This makes it possible to determine the diagnostic trouble.
EC-78
TROUBLE DIAGNOSIS 5 Electric Governor (Cont’d)
CD20T
BATTERY : Detectable line for DTC : Non-detectable line for DTC
Refer to EL-POWER.
INJECTION PUMP (ELECTRIC GOVERNOR)
ENGINE CONTROL MODULE RELAY
ECM
YEC803
EC-79
CD20T
TROUBLE DIAGNOSIS 5 Electric Governor (Cont’d) DIAGNOSTIC PROCEDURE INSPECTION START H
CHECK MAIN POWER SUPPLY. Refer to EC-CD-59. .
Electronic injection pump harness connector (Electric governor) NEF800
Injection pump connector
NEF199A
H
CHECK POWER SUPPLY CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector and electronic injection pump harness connector. 3. Check harness continuity between injection pump connector terminal 7 and ECM connector terminals p 107 , 108 , 109 . Continuity should exist. If OK, check harness for short-circuit.
NG
E
Repair harness or connectors.
E
Repair harness or connectors.
OK H
CHECK GROUND CIRCUIT. Check harness continuity between injection pump connector terminal p 4 and ECM connector terminals 101 , 102 , 103 . Continuity should exist. If OK, check harness for short-circuit.
Injection pump connector
NG
OK
NEF200A H
CHECK COMPONENT (Electric governor). Refer to “COMPONENT INSPECTION” on next page. OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. H
Trouble is not fixed.
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-80
NG
E
Have the injection pump assembly serviced by an authorised service representative.
TROUBLE DIAGNOSIS 5 Electric Governor (Cont’d)
CD20T
COMPONENT INSPECTION Electric governor Electronic injection pump harness connector
1. Disconnect electronic injection pump harness connector. 2. Check continuity between injection pump connector terminals p 4 and p 7 . Resistance: Approximately 1.0Ω [at 25°C (77°F)] If NG, replace.
YEC361
EC-81
CD20T
TROUBLE DIAGNOSIS 6 Injection Timing Control Valve
Timer piston
High pressure
Low pressure
Fuel injection timing control valve SEF638S
The injection timing control valve is built into the fuel injection pump. It controls the timer piston to change the fuel injection timing. The timing control valve is a solenoid valve located in the line between high-pressure chamber and low-pressure chamber. It changes fuel pressure in the high-pressure chamber. When current flows through the solenoid (the solenoid turns ON), the timing control valve opens, advancing fuel injection timing. When current does not flow through it, the timing control valve closes, retarding injection timing. The ECM emits an ON-OFF duty cycle signal. The longer the OFF-duration, the greater the advance angle. The longer the ON-duration, the greater the retard angle. This means that changing the ON-OFF duty cycle ratio makes it possible to achieve an optimal advance angle and accurately control fuel injection timing. Check Items (Possible cause)
Malfunction is detected when .... ●
Injection timing feedback system does not operate properly. (This system consists essentially of ECM, injection timing control valve and needle lift sensor.)
●
● ● ● ● ●
Injection timing control valve circuit it open or shorted.
●
●
Harness or connectors [Injection timing control valve, needle lift sensor, crankshaft position sensor (TDC) circuits] Injection timing control valve Needle lift sensor Crankshaft position sensor (TDC) Air in fuel line Harness or connectors (The Injection timing control valve is open or shorted.) Injection timing control valve
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE FOR INJECTION TIMING CONTROL SYSTEM 1)
Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. Start engine. Run engine for 10 seconds at idle.
2) NOTE: If malfunction occurs intermittently, conduct suitable driving pattern for 10 minutes. This makes it possible to determine the diagnostic trouble.
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE FOR INJECTION TIMING CONTROL VALVE CIRCUIT 1) 2) 3)
Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 2 seconds.
EC-82
CD20T TROUBLE DIAGNOSIS 6 Injection Timing Control Valve (Cont’d) BATTERY Refer to EL-POWER.
: Detectable line for DTC : Non-detectable line for DTC
ENGINE CONTROL MODULE RELAY
INJECTION PUMP (INJECTION TIMING CONTROL VALVE)
ECM
YEC804
EC-83
CD20T TROUBLE DIAGNOSIS 6 Injection Timing Control Valve (Cont’d)
DIAGNOSTIC PROCEDURE Priming pump
INSPECTION START
H
SEF671S
CHECK FOR AIR IN FUEL FILTER. 1. Move priming pump up and down to purge air from fuel filter. 2. Perform “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE”.
H
Fuel injection timing control valve harness connector
NEF804
CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect injection timing control valve harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between injection timing control valve connector terminal 3 and ground with CONSULT-II or p tester. Voltage: Battery voltage
Injection timing control valve harness connector
NG
E
OK
Check the following: ● Harness connectors E89 , F96 ● Electronic injection pump harness connector F49 ● 15A fuse ● Harness for open or short-circuit between injection timing control valve harness connector and ECM relay. If NG, repair harness or connectors.
H
NEF201A
Injection timing control valve harness connector
CHECK OUTPUT SIGNAL CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between injection timing control valve connector terminal p 2 and ECM terminals 202 . Continuity should exist. If OK, check harness for short-circuit. H
NEF202A
A p
EC-84
OK
NG
E
Check the following: ● Electronic injection pump harness connector F49 ● Harness for open or short-circuit between injection timing control valve and ECM. If NG, repair harness or connectors.
CD20T TROUBLE DIAGNOSIS 6 Injection Timing Control Valve (Cont’d) A p
H
CHECK COMPONENT (Injection timing control valve). Refer to “COMPONENT INSPECTION” below.
NG
E
Replace injection timing control valve.
OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. H
Trouble is not fixed.
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
COMPONENT INSPECTION Injection timing control valve 1. Disconnect injection timing control valve harness connector. 2 and p 3 . 2. Check resistance between terminals p Resistance: Approximately 15Ω [at 25°C (77°F)] If NG, replace injection timing control valve.
Injection timing control valve
YEC364
EC-85
CD20T
TROUBLE DIAGNOSIS 7 Engine Control Module (ECM)
The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The module monitors and controls the engine operation.
SEC220B
Check Item (Possible Cause)
Malfunction is detected when .... ●
ECM calculation function is malfunctioning.
●
ECM *
●
An excessively high or low voltage from the atmospheric pressure sensor is detected by the ECM.
●
ECM *
●
ECM reference voltage (2.5V) is excessively high or low.
●
ECM *
●
ECM version number or switching function is not plausible.
●
ECM *
●
Ignition switch “ON” signal evaluation circuit in ECM is malfunctioning.
●
ECM *
* Actually inspecting the ECM inside circuit is impossible. Then, ECM may be replaced.
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)
Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 2 seconds.
EC-86
CD20T
TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) SYSTEM DESCRIPTION Vehicle speed sensor
Vehicle speed
Engine coolant temperature sensor
Engine coolant temperature
Air conditioner switch
Air conditioner “ON” signal
E
E
ECM
E
Cooling fan relay(s)
E
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air conditioner system pressure and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/ OFF]. This system indirectly relates to diagnostic trouble code 28 (Overheat).
Operation Air conditioner is ON Engine coolant temperature °C (°F)
Engine coolant temperature °C (°F)
Air conditioner is OFF
.
102 (216) .
96 (205)
.
.
.
102 (216) 96 (205)
.
20 80 (12) (50) Vehicle speed km/h (mph) Cooling fans do not operate
.
20 (12)
.
80 (50)
Vehicle speed km/h (mph)
Cooling fans operate at low speed
Cooling fans operate at high speed
NEF772
ON-BOARD DIAGNOSIS LOGIC This diagnosis continuously monitors the engine coolant temperature. 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. Check Items (Possible Cause)
Malfunction is detected when ... ●
An excessive high engine coolant temperature sensor signal is detected by the ECM. (Overheat)
Harness or connectors (The cooling fan circuit is open or shorted.) ● Cooling fan ● Radiator hose ● Radiator ● Radiator cap ● Water pump ● Thermostat ● Fan belt ● Engine coolant temperature sensor For more information, refer to “12 MAIN CAUSES OF OVERHEATING”, EC-CD-95. ●
CAUTION: When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Also, replace the engine oil. a. 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 section (“Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED FLUIDS AND LUBRICANTS”). b. After refilling coolant, run engine to ensure that no water-flow noise is emitted.
EC-87
TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)
CD20T
OVERALL FUNCTION CHECK
MAX. OK MIN.
AEC640
SEF111X
SEC163BA
Cooling fan Engine coolant temperature sensor harness connector
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 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. 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. 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 “DIAGNOSTIC PROCEDURE”, EC-CD-90. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “DIAGNOSTIC PROCEDURE”, EC-CD-90. 3) Turn ignition switch to “ON” position. 4) Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II (LOW speed and HI speed). ------------------------------------------------------------------------------------------------------------------------------- OR ------------------------------------------------------------------------------------------------------------------------------3) Start engine. Be careful not to overheat engine. 4) Set temperature control switch to full cold position. 5) Push Air Conditioner switch to “ON” position. 6) Turn blower fan switch to “ON” position. 7) Run engine at idle for a few minutes with Air Conditioner operating. Be careful not to overheat engine. 8) Make sure that both cooling fans operate at low speed. 9) Turn ignition switch to “LOCK” position. 10) Push Air Conditioner switch and blower fan switch to “OFF” position. 11) Disconnect engine coolant temperature sensor harness connector. 12) Connect 150Ω resistor to engine coolant temperature sensor harness connector. 13) Restart engine and make sure that both cooling fans operate at higher speed than low speed. Be careful not to overheat engine.
150Ω resistor
MEC475B
EC-88
CD20T
TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d) BATTERY
IGNITION SWITCH ON or START FUSE BLOCK (J/B)
Refer to EL-POWER. : Detectable line for DTC : Non-detectable line for DTC
COOLING FAN RELAY-3
COOLING FAN RELAY-1
COOLING FAN RELAY-2
COOLING FAN MOTOR-1
HIGH
TRIPLEPRESSURE SWITCH
COOLING FAN MOTOR-2
LOW
ECM
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YEC805
EC-89
TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)
CD20T
DIAGNOSTIC PROCEDURE INSPECTION START .
Cooling fan relay 2 H
Cooling fan relay-3 Cooling fan relay-1
YEC383
SEF111X
NG CHECK COOLING FAN LOW SPEED OPERATION. 1. Disconnect cooling fan relay-3. 2. Turn ignition switch to “ON” position. 3. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. ------------------------------------------------------------- OR ------------------------------------------------------------2. Start engine. 3. Set temperature switch at full cold position. 4. Turn Air Conditioner switch to “ON” position. 5. Turn blower fan switch to “ON” position. 6. Run engine at idle speed for a few minutes with Air Conditioner operating. 7. Make sure that both cooling fans operate at low speed.
E
Check cooling fan low speed control circuit. (Go to PROCEDURE A .)
OK H
Cooling fan
NEF809
SEF111X
Cooling fan Engine coolant temperature sensor harness connector
NG CHECK COOLING FAN HIGH SPEED OPERATION. 1. Turn ignition switch to “LOCK” position. 2. Reconnect cooling fan relay-3. 3. Disconnect cooling fan relay-1. 4. Turn ignition switch to “ON” position. 5. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. ------------------------------------------------------------- OR ------------------------------------------------------------4. Turn Air Conditioner switch and blower fan switch to “OFF” position. 5. Disconnect engine coolant temperature sensor harness connector. 6. Connect 150Ω resistor to engine coolant temperature sensor harness connector. 7. Restart engine and make sure that both cooling fans operate at higher speed than low speed. H
B p
OK
(Go to EC-CD-94.) resistor YEC384
EC-90
E
Check cooling fan high speed control circuit. (Go to PROCEDURE B .)
TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)
CD20T
PROCEDURE A Cooling fan relay-1 connector
Cooling fan motor-1 connector
INSPECTION START
H
YEC385 .
Under the vehicle
.
A/C compressor
Cooling fan motor-1 harness connector
CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect cooling fan relay-1 and fan motor-1 connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between cooling fan motor-1 connector terminal p 1 , fan 1 and relay-1 connector terminal p ground. Voltage: Battery voltage
NG
E
OK
NEF416 .
Under the vehicle
.
Radiator lower hose .
Cooling fan motor-2 harness connector
NEF417
Cooling fan motor-1 connector Cooling fan relay-1 connector
Cooling fan relay-2 connector
YEC386
Cooling fan relay-1 connector
Cooling fan motor-2 connector
Check the following: ● 10A fuse ● 40A, 100A, fusible links ● Harness for open or short-circuit between cooling fan motor-1 and battery. ● Harness for open or short-circuit between cooling fan relay-1 and fuse. If NG, replace fuse or fusible links or repair harness or connectors.
H
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect cooling fan relay-2 and fan motor-2 harness connector. 3. Check harness continuity between cooling fan relay-1 connector terminal p 5 and cooling fan relay-2 connector terminal 4 ; cooling fan motor-1 conp 2 and cooling nector terminal p fan relay-2 connector terminal 3 . Continuity should exist. p If OK, check harness for shortcircuit. 4. Check harness continuity between cooling fan motor-2 connector terminal p 1 and cooling fan relay-1 connector terminal p 3 ; cooling fan motor-2 connector terminal p 2 and ground. Continuity should exist. If OK, check harness for shortcircuit. H
C p
YEC387
EC-91
OK
NG
E
Repair harness or connectors.
TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)
CD20T
C p
Cooling fan relay-1 connector
NEF207A
H
NG Check the following: CHECK OUTPUT SIGNAL CIRCUIT. E 1. Disconnect ECM harness connector. ● Harness connectors E43 , F2 2. Check harness continuity between ECM terminal 219 and cooling fan relay-1 con● Harness for open or short2 . nector terminal p circuit between cooling fan Continuity should exist. relay-1 and ECM If OK, check harness for short-circuit. If NG, repair harness or connectors. OK H
CHECK COMPONENT (Cooling fan relay-1, 2). Refer to “COMPONENT INSPECTION”, EC-CD-96. H
E
Replace cooling fan relay.
OK
CHECK COMPONENT (Cooling fan motors). Refer to “COMPONENT INSPECTION”, EC-CD-96. H
NG
NG E
Replace cooling fan motors.
OK
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed.
H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
PROCEDURE B
Cooling fan relay-3 connector
Cooling fan motor-1 connector
Cooling fan relay-2 connector
INSPECTION START
H
NEF203A
CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect cooling fan relay-2, 3 and cooling fan motor-1. 3. Turn ignition switch to “ON” position. 4. Check voltage between cooling fan motor-1 connector terminal p 1 ; cooling fan relay-2 connector terminal p 1 ; cooling fan relay-3 connector terminals p 1 & 3 and ground. p Voltage: Battery voltage OK H
D p
EC-92
NG E
Check the following: ● 10A-fuse ● 40A, 50A, 100A fusible links ● Harness for open or short-circuit between fan motor-1, fan relay-3 and fusible link or fan relay-2, 3 and fuse. If NG, replace fuse or fusible link or repair harness or connectors.
TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)
CD20T
D p
H Cooling fan motor-1 connector
Cooling fan relay-2 connector
Cooling fan relay-3 connector
Cooling fan motor-2 connector
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect cooling fan motor-2 harness connector. 3. Check harness continuity between cooling fan motor-1 connector terminal p 2 and cooling fan relay-2 connector terminal p 3 ; cooling fan motor-2 connector terminal p 1 and cooling fan relay-3 connector terminal p 5 ; cooling fan relay-2 connector terminal p 5 and ground. Continuity should exist. If OK, check harness for short-circuit. 4. Check harness continuity between cooling fan motor-2 terminal p 2 and ground.
NG E
Repair harness or connectors.
OK H
NEF876
Cooling fan motor-2 connector E18
CHECK OUTPUT SIGNAL CIRCUIT. 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 220 and cooling fan relay-3 connector terminal p 2 & cooling fan relay-2 connector terminal p 2 . Continuity should exist. If OK, check harness for short-circuit. H
H
H
OK
Disconnect and reconnect harness connectors in the circuit. Then retest. Cooling fan relay-2 connector NEF204A
H
Trouble is not fixed
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-93
NG E
Check the following: ● Harness connectors E43 , F2 ● Harness for open or short-circuit between cooling fan relay-2, 3 and ECM. If NG, repair harness or connectors. Replace cooling fan relays.
OK
CHECK COMPONENTS (Cooling fan motors). Refer to “COMPONENT INSPECTION”, ECCD-96. Cooling fan relay-3 connector
E
OK
CHECK COMPONENT (Cooling fan relay-2, 3). Refer to “COMPONENT INSPECTION”, ECCD-96. YEC389
NG
NG E
Replace cooling fan motors.
TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)
CD20T
B p
Hose adapter
H
CHECK COOLING SYSTEM FOR LEAK. Apply pressure to the cooling system with a tester, and check if the pressure drops. Testing pressure: 157kPa (1.57 bar, 1.6 kg/cm2, 23 psi) Pressure should not drop. CAUTION: Higher than the specified pressure may cause radiator damage. .
SLC754AA
NG
E
Check the following for leaks: ● Hose ● Radiator ● Water pump Refer to LC section (“Water Pump”).
E
Replace radiator cap.
E
Replace thermostat.
E
Replace engine coolant temperature sensor.
OK H
CHECK RADIATOR CAP. Apply pressure to cap with a tester. Radiator cap relief pressure: Standard 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 - 88 kPa (0.59 - 0.88 bar, 0.6 - 0.9 kg/cm2, 9 - 13 psi)
NG
OK SLC755AA
SLC343
H
CHECK THERMOSTAT. 1. Check valve seating condition at normal room temperatures. It should seat tightly. 2. Check valve opening temperature and maximum valve lift. Valve opening temperature: 76.5°C (170°F) [standard] Maximum valve lift: More than 8 mm/90°C (0.31 in/194°F) 3. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to LC section (“Thermostat”). H
OK
Check engine coolant temperature sensor. Refer to “COMPONENT INSPECTION”, EC-69. H
NG
NG
OK
If the cause can not be isolated, go to “12 MAIN CAUSES OF OVERHEATING” on next page. H
INSPECTION END
Perform FINAL CHECK by the following procedure after repair is completed. 1. Warm up engine. Run the vehicle for at least 20 minutes. Pay attention to engine coolant temperature gauge on the instrument panel. If the reading shows an abnormally high temperature, another part may be malfunctioning. 2. Stop vehicle and let engine idle. Check the intake and exhaust systems for leaks by listening for noise or visually inspecting the components. 3. Allow engine to cool and visually check for oil and coolant leaks. Then, perform “OVERALL FUNCTION CHECK”.
EC-94
CD20T
TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d) 12 MAIN CAUSES OF OVERHEATING Engine
Step
OFF
1
Inspection item
Standard
●
2
●
Coolant mixture
●
Coolant tester
50 - 50% coolant mixture
3
●
Coolant level
●
Visual
Coolant up to MAX level See “Changing Engine in reservoir tank and Coolant”, “ENGINE radiator filler neck MAINTENANCE” in MA section.
4
●
Radiator cap
●
Pressure tester
78 - 98 kPa (0.78 - 0.98 bar, 0.8 1.0 kg/cm2, 11 - 14 psi) 59 - 98 kPa (0.59 - 0.98 bar, 0.6 1.0 kg/cm2, 9 - 14 psi) (Limit)
See “System Check” “ENGINE COOLING SYSTEM” in LC section.
ON*2
5
●
Coolant leaks
●
Visual
No leaks
See “System Check” “ENGINE COOLING SYSTEM” in LC section.
ON*2
6
●
Thermostat
●
Touch the upper and lower radiator hoses
Both hoses should be hot
See “Thermostat” and “Radiator”, “ENGINE COOLING SYSTEM” in LC section.
ON*1
7
●
Cooling fan
●
CONSULT
Operating
See “TROUBLE DIAGNOSIS 8”.
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 “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA section. See “ENGINE MAINTENANCE” in MA section.
● ●
●
Visual
No blocking
Reference page
Blocked Blocked Blocked Blocked
●
radiator condenser radiator grille bumper
Equipment
−
See “RECOMMENDED FLUIDS AND LUBRICANTS” in MA section.
OFF*4
10
●
Coolant return from reservoir tank to radiator
●
Visual
Should be initial level in reservoir tank
OFF
11
●
Cylinder head
●
Straight gauge feeler gauge
0.1 mm (0.004 in) Maxi- See “Inspection”, “CYLmum distortion (warping) INDER HEAD” in EM section.
12
●
Cylinder block and pistons
●
Visual
No scuffing on cylinder walls or piston
*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. For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.
EC-95
See “Inspection”, “CYLINDER BLOCK” in EM section.
CD20T
TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d) COMPONENT INSPECTION Cooling fan relays-1, -2, -3
Cooling fan relay 1
Check continuity between terminals
3 p
and
5 . p
Conditions 5 1
2 3
Continuity
12V direct current supply between relay terminals p 1 and p 2
Yes
No current supply
No
If NG, replace cooling fan relay.
Cooling fan relay-2
Cooling fan relay 3
Check continuity between terminals
3 p
and
Conditions
2
5 4
1
3
4 . p
Continuity
No current supply
Yes
12V direct current supply between relay terminals p 1 and p 2
No
Cooling fan relay 2
2
5 4
1
3
YEC391
Cooling fan motors-1 and -2 1. Disconnect cooling fan motor harness connectors. 2. Supply cooling fan motor terminals with battery voltage and check operation.
Cooling fan motor-1 & -2
Terminals FUSE
Cooling fan motor-1 and -2 AEC781
Cooling fan motor should operate. If NG, replace cooling fan motor.
EC-96
(!)
(@)
1 p
2 p
CD20T
TROUBLE DIAGNOSIS 9 Needle Lift Sensor (NLS) Nozzle holder
Inductive pick-up coli
The needle lift sensor is built into the No. 1 nozzle. Its inductive pick-up element senses the lifting of the injection nozzle needle and thus the start of injection. The signal is evaluated by the ECM and compared with the target timing. Deviations in timing, for example caused by changes in fuel temperature, are sensed by the ECM and corrected.
Nozzle NEF689
Check Items (Possible Cause)
Malfunction is detected when .... ●
An improper signal from the sensor is sent to ECM.
●
● ● ●
Harness or connectors (The sensor circuit is open or shorted.) Needle lift sensor Air in fuel line Clogging No. 1 injection nozzle
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE NOTE: Before diagnostic trouble confirmation, be sure to check battery voltage is above 9V. 1) Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for 2 seconds above 1,200 rpm.
EC-97
TROUBLE DIAGNOSIS 9 Needle Lift Sensor (NLS) (Cont’d)
CD20T
NEEDLE LIFT SENSOR
: Detectable line for DTC : Non-detectable line for DTC
ECM
YEC806
EC-98
TROUBLE DIAGNOSIS 9 Needle Lift Sensor (NLS) (Cont’d)
CD20T
DIAGNOSTIC PROCEDURE Priming pump
INSPECTION START
H
SEF671S
Needle lift sensor harness connector
CHECK FOR AIR IN FUEL FILTER. 1. Move priming pump up and down to purge air from fuel filter. 2. Perform “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE”.
H
SEF606S
CHECK INPUT SIGNAL CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector and needle lift sensor harness connector. 3. Check harness continuity between needle lift sensor connector terminal 1 and ECM connector terminal p 345 . Continuity should exist. If OK, check harness for short-circuit.
Needle lift sensor connector
CHECK GROUND CIRCUIT. Check resistance between needle lift sensor connector terminal p 2 and ECM connector terminal 333 . Continuity should exist. If OK, check harness for short-circuit. H
Needle lift sensor connector
E
Repair harness or connectors.
E
Repair harness or connectors.
OK H
NEF206A
NG
OK
CHECK NO. 1 INJECTION NOZZLE FOR CLOGGING. Refer to spray pattern test of “INJECTION NOZZLE”. If NG, replace No. 1 injection nozzle. H
Disconnect and reconnect harness connectors in the circuit. Then retest. NEF205A H
Trouble is not fixed
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-99
NG
CD20T
TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve Fuel cut solenoid valve
ECM
Ignition switch
When the ignition switch is OFF, the ECM turns the fuel cut solenoid valve OFF (under this condition, no current flows through the fuel cut solenoid valve), shutting off fuel supply. When the engine is not operating due to trouble, the fuel cut solenoid valve may be OFF even when the ignition switch is ON.
SEF667S
Check Items (Possible Cause)
Malfunction is detected when ... ●
Fuel cut solenoid valve circuit is malfunctioning.
●
●
Harness or connectors (The solenoid valve circuit is open or shorted.) Fuel cut solenoid valve
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3) 4) 5) 6)
Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Start engine. (If no start, circuit is open). Warm engine up sufficiently. Turn ignition switch to “LOCK” position and wait at least 5 seconds. Start engine and rev it up above 1,300 rpm. Release pedal and wait at least 3 seconds.
EC-100
TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve (Cont’d)
CD20T
BATTERY Refer to EL-POWER. : Detectable line for DTC : Non-detectable line for DTC
INJECTION PUMP (FUEL CUT SOLENOID VALVE)
ENGINE CONTROL MODULE RELAY
ECM
YEC807
EC-101
TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve (Cont’d) .
CD20T
DIAGNOSTIC PROCEDURE
Electronic injection pump harness connector (Fuel cut solenoid valve)
INSPECTION START H
CHECK MAIN POWER SUPPLY. Check power supply. Refer to EC-CD-59.
NEF815
C2FCS01
Electronic injection pump harness connection
NEF226A
H
NG CHECK OUTPUT SIGNAL CIRCUIT. 1. Turn ignition switch to “ON” position. 2. Select “FUEL CUT SOL/V” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON” and “OFF” alternately. 4. Check that operating sound is emitted. ----------------------------------------------------------------- OR ----------------------------------------------------------------1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector and electronic injection pump harness connector. 3. Check harness continuity between fuel cut solenoid valve connector terminal p 1 and ECM connector terminal 349 . Continuity should exist. If OK, check harness for short.
E
Repair harness or connectors.
E
Replace fuel cut solenoid valve.
OK H
CHECK COMPONENT (Fuel cut solenoid valve). Refer to “COMPONENT INSPECTION” on next page. OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. H
Trouble is not fixed.
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-102
NG
TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve (Cont’d)
CD20T
COMPONENT INSPECTION FUSE
Shaft
Fuel cut solenoid valve 1. Remove fuel cut solenoid valve. 2. Check for lifting shaft when applying 12V direct current to terminals. If NG, replace fuel cut solenoid valve.
SEF859S
EC-103
CD20T
TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor (FTS)
The fuel temperature sensor is used to detect the fuel temperature in the injection pump. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the fuel 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. The sensor is built into the inside electrical circuit of the injection pump.
Check Items (Possible Cause)
Malfunction is detected when ... ●
An excessively high or low voltage from the sensor is detected by ECM.
●
●
Harness or connectors (The sensor circuit is open or shorted.) Fuel temperature sensor
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)
Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds.
EC-104
CD20T TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor (FTS) (Cont’d)
INJECTION PUMP (FUEL TEMPERATURE SENSOR)
: Detectable line for DTC : Non-detectable line for DTC
ECM
YEC808
EC-105
CD20T TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor (FTS) (Cont’d) .
DIAGNOSTIC PROCEDURE
Electronic injection pump harness connector (Fuel temperature sensor)
INSPECTION START
H
NEF818
Injection pump connector
CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect fuel temperature sensor harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between injection pump connector terminal p 6 and ground with CONSULT-II or voltage tester. Voltage: Approximately 5V
NG
E
Repair harness or connectors.
E
Repair harness or connectors.
OK H
NEF819
Injection pump connector
F50
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Check harness continuity between injection pump connector terminal 5 and ECM connector terminals p 335 , 436 . Continuity should exist. If OK, check harness for short-circuit.
NG
OK H NEF208A
CHECK COMPONENT (Fuel temperature sensor). Refer to “COMPONENT INSPECTION” on next page. OK H
Disconnect and reconnect harness connectors in the circuits. Then retest. Trouble is not fixed. H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest.
H
INSPECTION END
EC-106
NG
E
Have the injection pump assembly serviced by an authorised service representative.
CD20T TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor (FTS) (Cont’d)
COMPONENT INSPECTION Fuel temperature sensor Wait until fuel temperature sensor reaches room temperature. Check resistance between terminals p 5 and p 6 .
YEC366
Fuel temperature °C (°F)
Resistance kΩ
25 (77)
Approximately 1.9
If NG, have the injection pump assembly serviced by an authorised service representative.
EC-107
CD20T
TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch
Output voltage between terminal No. 4 and 5 (V)
The accelerator 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. The ECM uses the signal to determine the amount of fuel to be injected.
Throttle valve opening angle (deg) NEF822
Check Items (Possible Cause)
Malfunction is detected when ... ●
An excessively low or high voltage from the sensor is detected by the ECM.
●
● ●
Harness or connectors (The sensor or switch circuit is open or shorted.) Accelerator position sensor Accelerator position switch
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)
Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Depress accelerator pedal fully and keep it for at least 1 second. Then release it and wait at least 5 seconds.
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE (For accelerator stiching) 1) 2) 3) 4)
Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Start engine and rev it up above 1,300 rpm. Depress brake pedal immediately after releasing accelerator pedal and keep it at least 5 seconds.
EC-108
TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch (Cont’d)
CD20T
ACCELERATOR POSITION SENSOR
: Detectable line for DTC : Non-detectable line for DTC
ECM
YEC809
EC-109
TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch (Cont’d)
CD20T
ECM
: Detectable line for DTC : Non-detectable line for DTC
DEPRESSED
ACCELERATOR WORK UNIT
RELEASED
YEC810
EC-110
TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch (Cont’d)
CD20T
DIAGNOSTIC PROCEDURE Accelerator pedal
Accelerator position sensor harness connector
INSPECTION START (Accelerator position sensor)
H
NEF823
Accelerator position sensor connector
CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect accelerator position sensor harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between accelerator position sensor connector terminal p 5 and ground with CONSULT-II or voltage tester. Voltage: Approximately 5V
NG E
Check the following: ● Harness connectors M50 , F104 ● Harness for open or short-circuit between ECM and accelerator position sensor. If NG, repair harness or connectors.
OK H
NEF824
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Check harness continuity between accelerator position sensor connector terminal 4 and engine ground. p Continuity should exist. If OK, check harness for short-circuit.
E
OK
Accelerator position sensor connector H
NEF825
NG
CHECK INPUT SIGNAL CIRCUIT. 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 434 and accelerator position sensor connector terminal p 2 . Continuity should exist. If OK, check harness for short-circuit.
NG E
OK H
Accelerator position sensor connector
CHECK COMPONENT (Accelerator position sensor). Refer to “COMPONENT INSPECTION” EC-CD-113. OK H NEF209A
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed. H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-111
NG E
Check the following: ● Harness connectors M50 , F104 ● Harness for open or short-circuit between ECM and accelerator position sensor. If NG, repair harness or connectors.
Check the following ● Harness connectors M50 , F104 ● Harness for open or short-circuit between ECM and accelerator position sensor If NG, repair harness or connectors.
Replace accelerator pedal assembly.
TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch (Cont’d)
CD20T
DIAGNOSTIC PROCEDURE INSPECTION START (Accelerator position switch)
H
PEF123W
NEF210A
CHECK OVERALL FUNCTION. 1. Turn ignition switch to “ON” position. 2. Check “OFF ACCEL POS” in “DATA MONITOR” mode with CONSULT-II. Accelerator pedal released: ON Accelerator pedal depressed: OFF ---------------------------------------------------------------- OR ---------------------------------------------------------------1. Turn ignition switch to “LOCK” position. 2. Check continuity between ECM connector terminal 435 and ground. Continuity: Accelerator pedal released: No Accelerator pedal depressed: Yes
OK E
INSPECTION END
E
Check the following: ● Harness connectors M52 , F103 ● Harness for open circuit between accelerator switch and ECM connector terminal 426 . If NG, repair harness or connectors.
E
Check the following: ● Harness connectors F103 , M52 ● Harness for open or shortcircuit between accelerator switch and ECM
E
Replace accelerator switch.
NG H Accelerator switch connector
CHECK GROUND CIRCUIT. 1. Disconnect accelerator switch harness connector. 2. Check harness continuity between accelerator switch connector terminal 1 and ECM connector terminal 426 . p Continuity should exist.
NG
OK NEF212A
Accelerator switch connector
H
CHECK INPUT SIGNAL CIRCUIT. Check harness continuity between ECM connector terminal 435 and accelerator switch connector terminal p 3 . Continuity should exist. H
OK
CHECK COMPONENT (Accelerator switch). Refer to “COMPONENT INSPECTION” on next page. H NEF211A
OK
Disconnect and reconnect harness connectors in the circuit. Then retest. H
Trouble is not fixed
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-112
NG
NG
TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch (Cont’d)
Accelerator position sensor connector
CD20T
COMPONENT INSPECTION M68
1 2 3 4 5 2
Accelerator position sensor
M68
4
1. Disconnect accelerator position sensor harness connector. 2. Make sure that resistance between accelerator position sensor terminals p 2 and p 4 changes when opening throttle valve manually. Throttle valve conditions
YEC368
Completely closed
Resistance [at 25°C (77°F)] Approximately 1.2 kΩ
Partially open
1.2 - 1.9 kΩ
Completely open
Approximately 1.9 kΩ
If NG, replace accelerator pedal assembly. CAUTION: ● Do not disassemble accelerator pedal assembly.
COMPONENT INSPECTION
Accelerator position sensor connector
Accelerator switch M68
1 2 3 4 5 1
M68
3
1. Disconnect accelerator switch harness connector. 2. Check continuity between accelerator switch connector terminals p 1 and p 3 . Conditions
YEC369
Continuity
Accelerator pedal released
No
Accelerator pedal depressed
Yes
If NG, replace accelerator pedal assembly. CAUTION: ● Do not disassemble accelerator pedal assembly.
EC-113
CD20E
TROUBLE DIAGNOSIS 13 Core
Crankshaft Position Sensor (TDC) The crankshaft position sensor (TDC) monitors engine speed by means of signals from the sensing plate (with two protrusions) installed to the crankshaft pulley. The datum signal output is detected at ATDC 70° and sent to the ECM. The sensor signal is used for fuel injection control and fuel injection timing control.
Magnet Coil SEF615S
Crank pulley
Crankshaft position sensor (TDC)
SEF616S
Check Items (Possible Cause)
Malfunction is detected when .... ●
An incorrect signal from the sensor is detected by ECM during engine running and cranking.
●
●
Harness or connectors (The sensor circuit is open.) Crankshaft position sensor (TDC)
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE Before performing the following procedure, confirm that battery voltage is more than 9V. 1) 2)
Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 3 seconds above 1,200 rpm.
EC-114
CD20E TROUBLE DIAGNOSIS 13 Crankshaft Position Sensor (TDC) (Cont’d)
CRANKSHAFT POSITION SENSOR (TDC)
: Detectable line for DTC : Non-detectable line for DTC
ECM
YEC811
EC-115
CD20E TROUBLE DIAGNOSIS 13 Crankshaft Position Sensor (TDC) (Cont’d)
DIAGNOSTIC PROCEDURE INSPECTION START
H
Crankshaft position sensor (TDC) harness connector
SEF617S
Crankshaft position harness connector
CHECK INPUT SIGNAL CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect crankshaft position sensor (TDC) and ECM harness connectors. 3. Check continuity between ECM terminal 344 and crankshaft position sensor (TDC) connector terminal 3 . p Continuity should exist. If OK, check harness for short-circuit.
NG
E
Repair harness or connectors.
E
Repair harness or connectors.
E
Replace crankshaft position sensor (TDC).
OK H NEF213A
Loosen and retighten engine ground screws. OK H
Crankshaft position sensor connector
CHECK GROUND CIRCUIT. Check harness continuity between crankshaft position sensor (TDC) connector terminal p 2 and ECM connector terminal 331 . Continuity should exist. If OK, check harness for short-circuit.
NEF214A
NG
OK H
CHECK COMPONENT [Crankshaft position sensor (TDC)]. Refer to “COMPONENT INSPECTION” on next page. OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-116
NG
CD20E TROUBLE DIAGNOSIS 13 Crankshaft Position Sensor (TDC) (Cont’d)
COMPONENT INSPECTION Crankshaft position sensor (TDC)
SEF620S
Crankshaft position sensor (TDC) connector
1. Disconnect crankshaft position sensor (TDC) harness connector. 2. Loosen the fixing bolt of the sensor. 3. Remove the sensor. 4. Visually check the sensor for chipping. 5. Check resistance between crankshaft position sensor (TDC) terminals p 2 and p 3 . Resistance: Approximately 1.2 - 1.5kΩ [at 25°C (77°F)] If NG, replace crankshaft position sensor (TDC).
NEF440
EC-117
CD20T
TROUBLE DIAGNOSES 14 Glow Control System
.
Time , [S]
Glow lamp indicator
.
.
(-40) (-4) (32) (68) Engine coolant temperature
(104)
1.5
When coolant temperature is lower than 75°C (167°F): ● Ignition switch ON After ignition switch has been turned to ON, the glow relay turns ON for a period of time depending on engine coolant temperature, allowing current to flow through the glow plugs. ● Starting After starting the engine, current will flow through the glow plugs for 300 seconds, or until the coolant temperature exceeds 50°C (122°F).
(140)
, °C (°F)
.
Time , [S]
Pre-glow
.
(-40)
(-4)
(32)
(68)
(104) .
Engine coolant temperature
(140)
, °C (°F)
.
.
Time , [S]
Post glow
.
(-40) (-4) (32) (68). (104) (140) . Engine coolant temperature , °C (°F) NEF834
COMPONENT DESCRIPTION Glow plug Ceramic heater
Resistor
The glow plug is provided with a ceramic heating element to obtain a high-temperature resistance. It glows in response to a signal sent from the ECM, allowing current to flow through the glow plug via the glow relay.
SEF857S
Check Items (Possible cause)
Malfunction is detected when .... ●
Glow relay signal circuit is open or shorted.
●
● ●
Glow indicator lamp circuit is open or shorted.
●
●
Harness or connectors (The glow relay signal circuit is open or shorted) Glow relay Harness or connectors (The glow indicator lamp circuit is open or shorted.) Glow lamp
EC-118
TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)
CD20T
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)
Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds.
EC-119
TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)
CD20T
YEC102A
EC-120
TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)
CD20T
DIAGNOSTIC PROCEDURE Glow relay
INSPECTION START (Glow relay signal circuit) H
CHECK MAIN POWER SUPPLY. Check power supply to ECCS-D relay. Refer to “TROUBLE DIAGNOSIS FOR POWER SUPPLY” (EC-CD-59).
Glow relay harness connector NEF835
H
CHECK POWER SUPPLY. 1. Turn ignition switch to the “LOCK” position. 2. Disconnect glow relay. 3. Turn ignition switch to the “ON” position. 4. Check voltage between glow relay connector terminals p 1 , p 5 and ground with tester. Voltage: Battery voltage
Glow relay connector
YEC370
NEF215A
E
Check the following: ● 15A fuse ● 80A fusible link ● Harness continuity between glow relay and fuse. If NG, replace fuse or fusible link or repair harness or connectors.
OK H
Glow relay connector
NG
CHECK OUTPUT SIGNAL CIRCUIT. 1. Turn ignition switch to the “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM connector terminal 214 and 2 . glow relay connector terminal p Continuity should exist. If OK, check harness for short-circuit.
NG
E
Check harness connectors F96 , E89 Repair harness or connectors.
OK H
CHECK GLOW PLUG AND GLOW RELAY. Refer to “COMPONENT INSPECTION” (EC-CD-124, 125). OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-121
NG
E
Replace glow plug or glow relay.
TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)
CD20T
INSPECTION START (Glow indicator lamp circuit)
H
CHECK POWER SUPPLY CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect combination meter harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between combination meter harness connector terminal 5 or p 1 and body ground. p Voltage: Battery voltage
NG
E
Check the following: ● Harness for open or short-circuit between combination meter and battery. ● 10A fuse If NG, replace fuse or repair harness or connectors.
OK H
YEC119A
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM connector terminal 221 and combination meter connector terminal p 7 or p 17 . Continuity should exist. If OK, check harness for short-circuit.
NG
E
Check the following: ● Harness connectors M50 , F104 ● Harness for open or short-circuit between ECM and combination meter. If NG, repair harness or connectors.
OK H
CHECK GLOW INDICATOR LAMP. Make sure that glow indicator lamp is not burnt out. OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H YEC120A
INSPECTION END
EC-122
NG
E
Replace glow indicator lamp.
TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)
CD20T
INSPECTION START (Glow plug circuit) Glow relay connector H
NEF873
Glow relay connector
CHECK POWER SUPPLY-I. 1. Turn ignition switch to “LOCK” position. 2. Disconnect glow relay harness connector. 3. Check voltage between glow relay harness connector terminal p 5 and engine ground. Voltage: Battery voltage
NG
E
Check the following: ● Harness for open or short-circuit between glow relay and battery. ● 80A fusible link If NG, replace fusible link and repair harness connectors.
OK
Glow plug connector H
YEC374
CHECK POWER SUPPLY-II. 1. Disconnect glow plug harness connector. 2. Check harness continuity between glow plug harness connector and glow relay harness connector terminal p 3 . Continuity should exist. If OK, check harness for short-circuit.
NG
E
Check the following: ● Harness connectors E2 , F46 ● Harness for open or short-circuit between glow plug and glow relay. If NG, repair harness or connector.
OK H
CHECK GLOW PLUG AND GLOW RELAY. Refer to “COMPONENT INSPECTION” (EC-CD-124, 125). OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. H
INSPECTION END
EC-123
NG
E
Replace glow plug or glow relay.
CD20T
TROUBLE DIAGNOSES 14 Glow Control System (Cont’d) SYSTEM OPERATION CHECK Set voltmeter between glow plug and engine body.
Glow plug plate
SEC554B
Pre-glow time
1. Pre-glow control system a. Turn ignition switch to “ON” position. b. Read voltage. Voltage: Battery voltage for an engine coolant temperature dependent time. * Repeatedly turning the ignition switch to “ON” position and to “LOCK” position may change the pre-glow time. .
(-4) (32) (68) (104) Engine coolant temperature
NEF838
After glow time (sec.)
2. After-glow system Start engine and read voltage. Voltage: Battery voltage for 5* minutes * Engine coolant temperature is lower than 50°C (122°F).
.
(-4)
(32)
(68)
Engine coolant temperature
(104) NEF839
COMPONENT INSPECTION Glow relay
Glow relay
p
p
p5
p1
3
1. Check relay for coil continuity between glow relay terminals 1 and p 2 . p Continuity should exist. 2. Check relay for proper operation by applying 12V dc voltage between glow relay terminals p 1 and p 2 and checking continuity between terminals p 3 and p 5 .
2
Coil voltage Contact point
Continuity
3 p
and
5 p
Contact point
0V
No
OFF
12V
Yes
ON
12V dc
Ohmmeter SEC564B
EC-124
TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)
CD20T
Glow plug
Ohmmeter
1. Remove glow plug connecting plate. 2. Check each glow plug for continuity. Continuity should exist: Approximately 0.5Ω [at 25°C (77°F)] ● If NG, replace glow plug.
SEF630K Glow nut
Glow harness
Connecting plate Washer Spring washer Glow plug
3. Install glow plug connecting plate securely. ● Do not bump glow plug heating element. If it is bumped, replace glow plug with new one. (If glow plug is dropped from a height of 0.1 m (3.94 in) or greater, replace with new one.) ● If glow plug installation hole is contaminated with carbon, remove using a reamer or suitable tool. ● Hand-tighten glow plug by turning it 2 to 3 times, then tighten using a tool to specified torque. : 15 - 20 N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
SEC565B
EC-125
CD20T
TROUBLE DIAGNOSES 15 Air Conditioner Cut Control
The Air Conditioner relay is controlled by the ECM. During the following conditions, the ECM will cut the power supply towards the air conditioner relay: ● Starting engine ● Quick acceleration from low speed ● Undershooting of idle speed ● High engine coolant temperature [above 107°C (225°F)]. ● Malfunctioning of engine speed sensor, accelerator position sensor or vehicle speed sensor when engine speed is below 2,100 rpm.
Check Items (Possible cause)
Malfunction is detected when .... ●
Air conditioner relay signal circuit is shorted.
●
●
Harness or connectors (The air conditioner relay signal circuit is shorted). Air conditioner relay
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)
Turn ignition switch and air conditioner switch to the “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 2 seconds.
EC-126
CD20T
TROUBLE DIAGNOSES 15 Air Conditioner Cut Control (Cont’d) IGNITION SWITCH ON or START FUSE BLOCK (J/B)
Refer to EL-POWER.
: Detectable line for DTC : Non-detectable line for DTC
AIR CONDITIONER RELAY
To compressor (Refer to HA-A/C.) A/C CONTROL PANEL
LOW
HIGH
THERMO CONTROL AMP.
TRIPLEPRESSURE SWITCH
NORMAL THERMISTOR
ECM
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
YEC813
EC-127
TROUBLE DIAGNOSES 15 Air Conditioner Cut Control (Cont’d)
CD20T
INSPECTION START (Air conditioner relay signal circuit) Air conditioner relay harness connector H
YEC375
Air conditioner relay harness connector
CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect air conditioner relay harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between air conditioner relay connector terminals p 2 , 5 and engine ground. p Voltage: Battery voltage
E
Check the following: ● Harness and connectors for open or shortcircuit between ignition switch and air conditioner relay. ● 10A fuse If NG, replace or repair the parts affected.
OK H
NEF218A
NG
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM harness connector terminal 204 and air conditioner relay harness connector terminal p 1 . Continuity should exist. If OK, check harness for short-circuit.
NG
E
Check the following: ● Harness connectors E43 , F2 ● Harness for open or short-circuit between ECM and air conditioner relay. If NG, repair harness or connectors.
OK H
CHECK AIR CONDITIONER RELAY. Refer to HA section for inspection. OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-128
NG
E
Replace air conditioner relay.
CD20T
TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve SYSTEM DESCRIPTION Camshaft position sensor (TDC)
Air conditioner switch
Engine coolant temperature sensor
Atmospheric pressure sensor
Mass air flow sensor
Engine speed E
Air conditioner “ON” signal E
Engine coolant temperature E
E
EGRC-solenoid valve
ECM
Atmospheric pressure E
Mass air flow E
The ECM receives signals sent from the engine coolant temperature sensor, crankshaft position sensor (TDC), atmospheric pressure sensor, mass air flow sensor and air conditioner switch to determine engine speed and operating conditions. Based on these signals, the ECM controls the EGR control solenoid valve operation. No EGR operation will take place when the engine coolant temperature is below 70°C (158°F), when idling, at starting and during a period of time after starting the engine (70 - 200 seconds, depending on engine coolant temperature). Engine coolant temperature °C (°F) Below 70 (158)
Load
EGRC-solenoid valve
EGR valve
Amount of EGR gas
Any
OFF (Closed)
Fully closed
—
Low load
ON (Open)
Fully open
Large
High load
OFF (Closed)
Fully closed
—
Above 70 (158)
COMPONENT DESCRIPTION
To control valve To intake air flow
Vacuum signal
The EGR control solenoid valves control vacuum pressure acting on the EGR valve. The EGR control valve will then be fully opened or fully closed, as required. Thus, intake air passages are opened or closed in relation to exhaust gas and intake air. Utilizing the relationship between exhaust gas pressure and intake air pressure control, the amount of EGR (exhaust gas recirculated) is regulated in large or small volumes.
SEF240PH
Check Items (Possible cause)
Malfunction is detected when .... ●
EGRC-solenoid valve A circuit is shorted.
●
●
Harness or connectors (EGRC-solenoid valve A circuit is open or shorted). EGRC solenoid valve A
EC-129
TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d)
CD20T
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)
Turn ignition switch to the “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 2 seconds.
EC-130
TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d)
CD20T
BATTERY : Detectable line for DTC
Refer to EL-POWER.
: Non-detectable line for DTC
ENGINE CONTROL MODULE RELAY EGRCSOLENOID VALVE A
EGRCSOLENOID VALVE B
ECM
YEC814
EC-131
TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d)
CD20T
DIAGNOSTIC PROCEDURE INSPECTION START (Circuit for EGRC-solenoid valve A)
EGRC solenoid valve A harness connector
H
CHECK MAIN POWER SUPPLY. Refer to Trouble Diagnosis for main power supply (EC-CD-59) NEF219A
EGRC solenoid valve A harness connector
H
CHECK POWER SUPPLY. 1. Turn ignition switch to the “LOCK” position. 2. Disconnect EGRC-solenoid valve A harness connector. 3. Turn ignition switch to the “ON” position. 4. Check voltage between connector terminal p 2 and engine ground. Voltage: Battery voltage
NG
E
Check the following: ● Harness continuity between ECM relay and EGRC-solenoid valve A connector. If NG, repair harness or connectors.
OK
NEF220A H
CHECK OUTPUT SIGNAL CIRCUIT. 1. Turn ignition switch to the “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM harness connector terminal 208 and EGRC solenoid valve A 1 . connector terminal p Continuity should exist. If OK, check harness for short-circuit.
NG
E
Check the following: ● Harness for open or short-circuit between ECM and solenoid valve. If NG, repair harness or connectors.
OK H
CHECK COMPONENTS (EGRC-solenoid valve). Refer to “COMPONENT INSPECTION” EC-CD-135. OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H
Check ECM pin terminals for damage or the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-132
NG
E
Replace malfunctioning component(s).
CD20T
TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d) DIAGNOSTIC PROCEDURE INSPECTION START EGR CONTROL OPERATION
EGR valve
H
NEF433
EGR valve
NEF434
OK CHECK OVERALL FUNCTION. 1. Start engine and warm it up sufficiently. (Air conditioner is “OFF”). 2. Perform diagnostic test mode II (Self-diagnostic results). Make sure that diagnostic trouble code No. 55 is displayed. 3. Make sure that EGR diaphragm moves up and down (Use your finger or a suitable tool) under the following conditions: At idle: Spring does not move. Racing engine from idle to 2800 rpm: Spring moves up and down.
E
INSPECTION END
NG H
CHECK VACUUM SOURCES TO EGR VALVE. 1. Disconnect vacuum hoses to EGR valve. 2. Make sure that vacuum exists under the following conditions: At idle: Vacuum should not exist. Racing engine from idle to 2800 rpm: Vacuum should exist. H
A p
EC-133
NG
OK
E
CHECK COMPONENTS (EGR valve). (See page EC-CD-135.) NG
H
Replace malfunctioning component(s).
TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d)
CD20T
A p
H
C2ESA01
OK CHECK CONTROL FUNCTION. 1. Turn ignition switch to “ON” position. 2. Turn EGRC-solenoid valve A “ON” and “OFF” in “ACTIVE TEST” mode with CONSULT-II and check operating sound. -------------------------------------------------------------------- OR -------------------------------------------------------------------1. Check voltage between EGRC solenoid valve A connector terminal p 1 , and ground with tester under the following conditions: Voltage: At idle Battery voltage Engine speed is 2,800 rpm Approximately 0.4V
NEF435
NG H
Perform electrical circuit inspection. Refer to EC-CD-132.
Crack
H
B p
Clogging
Improper connection NEF846 . .
EGRC-solenoid valve harness connector
NEF436
EC-134
OK
E
CHECK VACUUM HOSE. Check vacuum hose for clogging, cracks or improper connection.
CD20T
TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d) COMPONENT INSPECTION EGR valve
EGR valve Apply vacuum to EGR vacuum port with a hand vacuum pump. EGR valve spring should lift. If NG, replace EGR valve.
MEF137D
EGRC-solenoid valve Check air passage continuity.
FUSE
Condition
BATTERY
Air passage continuity between p A and
B p
Air passage continuity between p A and
12V direct current supply between terminals 1 and p 2 p
Yes
No
No supply
No
Yes
MEC488B
If NG, replace solenoid valve.
EC-135
C p
CD20T
TROUBLE DIAGNOSES 17 Brake Switch
The ECM receives signals from two brake switches. One is a conventional brake lamp switch, the other is referred to as a redundant (RDNT) brake switch. In case the accelerator pedal does not return to the idle position (pedal sticks), the driver will react by depressing the brake. In this (emergency) situation, the ECM will disregard the accelerator pedal signal and bring back the engine speed to 1200 rpm. Check Items (Possible Cause)
Malfunction is detected when ... ●
Brake switch circuits are open or shorted.
●
● ●
Harness or connectors (Brake switch circuits are open or shorted.) Stop lamp switch RDNT brake switch
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2)
Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. Depress brake pedal for at least 1 minute.
EC-136
TROUBLE DIAGNOSES 17 Brake Switch (Cont’d)
CD20T
YEC103A
EC-137
CD20T
TROUBLE DIAGNOSES 17 Brake Switch (Cont’d) INSPECTION START (RDNT brake switch) RDNT brake switch harness connector
H
YEC377
RDNT brake switch harness connector
CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect RDNT brake switch harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between RDNT brake switch harness connector terminal 1 and body ground. p Voltage: Battery voltage
NG
E
OK
Check the following: ● Harness connectors F104 , M50 (RHD models) ● Harness connectors F2 , E43 (LHD models) ● Harness for open or short-circuit between RDNT brake switch harness connector terminal p 1 and ECM connector terminal 416 . If NG, repair harness or connectors.
YEC378 H
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Check harness continuity between RDNT brake switch harness connector terminal p 2 and body ground. Continuity should exist. If OK, check harness for shortcircuit. OK H
CHECK COMPONENT. (RDNT brake switch) Refer to “COMPONENT INSPECTION” on next page. OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-138
NG
E
Repair harness or connectors.
CD20T
TROUBLE DIAGNOSES 17 Brake Switch (Cont’d) COMPONENT INSPECTION
2 1
Stop lamp switch and RDNT brake switch 1 2
YEC379
1. Turn ignition switch to “LOCK” position. 2. Disconnect switch harness connectors. 3. Check continuity between terminals p 1 and Continuity:
2 . p
Brake pedal
Stop lamp switch
RDNT brake switch
Released
No
No
Depressed
Yes
Yes
If NG, replace stop lamp switch or RDNT brake switch.
EC-139
CD20T
TROUBLE DIAGNOSES 18 ECM Relay
The ECM Relay shuts off the main power supply to the ECM within 5 seconds after the ignition switch has turned to the “LOCK” position.
Check Items (Possible cause)
Malfunction is detected when .... ●
ECM relay shut-off time is too late.
●
● ●
Harness or connectors (The ECM relay circuit is shorted). ECM relay ECM
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)
Turn ignition switch to the “ON” position and select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch to the “LOCK” position and wait at least 5 seconds. Turn ignition switch to the “ON” position and wait at least 2 seconds.
DIAGNOSTIC PROCEDURE Refer to “Trouble Diagnosis for Power Supply” (EC-CD-59) for ECM relay circuit inspection.
EC-140
CD20T
TROUBLE DIAGNOSES 19 MI & Data Link Connectors
Malfunction indicator (MI) circuit is monitored for open or shortcircuit. If the circuit is malfunctioning, MI can not report it but CONSULT-II can. Check Items (Possible cause)
Malfunction is detected when .... ●
MI circuit is open or shorted.
●
● ●
Harness or connectors (MI circuit is open or shorted). MI lamp ECM
DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1)
Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 2 seconds at idle speed. ------------------------------------------------------------------------------------------------------------------------------- OR ------------------------------------------------------------------------------------------------------------------------------OVERALL FUNCTION CHECK 1) Turn ignition switch to “ON” position. 2) Check that MI lits on.
EC-141
TROUBLE DIAGNOSES 19 MI & Data Link Connectors (Cont’d)
CD20T
YEC104A
EC-142
TROUBLE DIAGNOSES 19 MI & Data Link Connectors (Cont’d)
CD20T
DIAGNOSTIC PROCEDURE: MODELS BEFORE VIN P11U0548750 INSPECTION START (MI circuit)
Combination meter harness connector
H
YEC380
Combination meter harness connector
CHECK MI BULB. 1. Turn ignition switch to “LOCK” position. 2. Disconnect combination meter harness connector. 3. Apply battery voltage between combination meter terminal p 5 and p 13 . 4. Check that MI lits on.
NG
E
Replace MI bulb.
OK H
YEC381
CHECK POWER SUPPLY. 1. Turn ignition switch to “ON” position. 2. Check voltage between combination meter terminal p 5 and body ground. Voltage: Battery voltage
NG
E
OK Combination meter harness connector
NEF222A
Check the following: ● Harness for open or short-circuit between combination meter and ignition switch. ● 10A fuse If NG, repair or replace harness or fuse.
H
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check continuity between combination meter connector terminal p 13 and ECM connector terminal 215 . Continuity should exist. If OK, check harness for short-circuit. OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-143
NG
E
Check the following: ● Harness connectors M50 , F104 If NG, repair harness or connectors. ● Harness and connectors for open or shortcircuit between ECM and combination meter.
TROUBLE DIAGNOSES 19 MI & Data Link Connectors (Cont’d)
CD20T
DIAGNOSTIC PROCEDURE: MODELS AFTER VIN P11U0548750 INSPECTION START (MI circuit)
H
YEC121A
CHECK MI DIODE. 1. Turn ignition switch to “LOCK” position. 2. Disconnect combination meter harness connector. 3. Apply battery voltage between combination meter terminal p 1 and p 8 . 4. Check that MI lits on.
NG
E
Repair or replace combination meter.
OK H
YEC122A
CHECK POWER SUPPLY. 1. Turn ignition switch to “ON” position. 2. Check voltage between combination meter terminal p 1 and body ground. Voltage: Battery voltage
NG
E
OK
Check the following: ● Harness for open or short-circuit between combination meter and ignition switch. ● 10A fuse If NG, repair or replace harness or fuse.
H
YEC123A
CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check continuity between combination meter connector terminal p 8 and ECM connector terminal 215 . Continuity should exist. If OK, check harness for short-circuit. OK H
Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-144
NG
E
Check the following: ● Harness connectors M50 , F104 If NG, repair harness or connectors. ● Harness and connectors for open or shortcircuit between ECM and combination meter.
CD20T
TROUBLE DIAGNOSES 20 Start Signal BATTERY
Refer to EL-POWER.
: Detectable line for DTC : Non-detectable line for DTC
OFF
ST
ACC
IGNITION SWITCH
ON
FUSE BLOCK (J/B)
Refer to EL-POWER.
ECM
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
YEC817
EC-145
CD20T
TROUBLE DIAGNOSES 20 Start Signal (Cont’d) DIAGNOSTIC PROCEDURE INSPECTION START
H
C2DMM04
NEF223A
Fuse
CHECK OVERALL FUNCTION. 1. Turn ignition switch to “ON” position. 2. Check “START SIGNAL” in “DATA MONITOR” mode with CONSULT-II. IGN “ON”
OFF
IGN “START”
ON
OK
INSPECTION END
E
-------------------------------------------------------------------- OR -------------------------------------------------------------------1. Turn ignition switch to the “LOCK” position. 2. Disconnect ECM harness connector. 3. Turn ignition switch to “START” position. 4. Check voltage between ECM connector terminal 422 and ground. Voltage: Ignition switch “START” — Battery voltage Except above — Approximately 0V H
NG
Check if 10A fuse is OK.
NG
E
Replace 10A fuse.
OK NEF224A
H
CHECK INPUT SIGNAL CIRCUIT. 1) Turn ignition switch to “LOCK” position. 2) Disconnect 10A fuse. 3) Check harness continuity between ECM connector terminal 422 and fuse block. Continuity should exist. If OK, check harness for short-circuit. H
OK
Disconnect and reconnect harness connectors in the circuit. Then retest. H
Trouble is not fixed
Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H
INSPECTION END
EC-146
NG
E
Check the following: Harness or connectors M50 , F104 ● Harness for open or short-circuit between ECM and fuse block. If NG, repair harness or connectors. ●
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications Unit : rpm Engine
Pump numbers
CD20T
Maximum engine speed
5,400
A/C ON
825 ± 25
A/C OFF
825 ± 25
Idle speed
Engine
Part number
Pump assembly number
CD20T
16700 2J620
NP-VE4/ 10E2200L736
Pump data is not yet available. Refer to CALIBRATION STANDARD published by BOSCH.)
Injection Nozzle INSPECTION AND ADJUSTMENT Injection nozzle assembly Unit: kPa (bar, kg/cm2, psi) Initial injection pressure New
14,423 - 15,651 (144.2 - 156.5, 148 - 159, 2,091 - 2,269)
Used
15,000 - 16,000 (150.0 - 160.0, 153 - 163, 2,175 - 2,320)
Inspection and Adjustment Plunger lift (Injection timing)
mm (in)
ELECTRIC GOVERNOR
0.89 ± 0.08 at plunger lift timing mark
Resistance [at 25°C (77°F)]
MASS AIR FLOW SENSOR
Ω
1.0
CRANKSHAFT POSITION SENSOR (TDC)
Supply voltage
V
5.0V
Output voltage
V
1.9 - 2.3*
Resistance [at 25°C (77°F)]
Ω
Approximately 1,215 - 1,485
Ω
0.5
*: Engine is warmed up sufficiently and idling under no-load.
GLOW PLUG ENGINE COOLANT TEMPERATURE SENSOR Temperature °C (°F)
Resistance kΩ
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
Resistance [at 25°C (77°F)]
ACCELERATOR POSITION SENSOR Throttle valve conditions Completely closed Partially open
CONTROL SLEEVE POSITION SENSOR Resistance [at 25°C (77°F)]
Ω
Completely open
Resistance kΩ [at 25°C (77°F)] Approximately 1.2 1.2 - 1.9 Approximately 1.9
6.0
FUEL TEMPERATURE SENSOR INJECTION TIMING CONTROL VALVE Resistance [at 25°C (77°F)]
Ω
Approximately 15
EC-147
Temperature °C (°F)
Resistance kΩ
25 (77)
Approximately 1.9
SERVICE DATA AND SPECIFICATIONS (SDS) NOTE
EC-148
CD20T
ACCELERATOR CONTROL, FUEL & EXHAUST SYSTEMS SECTION
FE FE
CONTENTS PREPARATION.............................................................. 2 Special Service Tool .................................................. 2
QG16DE, QG18DE, SR20DE ACCELERATOR CONTROL SYSTEM ......................... 3 Adjusting Accelerator Cable ...................................... 4
CD20T ACCELERATOR CONTROL SYSTEM ......................... 5
QG16DE, QG18DE, SR20De, CD20T FUEL SYSTEM .............................................................. 6 Fuel Pump and Gauge .............................................. 7 EXHAUST SYSTEM ...................................................... 9
PREPARATION Special Service Tool Tool number Tool name
Description
KV999G0010 Fuel tank lock ring socket
Removing and installing fuel tank lock ring
NT057
FE-2
ACCELERATOR CONTROL SYSTEM
QG16DE, QG18DE, SR20DE
CAUTION: ● When removing accelerator cable, mark location to indicate lock nut’s initial position. ● Check that throttle valve is completely open when accelerator pedal is fully depressed. Check that throttle valve returns to idle position when accelerator pedal is released. ● Check accelerator control does not interfere with any adjacent parts. ● When connecting accelerator cable, be careful not to twist or scratch cable. SEC. 180
p1
p2
(LHD models)
p1
p2
(RHD models)
3 - 4 (0.3 - 0.4, 27 - 35) 3 - 4 (0.3 - 0.4, 27 - 35)
p3
3 - 4 (0.3 - 0.4, 27 - 35)
p4 p5
: N·m (kg-m, in-lb) NFE062 1 p 2 p
Accelerator cable Cable bracket
3 p 4 p
Pedal bracket Return spring
FE-3
5 p
Accelerator pedal
ACCELERATOR CONTROL SYSTEM
QG16DE, QG18DE, SR20DE
Adjusting Accelerator Cable Throttle drum
Lock nut 8 - 11 N·m (0.8 - 1.1 kg-m, 71 - 97 in-lb)
1. Loosen lock nut, and tighten adjusting nut until throttle drum starts to move. 2. From that position turn back adjusting nut 1.5 to 2 turns, and secure lock nut.
Accelerator Adjusting nut NFE020
FE-4
CD20T
ACCELERATOR CONTROL SYSTEM SEC. 180
6 - 7 (0.61 - 0.71, 53.1 - 62.0) 2.9 - 3.9 (0.3 - 0.4, 25.7 - 34.5)
p1
p2 p3 p5
2.9 - 3.9 (0.30 - 0.40, 25.7 - 34.5)
p4
: Apply grease : N·m (kg-m, in-lb) : Do not re-use NFE043 1 p 2 p
Pedal bracket Accelerator position sensor
3 p 4 p
Accelerator cable Return spring
●
5 p
Accelerator pedal
If MIL illuminates after engine has started, refer to “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION” in EC section for instructions.
FE-5
FUEL SYSTEM WARNING: When replacing fuel line parts, be sure to observe the following: ● Display a “CAUTION: INFLAMMABLE” sign in workshop. ● Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. ● Be sure to disconnect battery ground cable before conducting service operations. ● Be sure to furnish workshop with a CO2 fire extinguisher. ● Pour drained fuel into an explosion-proof container then ensure container lid is installed securely. CAUTION: ● For ECCS engine models, release fuel pressure from fuel line. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”). ● Do not disconnect any fuel line unless absolutely necessary. ● Plug hose and pipe openings to prevent entry of dust or dirt. ● Always replace top lid seal and hose clamps with new ones. ● Do not kink or twist hoses and tubes during installation. ● Do not tighten hose clamps excessively because this could cause damage to the hose. ● Ensure fuel check valve is installed in the correct orientation. Refer to EC section (“FUEL CHECK VALVE”, “EVAPORATIVE EMISSION SYSTEM”). ● After installation, run engine and check for fuel leaks at connections. QG & SR engine models SEC. 172
CD engine models
p 1
p1
p4 p3 p2 p2
27 - 36 (2.8 - 3.9, 20 - 27)
7.9 - 10.4 (0.81 - 1.06, 69.9 - 92.1)
31 - 35 (3.2 - 3.6, 23 - 26)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) NFE078
1 p 2 p
Top lid Fuel gauge
3 p 4 p
Fuel pump Fuel chamber
FE-6
FUEL SYSTEM Fuel Pump and Gauge REMOVAL 1. Release fuel pressure from fuel line. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”). 2. Remove inspection hole cover located under the rear seat.
NFE023
3. Remove fuel filler lid. 4. Disconnect fuel outlet, return tube and connectors. CAUTION: Mark the fuel tubes to ensure correct position during installation.
Fuel tube
Connectors
SFE385A
5. Using SST KV999G0010, remove fuel gauge locking ring. 6. Lift the top plate from the fuel tank. CAUTION: ● Do not disconnect fuel hoses from top plate. Top plate has to be removed together with fuel chamber assy. ● For CD20T models the fuel gauge sender unit is attached to the top plate.
UFE004
.
.
Slide chamber
QG16DE, QG18DE & SR20DE models only: 7. Remove fuel pump with fuel tank chamber assy as follows: a. Push the locking clip upwards and slide the pump chamber assy towards the rear of the vehicle. b. Lift the pump chamber assy from the bracket. c. Carefully remove the pump chamber assy and top plate from the tank. CAUTION: While removing the pump chamber assy lift the fuel gauge sender float, to prevent it from bending.
PUSH Locking clip
NFE015
8. Take off the fuel pump chamber lid by opening out the 4 clips. Remove the fuel pump from the fuel pump chamber. 9. Remove the fuel gauge sender unit from the chamber by lifting the clip and sliding the sender unit upwards.
NFE016
FE-7
FUEL SYSTEM Fuel Pump and Gauge (Cont’d) INSTALLATION Installation is reverse procedure of removal. CAUTION: ● Always use a new top plate seal. ● Use the alignment marks to position the top plate. ● Tighten to specified torque.
FE-8
EXHAUST SYSTEM
SFE180A
CAUTION: ● Always replace exhaust gaskets with new ones when reassembling. Scrape off all residue of old gasket from flange surface. ● With engine running, check all tube connections for exhaust gas leaks, and entire system for unusual noises. ● After installation, check to ensure that mounting brackets and mounting insulators are free from undue stress. If any of the above parts are not installed properly, excessive noise or vibration may be transmitted to the vehicle body.
QG engine models SEC. 200⋅208
12.7 - 15.7 (1.30 - 1.60, 9.4 11.6)
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
51.0 - 64.7 (5.20 - 6.60, 37.6 - 47.7)
40 - 60 (4.1 - 6.1, 30 - 44)
5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)
Gasket Catalyst
36.3 - 45.1 (3.7 - 4.6, 26.8 - 33.3)
30 - 35 (3.1 - 3.5, 23 - 25) Gasket
51.0 - 64.7 (5.20 - 6.60, 37.6 - 47.7)
Gasket Gasket
Without catalyst 5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)
5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Do not re-use NFE079
FE-9
EXHAUST SYSTEM SR engine models SEC. 200⋅208
12.7 - 15.7 (1.30 - 1.60, 9.4 11.6)
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
51.0 - 64.7 (5.20 - 6.60, 37.6 - 47.7)
40 - 60 (4.1 - 6.1, 30 - 44)
5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)
Gasket Catalyst
36.3 - 45.1 (3.7 - 4.6, 26.8 - 33.3)
60 - 70 (6.1 - 7.1, 44 - 51) Gasket
51.0 - 64.7 (5.20 - 6.60, 37.6 - 47.7)
Gasket Gasket
Without catalyst 5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)
5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Do not re-use NFE080
FE-10
EXHAUST SYSTEM CD engine model SEC. 200⋅208
Gasket
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
51.0 - 64.7 (5.20 - 6.60, 37.6 - 47.7)
36.3 - 45.1 (3.7 - 4.6, 26.8 - 33.3) 12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
60.0 - 70.0 (6.12 - 7.14, 44.3 - 51.6) Gasket
Gasket
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Do not re-use
NFE077
FE-11
EXHAUST SYSTEM NOTE
FE-12
CLUTCH SECTION
CL
CONTENTS PRECAUTIONS AND PREPARATION.......................... 2 Precautions ................................................................ 2 Preparation ................................................................ 2 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................... 3 NVH Troubleshooting Chart....................................... 3 CLUTCH SYSTEM......................................................... 4 INSPECTION AND ADJUSTMENT ............................... 5 Inspecting and Adjusting Clutch Pedal...................... 5 Bleeding Procedure ................................................... 7
HYDRAULIC CLUTCH CONTROL ............................... 8 Clutch Master Cylinder .............................................. 8 Clutch Operating Cylinder ......................................... 9 Clutch Damper......................................................... 10 CLUTCH RELEASE MECHANISM ..............................11 CLUTCH DISC AND CLUTCH COVER ...................... 13 Clutch Disc............................................................... 13 Clutch Cover and Flywheel ..................................... 14 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 15 General Specifications............................................. 15 Inspection and Adjustment ...................................... 16
CL
PRECAUTIONS AND PREPARATION Precautions ● ● ● ● ● ●
GG94310000
SBR820B
Recommended fluid is brake fluid “DOT 4”. Do not reuse drained brake fluid. Be careful not to splash brake fluid on painted areas. When removing and installing clutch piping, use Tool. Use new brake fluid to clean or wash all parts of master cylinder, operating cylinder and clutch damper. Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic system.
WARNING: After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.
Preparation SPECIAL SERVICE TOOLS Tool number Tool name
Description
GG94310000 Flare nut torque wrench
Removing and installing clutch piping
a: 10 mm (0.39 in)
NT406
KV30101600 (New) KV30101000 (Former) Clutch aligning bar
Installing clutch cover and clutch disc
a: 15.9 mm (0.626 in) dia. b: 17.9 mm (0.705 in) dia. c: 40 mm (1.57 in)
NT645
ST20050240 Diaphragm spring adjusting wrench
Adjusting unevenness of diaphragm spring of clutch cover
a: 150 mm (5.91 in) b: 25 mm (0.98 in)
NT404
COMMERCIAL SERVICE TOOLS Tool name
Description
Equivalent to GG94310000 1 Flare nut crows foot p 2 p Torque wrench
Removing and installing clutch piping
a: 10 mm (0.39 in)
NT360
CL-2
2 1
ENGINE MOUNTING (Loose)
Refer to EM section
CLUTCH DISC (Out of true)
CL-13
CLUTCH DISC (Runout is excessive)
CL-13
5
CLUTCH DISC (Lining broken)
CL-13
5
CLUTCH DISC (Dirty or burned)
CL-13 CL-13 CL-13 CL-13
CLUTCH DISC (Lack of spline grease)
CL-13
DIAPHRAGM SPRING (Damaged)
CL-14
DIAPHRAGM SPRING ( Out of tip alignment)
CL-14
4
CLUTCH COVER (Distortion)
CL-14
5
1
CL-11
FLYWHEEL (Discoloration)
CL-14
5
RELEASE BEARING (Worn, dirty or damaged)
2
5 2
2
2
2
CLUTCH DISC (Worn out)
2
5
CLUTCH DISC (Oily)
CLUTCH DISC (Hardened)
5 3
6
2
6 7
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
2
OPERATING CYLINDER PISTON CUP (Damaged)
NVH Troubleshooting Chart
1
CL-9
MASTER CYLINDER PISTON CUP (Damaged)
4
CL-8
CLUTCH LINE (Air in line)
3
CL-7
2
CL-5
Use the chart below to help you to find the cause of the symptom. The numbers indicate the order of inspection. Check each part in order. If necessary, repair or replace these parts.
Reference page
Clutch grabs/chatters
Clutch pedal spongy
1
Clutch noisy
Clutch slips
1
SUSPECTED PARTS (Possible cause)
Symptom
Clutch does not disengage
CL-3
CLUTCH PEDAL (Free play out of adjustment)
CLUTCH SYSTEM
YCL007
CL-4
INSPECTION AND ADJUSTMENT Inspecting and Adjusting Clutch Pedal Inspect and adjust clutch pedal stroke. Pedal stroke “S”: Refer to SDS, CL-16.
Pedal bracket
Pedal stopper bolt
Pedal pad
NCL057
B Pedal fully depressed position Master cylinder push rod Pedal bracket
A Pedal fully up position Pedal stopper bolt
NCL058
CL-5
INSPECTION AND ADJUSTMENT Inspecting and Adjusting Clutch Pedal (Cont’d) INSPECITON Pedal stroke Check clutch pedal stroke using a 1-meter rule to measure the total pedal stroke. Place end of rule onto the middle of the clutch pedal pad. Place a book/clipboard on the driver’s set to set a reference point, ensure the book/clipboard does not move during pedal depression. Mark (A) the pedal fully up position on the rule. Depress the clutch pedal and mark (B) the rule again next to the reference point on the book/clipboard. Measure the distance between the marks (A and B), this is the actual pedal stroke (S). Check the specified pedal stroke in the table, adjust actual pedal stroke if necessary (refer to “ADJUSTMENT”). Note: ● Do not use steering wheel as a reference point, angle gives incorrect reading. ● Ensure there is no interference between the floor carpet and clutch pedal when fully depressed.
SCL702
Pedal free play Check pedal free play. If out of specification, refer to “ADJUSTMENT”. ● Push on the clutch pedal until resistance is felt, and check the distance the pedal moves.
ADJUSTMENT Pedal stroke 1. 2. 3. 4.
Loosen the pedal stopper bolt completely (so there is no contact between pedal and stopper bolt). Adjust pedal stroke to the specified value with the master cylinder push rod. Adjust the pedal stopper bolt until it is just in contact with the pedal, then tighten the lock nut. Once stroke is set to specification, adjust clutch pedal free play.
Pedal free play 1. Adjust pedal free play to the specified value with the master cylinder push rod. 2. Tighten lock nut of the master cylinder push rod. ● Push on the clutch pedal until resistance is felt, and check the distance the pedal moves. Pedal free play “A”: Refer to SDS, CL-16.
CL-6
INSPECTION AND ADJUSTMENT Bleeding Procedure .
.
Operating cylinder
Air bleeder valve .
NCL005 Air bleed valve
.
Clutch damper
1. Bleed air from clutch operating cylinder according to the following procedure. Carefully monitor fluid level at master cylinder during bleeding operation. a. Top up reservoir with recommended brake fluid. b. Connect a transparent vinyl tube to air bleeder valve of clutch operating cylinder. c. Fully depress clutch pedal several times. d. With clutch pedal depressed, open bleeder valve to release air. e. Close bleeder valve. f. Repeat steps (c) through (e) above until brake fluid flows from air bleeder valve without air bubbles. 2. Bleed air from clutch damper according to the above procedure. 3. Repeat the above bleeding procedures 1 and 2 several times.
NCL006
CL-7
HYDRAULIC CLUTCH CONTROL Clutch Master Cylinder
YCL008
DISASSEMBLY AND ASSEMBLY ● ●
Push piston into cylinder body with screwdriver when removing and installing valve stopper. Check direction of piston cups.
INSPECTION ● ● ● ● ●
Check cylinder and piston contact surfaces for uneven wear, rust or damage. Replace if necessary. Check piston and piston cup for wear or damage. Replace if necessary. Check return spring for wear or damage. Replace if necessary. Check reservoir for deformation or damage. Replace if necessary. Check dust cover for cracks, deformation or damage. Replace if necessary.
CL-8
HYDRAULIC CLUTCH CONTROL Clutch Operating Cylinder SEC. 306
Hydraulic pipe
18 - 25 (1.9 - 2.5, 14 - 18)
30 - 38 (3.1 - 3.8, 23 - 28) Operating cylinder
R p
Air bleeder valve 7 - 9 (0.8 - 0.9, 62 - 79)
Spacer Dust cover Push rod
Spring Piston assembly Piston cup
R p
R p
: Apply rubber grease
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) NCL008
INSPECTION ● ● ● ●
Check contact surfaces of cylinder for wear, rust or damage. Replace if necessary. Check piston and piston cup for wear or damage. Replace if necessary Check piston spring for wear or damage. Replace if necessary. Check dust cover for cracks, deformation or damage. Replace if necessary.
CL-9
HYDRAULIC CLUTCH CONTROL Clutch Damper SEC. 306
Cylinder body Bleeder Screw 6 - 10 (0.7 - 1.0, 54 - 88)
R Rubbing surp face to piston assembly
Gasket Spring
Piston cup
R p
Damper cover (LHD model)
Piston assembly Plate R p
2.9 - 5.9 (0.29 - 0.60, 26 - 52)
Contact surface to piston assembly Damper rubber
5.1 - 6.5 (0.52 - 0.66, 46 - 57) : Do not re-use : N·m (kg-m, in-lb) R p
: Apply rubber grease
NCL009
DISASSEMBLY AND ASSEMBLY 1. Remove damper assembly mounting bolts. 2. Remove gasket, damper rubber, plate, piston assembly, and piston spring from cylinder body. 3. Clean gasket contact surface on cylinder body and damper bracket with scrapers. CAUTION: Be careful not to scratch the contact surface.
INSPECTION ● ●
Check cylinder and piston contact surfaces for uneven wear, rust or damage. Replace if necessary. Check damper rubber and piston cup for cracks, deformation or damage. Replace if necessary.
CL-10
CLUTCH RELEASE MECHANISM
Withdrawal lever
Release bearing spring
L p
Release bearing
Clutch lever Release bearing spring Apply lithium-based grease including molybdenum disulphide
Spring pin
SCL819
REMOVAL AND INSTALLATION 1. Remove manual transaxle from vehicle. Refer to MT section “REMOVAL AND INSTALLATION”. 2. Remove release bearing by pulling bearing retainers outward.
SCL344
Tool
Retaining pin
Cavity of clutch housing
3. Align retaining pin with cavity of clutch housing and tap out retaining pin. CAUTION: ● Be sure to apply grease to the clutch components. Otherwise, abnormal noise, poor clutch disengagement, or clutch damage may occur. Wipe the excess grease off completely, because it may cause the clutch components to slip and shudder. ● Keep the clutch disc facing, pressure plate, and flywheel free of oil and grease.
SCL149
INSPECTION ● ● ● ●
Replace the release bearing if it is seized, damaged, faulty in rotation direction, or has poor aligning function. Replace the withdrawal lever if its contact surface is worn abnormally. Replace the clutch lever if its contact surface is worn abnormally. Replace the dust seal if it is deformed or cracked.
CL-11
CLUTCH RELEASE MECHANISM LUBRICATION ●
Apply molykote BR2 plus
●
Apply recommended grease to contact surface and rubbing surface. Too much lubricant might damage clutch disc facing.
SCL150
CL-12
CLUTCH DISC AND CLUTCH COVER
SEC. 300 Flywheel Clutch disc ● Do not clean in solvent. ● When installing, be careful that grease applied to main drive shaft does not adhere to clutch disc.
Clutch cover securing bolt 22 - 29 (2.3 - 2.9, 17 - 21)
. .
Clutch cover : Apply molykote BR2 plus : N·m (kg-m, ft-lb) SCL206
0.3 mm (0.012 in)
Clutch Disc INSPECTION Check clutch disc for wear of facing. Wear limit of facing surface to rivet head: 0.3 mm (0.012 in)
SCL229
●
Runout of facing
Backlash of spline
●
Check clutch disc for backlash of spline and runout of facing. Maximum backlash of spline (at outer edge of disc): Model 215/225 0.9 mm (0.035 in) Runout limit: 1.0 mm (0.039 in) Distance of runout check point (from hub center): Model 215 102.5 mm (4.04 in) Model 225 107.5 mm (4.23 in) Check clutch disc for burns, discoloration or oil or grease contamination. Replace if necessary.
SCL221
INSTALLATION ● ●
Apply recommended grease to contact surface of spline portion. Too much lubricant may damage clutch disc facing.
CL-13
CLUTCH DISC AND CLUTCH COVER Clutch Cover and Flywheel INSPECTION AND ADJUSTMENT ●
Check clutch cover installed on vehicle for unevenness of diaphragm spring toe height. Uneven limit: Model 225 0.7 mm (0.028 in) Model 215 0.8 mm (0.031 in)
SCL504
FLYWHEEL INSPECTION Flywheel
● ●
Dial gauge
Check contact surface of flywheel for slight burns or discoloration. Repair flywheel with emery paper. Check flywheel runout. Maximum allowable runout: Refer to EM section (“Inspection”, “CYLINDER BLOCK”).
SCL349
Except for CD20T engine models 3
INSTALLATION
6
KV30101600
●
1
●
4
5
●
2
Insert Tool into clutch disc hub when installing clutch cover and disc. Tighten bolts to specified torque. Tightening procedure a. Tighten all bolts, in numerical order, to 10 - 20 N·m (1.1 2.0 kg-m, 8 - 14 ft-lb). b. Tighten all bolts, in numerical order, to 22 - 29 N·m (2.3 2.9 kg-m, 17 - 21 ft-lb). Do not allow grease to contaminate clutch facing.
NCL023
For CD20T engine models KV30101600
7
5
1
2 4 8
9 3
6 NCL024
CL-14
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications CLUTCH CONTROL SYSTEM Type of clutch control
CLUTCH MASTER CYLINDER Hydraulic
Inner diameter
CLUTCH DAMPER
mm (in)
15.87 (5/8)
CLUTCH OPERATING CYLINDER
Inner diameter mm (in)
19.05 (3/4)
Inner diameter
mm (in)
17.46 (11/16)
CLUTCH DISC Unit: mm (in) Engine
QG16DE, QG18DE, SR20DE
CD20T
Model
215
225
216 x 153 x 3.5 (8.50 x 6.02 x 0.138)
225 x 150 x 3.5 (8.86 x 5.91 x 0.138)
7.3 - 7.9 (0.287 - 0.311) with 4,900 N (499.8 kg, 1,101.5 lb)
7.6 - 8.0 (0.299 - 0.315) with 3,923 N (400 kg, 882 lb)
Engine
QG16DE, QG18DE, SR20DE
CD20T
Model
L215K
L225K
Facing size (Outer dia. x inner dia. x thickness) Thickness of disc assembly with load
CLUTCH COVER
Full-load
N (kg, lb)
4,413 (450, 992)
CL-15
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment CLUTCH PEDAL Unit: mm (in) Applied model CD20T
RHD
LHD
145 - 150 (5.71 - 5.91)
140 - 145 (5.51 - 5.71)
153 - 158 (6.02 - 6.22)
140 - 145 (5.51 - 5.71)
QG16DE Pedal stroke “S” QG18DE SR20DE Pedal free play “A” (at pedal pad)
1 - 3 (0.04 - 0.12)
* : Measured from surface of dash reinforcement panel to surface of pedal pad.
CLUTCH DISC Unit: mm (in) Disc model
215
Wear limit of facing surface to rivet head
225 0.3 (0.012)
Runout limit of facing
1.0 (0.039)
Distance of runout check point (from hub center)
102.5 (4.04)
Maximum backlash of spline (at outer edge of disc)
107.5 (4.23) 0.9 (0.035)
CLUTCH COVER Unit: mm (in) Cover model Uneven limit of diaphragm spring toe height
CL-16
L215K
L225K
0.8 (0.031)
0.7 (0.028)
MANUAL TRANSAXLE SECTION
MT
CONTENTS PREPARATION ...............................................................3 Special Service Tools ..................................................3 Commercial Service Tools ...........................................6 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................7 NVH Troubleshooting Chart.........................................7 ON-VEHICLE SERVICE ..................................................8 Replacing Oil Seal .......................................................8 DIFFERENTIAL OIL SEAL ..........................................8 STRIKING ROD OIL SEAL..........................................8 Position Switch Check .................................................9 BACK-UP LAMP SWITCH...........................................9 NEUTRAL POSITION SWITCH ...................................9 REMOVAL AND INSTALLATION .................................10 Removal.....................................................................10 Installation..................................................................12 RS5F32A DESCRIPTION ...............................................................13 Cross-sectional View .................................................13 MAJOR OVERHAUL .....................................................14 Transaxle Gear Control .............................................14 Case Components .....................................................15 Gear Components .....................................................16 Shift Control Components .........................................17 DISASSEMBLY..............................................................18 REPAIR FOR COMPONENT PARTS............................21 Input Shaft and Gears ...............................................21 DISASSEMBLY ........................................................21 INSPECTION ...........................................................22 ASSEMBLY .............................................................23 Mainshaft and Gears .................................................24 DISASSEMBLY ........................................................24 INSPECTION ...........................................................26 ASSEMBLY .............................................................28 Final Drive..................................................................32 DISASSEMBLY ........................................................32
INSPECTION ...........................................................33 ASSEMBLY .............................................................33
Shift Control Components .........................................35 INSPECTION ...........................................................35 ADJUSTMENT OF INPUT SHAFT BRAKING MECHANISM ...........................................................36
Case Components .....................................................37 REMOVAL AND INSTALLATION ................................37 ADJUSTMENT ...............................................................39 Differential Side Bearing Preload ..............................39 ASSEMBLY....................................................................41 RS5F70A DESCRIPTION ...............................................................45 Cross-sectional View .................................................45 DOUBLE-CONE SYNCHRONIZER ............................46 MAJOR OVERHAUL .....................................................47 Transaxle Gear Control .............................................47 Case Components .....................................................48 Gear Components .....................................................49 Shift Control Components .........................................50 Final Drive Components ............................................51 DISASSEMBLY..............................................................52 Transaxle Case..........................................................52 Clutch Housing ..........................................................54 REPAIR FOR COMPONENT PARTS ...........................58 Input Shaft and Gears ...............................................58 DISASSEMBLY ........................................................58 INSPECTION ...........................................................59 ASSEMBLY .............................................................60 Mainshaft and Gears .................................................63 DISASSEMBLY ........................................................63 INSPECTION ...........................................................64 ASSEMBLY .............................................................66 Final Drive..................................................................71 PRE-INSPECTION ...................................................71 DISASSEMBLY ........................................................72 INSPECTION ...........................................................72
MT
CONTENTS ASSEMBLY .............................................................73 Shift Control Components .........................................74 INSPECTION ...........................................................74 ASSEMBLY....................................................................76 Clutch Housing ..........................................................76 Transaxle Case..........................................................80
(Cont’d) AVAILABLE C-RINGS ...............................................87 AVAILABLE SPACERS .............................................88 AVAILABLE WASHERS ............................................88 AVAILABLE SHIMS - DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM............88 INPUT SHAFT BRAKING MECHANISM .....................89 MAINSHAFT END PLAY ...........................................89
RS5F70A SERVICE DATA AND SPECIFICATIONS (SDS) ..........86 General Specifications - RS5F32A and RS5F70A....86 TRANSAXLE ...........................................................86 FINAL GEAR ...........................................................86
SERVICE DATA AND SPECIFICATIONS (SDS) .........90 Inspection and Adjustment - RS5F70A .....................90 GEAR END PLAY ....................................................90
RS5F32A SERVICE DATA AND SPECIFICATIONS (SDS) ..........87 Inspection and Adjustment - RS5F32A .....................87 GEAR END PLAY ....................................................87 CLEARANCE BETWEEN BAULK RING AND GEAR .....................................................................87 AVAILABLE CHECK PLUGS .....................................87 AVAILABLE SNAP RINGS ........................................87
MT-2
CLEARANCE BETWEEN BAULK RING AND GEAR .....................................................................90 AVAILABLE SNAP RINGS ........................................90 AVAILABLE C-RINGS ..............................................90 AVAILABLE ADJUSTING SHIMS ...............................91 AVAILABLE THRUST WASHER ................................92 AVAILABLE WASHERS ............................................92 AVAILABLE SHIMS - DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM ...........92
PREPARATION Special Service Tools
Special Service Tools Tool number Tool name
NCMT0001
Description
KV38107700 Preload adapter
Measuring turning torque of final drive assembly Measuring total turning torque Measuring clearance between side gear and differential case with washer Selecting differential side bearing adjusting shim (Use with KV38106000.)
NT087
KV38106000 Height gauge adapter (differential side bearing)
Selecting differential side bearing adjusting shim (Use with KV38107700 or KV38105900.) a: 140 mm (5.51 in) b: 40 mm (1.57 in) c: 16 mm (0.63 in) dia. d: M8 × 1.25P
NT418
KV32101000 Pin punch
Removing and installing retaining pin Removing and installing lock pin Removing selector shaft Removing welch plug a: 4 mm (0.16 in) dia. NT410
KV31100300 Pin punch
Removing and installing retaining pin a: 4.5 mm (0.177 in) dia.
NT410
ST30031000 Puller
NT411
Removing 3rd, 5th input gear Removing 3rd & 4th and 5th & Rev synchronizer hub Removing mainshaft rear bearing Removing 2nd gear, 5th gear bushing Removing 1st & 2nd synchronizer hub, 1st and 4th main gear Removing and installing differential side bearing a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia.
NT411
Removing input shaft front and rear bearing Installing input shaft front and rear bearing Installing 5th input gear, 3rd main gear and 4th main gear Installing 1st & 2nd, 3rd & 4th and 5th & Rev synchronizer hub Installing 2nd gear bush, 5th gear bush, Rev gear bushing Installing mainshaft rear bearing a: 110 mm (4.33 in) dia. b: 68 mm (2.68 in) dia.
ST30021000 Puller
ST22730000 Puller
Removing mainshaft front and rear bearing inner race (F31A) Removing 5th main gear
a: 82 mm (3.23 in) dia. b: 30 mm (1.18 in) dia.
NT411
MT-3
PREPARATION Special Service Tools (Cont’d) Tool number Tool name
Description Removing differential side bearing a: 49 mm (1.93 in) dia. b: 41 mm (1.61 in) dia.
ST35321000 Drift
NT073
I Removing idler gear bearing outer race a: 250 mm (9.84 in) b: 160 mm (6.30 in)
KV381054S0 Puller
NT414
ST33200000 Drift
Installing mainshaft front bearing outer race (F31A) Installing mainshaft front bearing (F32A) a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia. NT091
ST33230000 Drift
Removing differential oil seal Installing differential side bearing a: 51 mm (2.01 in) dia. b: 28.5 mm (1.122 in) dia.
NT084
ST33400001 Drift
Installing differential oil seal (F31A) a: 60 mm (2.36 in) dia. b: 47 mm (1.85 in) dia.
NT086
KV38102100 Drift
Installing differential oil seal a: 44 mm (1.73 in) dia. b: 24.5 mm (0.965 in) dia.
NT427
KV38100200 Drift
Installing differential oil seal a: 65 mm (2.56 in) dia. b: 49 mm (1.93 in) dia.
NT120
ST3072000 Drift
Installing side bearing outer race a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia.
NT115
MT-4
PREPARATION Special Service Tools (Cont’d) Tool number Tool name
Description Installing input shaft front and rear bearing a: 34 mm (1.34 in) dia. b: 28 mm (1.10 in) dia.
ST22350000 Drift
NT065
ST22360002 Drift
Installing mainshaft rear bearing inner race (F31A) a: 29 mm (1.14 in) dia. b: 23 mm (0.91 in) dia.
NT065
ST22452000 Drift
Installing 3rd and 4th main gear Installing 5th gear bush Installing 5th & Rev synchronizer hub Installing Rev gear bush Installing mainshft rear bearing a: 45 mm (1.77 in) dia. b: 36 mm (1.42 in) dia.
NT065
ST37750000 Drift
Installing input shaft oil seal Installing 5th synchronizer Installing mainshaft rear bearing Installing 5th main gear Installing 3rd & 4th synchronizer hub Installing striking rod oil seal Installing clutch housing dust seal a: 40 mm (1.57 in) dia. b: 31 mm (1.22 in) dia.
NT065
ST23860000 Drift
Installing 2nd gear bush a: 38 mm (1.50 in) dia. b: 33 mm (1.30 in) dia.
NT065
ST01530000 Drift
Installing 3rd & 4th and 1st & 2nd synchronizer hub Installing mainshaft front bearing a: 50 mm (1.97 in) dia. b: 41 mm (1.61 in) dia. NT065
KV38100130 Drift
Installing input shaft oil seal Installing 5th input gear a: 39 mm (1.54 in) dia. b: 30 mm (1.18 in) dia. NT065
ST30621000 Drift
Installing differential side bearing outer race (Use with ST30611000.) a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia.
NT073
KV31103000 Drift
Installing differential oil seal (F32A) Right and left sides (Use with ST35325000.) a: 56 mm (2.20 in) dia. b: 49 mm (1.93 in) dia. NT105
MT-5
PREPARATION Special Service Tools (Cont’d) Tool number Tool name
Description Removing input shaft rear bearing Removing mainshaft rear bearing a: 22 mm (0.87 in) dia. b: 28 mm (1.10 in) dia.
ST33052000 Drift
NT431
ST30611000 Drift handle
Installing differential side bearing outer race (Use with ST30621000.) a: 15 mm (0.59 in) b: 335 mm (13.19 in) c: 25 mm (0.98 in) dia. d: M12 × 1.5P NT419
ST35325000 Drift handle
Installing differential oil seal (F32A) (Use with KV31103000.) a: 215 mm (8.46 in) b: 25 mm (0.98 in) dia. c: M12 × 1.5P
NT417
Commercial Service Tools Tool name
Description
Puller
Removing input shaft front bearing (F31A) Removing mainshaft rear bearing (F32A)
NT077
Drift
Installing differential side bearing inner race a: 12 mm (0.47 in) dia. b: 10 mm (0.39 in) dia.
NT065
Drift
Installing mainshaft front bearing inner race a: 26 mm (1.02 in) dia. b: 21 mm (0.83 in) dia. (F30A) a: 31 mm (1.22 in) dia. b: 26 mm (1.02 in) dia. (F32A) NT065
Drift
Installing differential side bearing inner race (F31A and F32A) a: 56 mm (2.20 in) dia. b: 50.5 mm (1.988 in) dia. NT065
Drift
Installing striking rod oil seal (F31A and F32A) a: 38 mm (1.50 in) dia. b: 32 mm (1.26 in) dia. NT065
MT-6
NCMT0002
2
O-RING (Worn or damaged)
MT-15, 48
CONTROL ROD (Worn)
MT-14, 47
2
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
MT-17, 50
3
SHIFT FORK (Worn)
MT-17, 50
3
3
GEAR (Worn or damaged)
MT-16, 49
3
BEARING (Worn or damaged)
MT-16, 49
3
BAULK RING (Worn or damaged)
MT-16, 49
3
INSERT SPRING, SHIFTING INSERT (Damaged)
MT-16, 49
1 2
1
NCMT0003
MT-15, 48
NVH Troubleshooting Chart
2
OIL SEAL (Worn or damaged)
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
2
MT-15, 48
NCMT0003S01
1
GASKET (Damaged)
MT-7
(Oil level is high.)
NVH Troubleshooting Chart
2
Refer to MA section (“Checking M/T Oil”, “CHASSIS AND BODY MAINTENANCE”).
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.
1 3
1
(Wrong oil)
Reference page
Noise
Oil leakage
Hard to shift or will not shift
SUSPECTED PARTS (Possible cause)
Symptom Jumps out of gear
(Oil level is low.)
ON-VEHICLE SERVICE Replacing Oil Seal
Replacing Oil Seal ST33290001
NCMT0005
DIFFERENTIAL OIL SEAL
NCMT0005S01
1. 2. 3.
Drain gear oil from transaxle. Remove drive shafts — Refer to section FA. Remove differential oil seal.
4. I
Install differential oil seal. Apply multi-purpose grease to seal lip of oil seal before installing. Install drive shafts — Refer to section FA.
SMT563A
Drift
5.
.
Drift: LH side ST33400001 (F31A) KV31103000 and ST35325000 (F32A & F32V) RH side ST30720000 (F31A) LH and RH side KV38100200 (F70A) SMT564AB F32A Transmission case side
Clutch housing side
I
Install differential oil seal so that dimension “A” and “B” are within specifications. Unit: mm (in)
Oil seal
Item
A
F32A
5.9 - 6.1 (0.232 - 0.240)
F70A
0.5 (0.020) or less
B 0.5 (0.020) or less
SMT738B F70A Transaxle case side
Clutch housing side
Differential oil seal
Differential oil seal
SMT869D
STRIKING ROD OIL SEAL KV32101000
1. 2. I
Remove transaxle control rod from yoke. Remove retaining pin of yoke. Be careful not to damage boot.
SMT565A
MT-8
NCMT0005S02
ON-VEHICLE SERVICE Replacing Oil Seal (Cont’d) Drift
3.
Remove striking rod oil seal.
4. I
Install striking rod oil seal. Apply multi-purpose grease to seal lip of oil seal before installing.
SMT566A
Drift
SMT570A
Position Switch Check
F31A and F32A
NCMT0006
BACK-UP LAMP SWITCH I Neutral position switch connector
Back-up lamp switch harness connector
SMT715B
F70A Back-up lamp switch harness connector
Neutral position switch harness connector
NCMT0006S01
Check continuity Gear Position
Continuity
Reverse
Yes
Except reverse
No
NEUTRAL POSITION SWITCH I
NCMT0006S02
Check continuity. Gear position
Continuity
Neutral
Yes
Except neutral
No
NMT090
MT-9
REMOVAL AND INSTALLATION Removal
Removal 1. 2. 3. 4. 5.
Front
.
.
SMT653B
6.
Remove starter motor from transaxle.
7. 8. 9.
Remove shift control rod and support rod from transaxle. Drain gear oil from transaxle. Remove exhaust front tube.
Starter motor
Front .
NCMT0007S01
Remove battery negative terminal. Remove air duct. Disconnect clutch control cable from transaxle (GA16 models). Remove clutch operating cylinder from transaxle (except GA16 models). Disconnect back-up lamp switch, speedometer sensor, neutral position switch and ground harness connectors.
SMT654B
F31A and F32A Shift control rod
Shift support rod
SMT655B .
F70A .
Support rod
.
Control rod
NMT091
10. Draw out drive shafts from transaxle — Refer to section FA. Knuckle spindle upper nut
Drive shaft
SMT656B
MT-10
REMOVAL AND INSTALLATION Removal (Cont’d) .
11. Supprt engine by placing a jack under oil pan. CAUTION: Do not place jack under oil pan drain plug. 12. Remove rear and LH mounts.
F31A and F32A
SMT657B .
F70A
NMT092
13. Raise jack for access to lower housing bolts. Remove bolts. Lower jack.
Center member
Front
SMT658B
MT-11
REMOVAL AND INSTALLATION Installation
14. Remove bolts securing transaxle. 15. Lower transaxle while supporting it with a jack.
SMT659B
Installation I Tighten bolts securing transaxle. QG engine models:
NCMT0007S02
Bolt No.
Tightening torque N·m (kg-m, ft-lb)
in mm (in)
1
30 - 40 (3.1 - 4.1, 22 - 30)
70 (2.76)
2
30 - 40 (3.1 - 4.1, 22 - 30)
80 (3.15)
3
16 - 21 (1.6 - 2.1, 12 - 15)
25 (0.98)
4
30 - 40 (3.1 - 4.1, 22 - 30)
30 (1.18)
Bolt No.
Tightening torque N·m (kg-m, ft-lb)
in mm (in)
1
70 - 79 (7.1 - 8.1, 51 - 59)
55 (2.17)
2
70 - 79 (7.1 - 8.1, 51 - 59)
65 (2.56)
3
30 - 40 (3.1 - 4.1, 22 - 30)
35 (1.38)
4
30 - 40 (3.1 - 4.1, 22 - 30)
45 (1.77)
NMT094
SR engine models: : M/T to engine : Engine to M/T
SMT661B
CD20T engine models: M/T to engine Engine (gusset) to M/T
Bolt No.
Tightening torque N·m (kg-m, ft-lb)
in mm (in)
1
30 - 40 (3.1 - 4.1, 22 - 30)
120 (4.72)
2
30 - 40 (3.1 - 4.1, 22 - 30)
85 (3.35)
3
64 - 74 (6.5 - 7.5, 47.2 - 54.6)
75 (2.95)
4
16 - 21 (1.6 - 2.1, 12 - 15)
30 (1.18)
5
16 - 21 (1.6 - 2.1, 12 - 15)
25 (0.98)
Front gusset to engine
30 - 40 (3.1 - 4.1, 22 - 30)
35 (1.38)
Rear gusset to engine
30 - 40 (3.1 - 4.1, 22 - 30)
M10 × 1.25 (nut)
SMT740A
MT-12
DESCRIPTION
RS5F32A Cross-sectional View
Cross-sectional View
SMT123D
MT-13
RS5F32A
MAJOR OVERHAUL Transaxle Gear Control
Transaxle Gear Control SEC. 341
4.4 - 5.9 (0.45 - 0.60, 39.1 - 52.1)
12 - 15 (1.2 - 1.5, 9 - 11)
12 - 15 (1.2 - 1.5, 9 - 11)
22 - 29 (2.2 - 3.0, 16 - 22)
43 - 55 (4.4 - 5.6, 32 - 41)
18 - 24 (1.8 - 2.4, 13 - 17)
: Apply multi purpose grease : N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) 14 - 18 (1.4 - 1.8, 10 - 13) NMT097 1 p 2 p 3 p 4 p 5 p 6 p
Control lever knob Boot Control lever socket Control lever Bushing Hand lever socket
7 p 8 p 9 p 10 p 11 p 12 p
Plate bolt Transaxle hole cover Support rod Plate Collar Bushing
MT-14
13 p 14 p 15 p 16 p 17 p 18 p
Collar Bushing Control rod Return spring Holder bracket Dynamic damper
MAJOR OVERHAUL
RS5F32A Case Components
Case Components
YMT004
MT-15
Input shaft front bearing 5th gear needle bearing 5th input gear Baulk ring
Coupling sleeve Spread ring Input shaft
MT-16
: N·m (kg-m, ft-lb) ★ : Select correct thickness L : Apply locking sealant p ✩ : Ensure correct direction ° : Apply gear oil : Do not re-use : Apply gear oil
3rd & 4th synchronizer hub Insert spring Baulk ring 4th main gear 4th gear bushing 5th main gear Spacer ★ Mainshaft rear bering C-ring ★ C-ring holder Snap ring Differential side bearing adjusting shim ★ Snap ring Differential side bearing L p
Snap ring ★ Mainshaft 1st main gear
Steel ball
Mainshaft front bearing
Pinion mate shaft Thrust washer
Pinion mate shaft . Side gear Thrust washer ★
2nd outer baulk ring 2nd gear synchronizer cone 2nd inner baulk. ring Speedometer drive gear Speedometer stopper Differential side bearing Differential case
Retaining pin 98 - 100 (10.0 - 11.0, 72 - 80)
Final gear
3rd gear synchronizer cone 3rd outer baulk ring Coupling sleeve
.
Spacer
Baulk ring 1st gear needle bearing . Reverse main gear (Coupling sleeve) ✩ Insert spring 1st & 2nd synchronizer hub
2nd main gear 2nd & 3rd bushing ° 5th gear synchronizer hub Spread ring 3rd main gear 5th stopper . 3rd inner baulk ring Snap ring ★ Input shaft bearing
Insert spring
Reverse idler spacer
Reverse idler gear Reverse idler bushing
MAJOR OVERHAUL RS5F32A
Gear Components
Gear Components
SEC. 322
NMT024
RS5F32A
MAJOR OVERHAUL
Shift Control Components
Shift Control Components SEC. 328
.
6.3 - 8.3 (0.64 0.85, 55.6 - 73.8) 12 - 16 (1.2 - 1.6, 9 - 12)
.
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
.
: Apply gear oil : Do not re-use : N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) L : p
★: ✩:
Apply locking sealant Select correct length Select correct part. Adjustment required NMT025
1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p
Check plunger Select return spring O-ring Check sleeve Striking lever Snap ring Striking interlock Reverse brake cam Reverse brake cam spring Check ball plug
11 p 12 p 13 p 14 p 15 p 16 p 17 p 18 p 19 p 20 p
Shift check ball Check spring Fork shaft support spring Fork shaft 5th shift fork Shifter cap 3rd & 4th shift fork Shifter cap 1st & 2nd shift fork Control bracket
MT-17
21 p 22 p 23 p 24 p 25 p 26 p 27 p 28 p 29 p
Control bracket pin Retaining pin Striking rod Retaining pin Yoke Reverse check plug Check ball (Large) Check ball (Small) Stopper pin
DISASSEMBLY
RS5F32A
1.
Remove case cover.
2.
Remove mainshaft bearing snap ring.
3.
Remove transmission case while slightly tilting it to prevent 5th shift fork from interfering with case.
4.
Draw out reverse idler spacer and fork shaft.
5. I
Remove 5th and 3rd & 4th shift forks. Be careful not to lose shifter cap.
Case cover
SMT664B
Snap ring
SMT665B
SMT666B
Fork shaft
SMT667B
5th shift fork
3rd & 4th shift fork
SMT188A
MT-18
DISASSEMBLY
.
RS5F32A
6.
Remove control bracket with 1st & 2nd shift fork.
7. a.
Remove gear components from clutch housing. Remove input shaft front bearing retainer securing bolts.
b.
Remove input shaft with bearing retainer, mainshaft assembly and reverse idler gear. Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side. Do not draw out reverse idler shaft from clutch housing because these fittings will be loose. When removing input shaft, be careful not to scratch oil seal lip with shaft spline.
1st & 2nd shift fork
Control bracket
SMT668B
Bearing retainer SMT669B
I I
SMT670B
c.
Remove final drive assembly.
8.
Remove oil pocket, shift check ball, check spring and check ball plug. Be careful not to lose check ball.
SMT671B
Check spring
I
Shift check ball Check ball plug
SMT648A
MT-19
DISASSEMBLY 9. KV320101000
I
RS5F32A
Drive retaining pin out of striking lever, then remove striking rod, striking lever and striking interlock. Ensure striking lever is positioned so that retaining pin does not foul clutch housing during removal.
SMT599A
I Oil seal
Be careful not to damage oil seal lip, when removing striking rod. If necessary, tape edges of striking rod.
SMT583
10. Remove reverse check plug, then detach reverse check spring and check balls. I Be careful not to lose check balls. I If the smaller ball does not come out, remove it together with check sleeve assembly.
SMT584
11. Remove check sleeve assembly.
SMT585
MT-20
RS5F32A
REPAIR FOR COMPONENT PARTS
Input Shaft and Gears
Input Shaft and Gears DISASSEMBLY 1.
Before disassembly, check 5th input gear end play.
Feeler gauge
Gears
End play mm (in)
5th input gear
0.18 - 0.31 (0.0071 - 0.0122)
End play Gear
Needle bearing
I
If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring groove — Refer to “Assembly”.
2.
Remove snap ring and 5th stopper.
3.
Remove 5th synchronizer, 5th input gear and 5th gear needle bearing.
4.
Remove snap ring of input shaft front bearing and input gear spacer.
SMT734A
SMT673B
5th input gear Set tool below 5th input gear 5th synchronizer hub ST30021000
SMT417CA
Snap ring
Spacer
Input shaft front bearing
SMT674B
MT-21
REPAIR FOR COMPONENT PARTS
RS5F32A
Input Shaft and Gears (Cont’d)
5. 6.
Pull out input shaft front bearing. Remove bearing retainer.
Puller
Bearing retainer Vise SMT675B
INSPECTION Gear and shaft I Check shaft for cracks, wear or bending. I Check gears for excessive wear, chips or cracks.
SMT602A
Synchronizer
Shifting insert
Spline area
I I I
Check spline area of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for wear or deformation.
NMT022
I
Baulk ring to gear clearance
Measure clearance between baulk ring and gear. Clearance between baulk ring and 5th input gear: Standard 1.0 - 1.35 mm (0.0394 - 0.0531 in) Wear limit 0.7 mm (0.028 in)
SMT140
Bearing ● Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
SMT148A
MT-22
REPAIR FOR COMPONENT PARTS
RS5F32A Input Shaft and Gears (Cont’d)
ASSEMBLY 1.
Assemble 5th synchronizer.
I
Be careful not to hook front and rear ends of spread spring to the same shifting insert.
2. 3. 4.
Install bearing retainer. Press on input shaft front bearing. Install input gear spacer.
SMT736A
Spread spring
Shifting insert
SMT761B
ST22350000
Bearing retainer
SMT731
5. Snap ring
Select correct snap ring of input shaft front bearing to minimize clearance of groove in input shaft and then install it. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Snap rings of input shaft front bearing: Refer to SDS, MT-87.
SMT708B
6. 7.
ST37750000
Install 5th gear needle bearing, 5th input gear, 5th synchronizer and 5th stopper. Measure gear end play as a final check — Refer to “Disassembly”.
5th synchronizer hub
SMT779A
MT-23
RS5F32A
REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Cont’d)
8.
Select correct snap ring of 5th synchronizer hub to minimize clearance of groove in input shaft and install it. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Snap rings of 5th synchronizer: Refer to SDS, MT-87.
5th stopper Snap ring
SMT591
Mainshaft and Gears
End play
DISASSEMBLY
Gear
Feeler gauge
1. Before disassembly, measure gear end play. Gear end play:
Needle bearing or bushing
Gears
End play mm (in)
1st main gear
0.18 - 0.31 (0.0071 - 0.0122)
2nd-4th main gear
0.20 - 0.30 (0.0079 - 0.0118)
SMT605
●
If end play is not within the specified limit, disassemble and check the parts.
2.
Remove mainshaft rear bearing snap ring, C-ring holder and C-rings.
Snap ring
C-ring holder
SMT709B
Snap ring C-ring holder C-ring
Bearing
SMT676B
MT-24
RS5F32A
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont’d)
3.
Remove mainshaft bearing and spacer.
4.
Remove 5th main gear.
5. I
Remove 4th main gear, 4th gear bushing and steel ball. Take care not to lose steel ball.
6.
Remove 3rd & 4th synchronizer and 3rd main gear.
Puller Suitable drift Mainshaft bearing
Spacer
SMT677B
ST22730000
Hook tool under flange as indicated by arrows
SMT593
4th main gear
Bushing
Steel ball
SMT418C
Drift
SMT679B
MT-25
REPAIR FOR COMPONENT PARTS
RS5F32A
Mainshaft and Gears (Cont’d)
7. I
Remove 2nd & 3rd bushing and 2nd gear. Take care not to lose the steel ball.
8.
Remove 1st & 2nd synchronizer hub and 1st main gear.
SMT740B
Drift
SMT681B
INSPECTION Gear and shaft I I
Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.
SMT604A
MT-26
REPAIR FOR COMPONENT PARTS
RS5F32A Mainshaft and Gears (Cont’d)
Synchronizer
Shifting insert
Spline area
I I I
Check spline area of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for deformation.
NMT022
I
Baulk ring to gear clearance
I
Measure clearance between baulk ring and gear. Clearance between baulk rings and gears, for 1st and 4th gears only: Standard 1.0 - 1.35 mm (0.0394 - 0.0531 in) Wear limit 0.7 mm (0.028 in) 2nd and 3rd gears have inner and outer baulk rings and so have different measurements.
SMT140
I a. b.
c.
Inner baulk ring
Measure wear of 2nd and 3rd baulk ring. Place baulk rings in position on synchronizer cone. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions “A” and “B”. Standard: A 0.7 - 0.9 mm (0.028 - 0.035 in) B 0.6 - 1.1 mm (0.024 - 0.043 in) Wear limit: 0.2 mm (0.008 in) If dimension “A” or “B” is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.
Synchronizer cone
SMT695B
MT-27
REPAIR FOR COMPONENT PARTS
RS5F32A
Mainshaft and Gears (Cont’d)
Outer baulk ring
Synchronizer cone SMT682B
Bearing I I
Make sure bearings roll freely and are free from noise, cracks, pitting or wear. The mainshaft front bearing cannot be re-used. It must be replaced once removed.
SPD715
ASSEMBLY 1. 2.
Install 1st gear needle bearing, 1st main gear and baulk ring. Press on 1st & 2nd synchronizer hub.
ST22452000
SMT689B
MT-28
REPAIR FOR COMPONENT PARTS
RS5F32A Mainshaft and Gears (Cont’d)
1st gear
I
Ensure correct fitting of 1st & 2nd synchronizer hub.
3.
Install 2nd synchronizer cone, outer & inner baulk ring and 1st & 2nd coupling sleeve.
4. I I
Install steel ball, 2nd main gear, 2nd & 3rd bushing. Apply gear oil to 2nd & 3rd gear bushing. Apply multi-purpose grease to steel ball before installing it. 2nd & 3rd bushing has a groove in which steel ball fits.
2nd gear
SMT701B
SMT683B
2nd & 3rd gear bushing 2nd gear
I
Steel ball
SMT680B
MT-29
REPAIR FOR COMPONENT PARTS
RS5F32A
Mainshaft and Gears (Cont’d)
5. 6.
Install 3rd main gear, synchronizer cone, and outer & inner baulk ring. Press on 3rd & 4th synchronizer hub.
7. I
Install 3rd & 4th coupling sleeve and 4th baulk ring. Ensure correct fitting of 3rd & 4th synchronizer hub.
8. I
Install steel ball, 4th bushing and 4th main gear. Apply multi-purpose grease to steel ball before installing it. 4th bushing has a groove in which steel ball fits.
ST37750000
SMT690B
4th gear
3rd gear
SMT702B
I
Steel ball
SMT691B
MT-30
REPAIR FOR COMPONENT PARTS
RS5F32A Mainshaft and Gears (Cont’d)
9.
Press on 5th main gear.
ST37750000
SMT692B
Mainshaft rear bearing Mainshaft adjusting spacer
Mainshaft
10. Install spacer and measure distance “C”. 11. Select proper mainshaft bearing spacer to give correct bearing distance. Bearing distance “C”: 230.15 - 230.25 mm (9.0610 - 9.0649 in) Spacers available: Refer to SDS, MT-88.
SMT693B
12. Press on mainshaft rear bearing.
ST22360002
SMT694B
MT-31
REPAIR FOR COMPONENT PARTS
RS5F32A
Mainshaft and Gears (Cont’d)
13. Select proper C-ring to minimize clearance of groove in mainshaft and install it. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Mainshaft C-rings: Refer to SDS, MT-87.
Snap ring C-ring holder C-ring
Bearing
SMT676B
14. Install C-ring holder and snap ring. 15. Measure gear end play as a final check — Refer to “Disassembly”. C-ring
SMT712B
Final Drive DISASSEMBLY
ST30031000
Drift
1.
Remove final gear.
2. 3. I
Remove speedometer drive gear by cutting it. Press out differential side bearings. Be careful not to mix up the right and left bearings.
4. 5.
Drive out retaining pin and draw out pinion mate shaft. Remove pinion mate gears and side gears.
SMT647A
SMT699B
MT-32
REPAIR FOR COMPONENT PARTS
RS5F32A Final Drive (Cont’d)
INSPECTION Gear, washer, shaft and case I I
Check mating surfaces of differential case, side gears and pinion mate gears. Check washers for wear.
SMT083A
Bearing I I
Make sure bearings roll freely and are free from noise, cracks, pitting or wear. When replacing tapered roller bearing, replace outer and inner race as a set.
SPD715
ASSEMBLY 1.
Attach side gear thrust washers to side gears, then install pinion mate washers and pinion mate gears in place.
2. I
Insert pinion mate shaft. When inserting, be careful not to damage pinion mate thrust washers.
3.
Measure clearance between side gear and differential case with washers using the following procedure: Set Tool and dial indicator on side gear. Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears. Clearance between side gear and differential case with washers: 0.1 - 0.2 mm (0.004 - 0.008 in) If not within specification, adjust clearance by changing thickness of side gear thrust washers.
SMT839
SMT840
Dial gauge
KV38107700
a. b.
c. SMT610A
MT-33
REPAIR FOR COMPONENT PARTS
RS5F32A
Final Drive (Cont’d)
Side gear thrust washers: Refer to SDS, MT-88.
SMT611A
4. I
Install retaining pin. Make sure that retaining pin is flush with case.
5. I 6.
Install final gear. Apply locking sealant to final gear fixing bolts before installing them. Install speedometer drive gear.
7.
Press on differential side bearings.
SMT699B
Chamfer
SMT609A
Drift
SMT648
MT-34
REPAIR FOR COMPONENT PARTS
RS5F32A Shift Control Components
Shift Control Components
Striking rod
INSPECTION I
Check contact surface and sliding surface for wear, scratches, projections or other damage.
Control bracket
Shift fork and shifter cap
SMT703B
SMT727B
MT-35
REPAIR FOR COMPONENT PARTS
RS5F32A
Shift Control Components (Cont’d)
ADJUSTMENT OF INPUT SHAFT BRAKING MECHANISM 1. I
Control bracket
Install striking lever & rod, striking interlock assembly and control bracket on clutch housing exactly. When installing control bracket on clutch housing, assure protrusion beneath bracket is correctly seated.
Clutch housing SMT774B
2.
Measure maximum height “H” while shifting from neutral to reverse position. Maximum height “H”: 67.16 - 67.64 mm (2.6441 - 2.6630 in)
3. 4.
Remove control bracket from clutch housing. Measure clearance “C” between reverse brake cam and striking lever at reverse position. Clearance “C”: 0.05 - 0.125 mm (0.0020 - 0.0044 in) If height “H” and clearance “C” are not within specifications, replace control bracket, striking lever and striking interlock assembly as a set.
1st & 2nd shifter
Height gauge
1st & 2nd shifter Striking lever
Control bracket fitting surface
.
Reverse brake cam SMT728B
5.
Reverse brake cam Striking lever
SMT729B
MT-36
REPAIR FOR COMPONENT PARTS
RS5F32A Case Components
Case Components REMOVAL AND INSTALLATION Input shaft oil seal
Drift SMT660A
I
Apply multi-purpose grease to seal lip of oil seal before installing.
KV38102100
SMT751BA
Input shaft rear bearing 1.
Remove welch plug from transmission case.
2.
Remove input shaft rear bearing by tapping it from welch plug hole.
3. I
Install welch plug. Apply recommended sealant to mating surface of transmission case.
SMT705B
SMT704B
SMT705B
MT-37
REPAIR FOR COMPONENT PARTS
RS5F32A
Case Components (Cont’d)
4.
Install input shaft rear bearing.
SMT706B
Mainshaft front bearing and oil channel 1.
Remove mainshaft front bearing retainer.
2. 3.
Remove mainshaft front bearing. Remove oil channel.
4. I
Install oil channel. Ensure that oil groove in oil channel always faces toward oil pocket when installing it on clutch housing.
5. 6. I
Install mainshaft front bearing. Install mainshaft front bearing retainer. Apply locking sealant to thread of screw before installation.
Bearing retainer
SMT707B
Mainshaft front bearing SMT714B
Toward oil pocket
Oil groove
SMT595
Drift SMT752BA
MT-38
RS5F32A
ADJUSTMENT
Differential Side Bearing Preload
Differential Side Bearing Preload If any of the following parts are replaced, adjust differential side bearing preload. I Differential case I Differential side bearing I Clutch housing I Transmission case
1.
Remove differential side bearing outer race (transmission case side) and shim.
2. 3. 4. I
Reinstall differential side bearing outer race without shim. Install final drive assembly on clutch housing. Install transmission case on clutch housing. Tighten transmission case fixing bolts to the specified torque.
ST33290001
SMT645
SMT646A
5. Set dial indicator on front end of differential case. 6. Insert Tool all the way into differential side gear. 7. Move Tool up and down and measure dial indicator deflection. 8. Select shim of proper thickness using SDS table as a guide. Differential side bearing adjusting shims: Refer to SDS MT-88.
KV38106000
KV38107700
SMT454
MT-39
ADJUSTMENT
RS5F32A
Differential Side Bearing Preload (Cont’d)
9. 10. a. b. I
Install selected shim and differential side bearing outer race. Check differential side bearing turning torque. Install final drive assembly on clutch housing. Install transmission case on clutch housing. Tighten transmission case fixing bolts to the specified torque. Page MT-15
c.
Measure turning torque of final drive assembly. Turning torque of final drive assembly (New bearing): 2.9 - 6.9 N·m (30 - 70 kg-cm, 26 - 61 in-lb) When old bearing is used again, turning torque will be slightly less than the above. Make sure torque is close to the specified range. Changes in turning torque of final drive assembly per revolution should be within 1.0 N·m (10 kg-cm, 8.7 in-lb) without binding.
KV38107700
I I I SMT600
MT-40
ASSEMBLY Cellophane tape
Striking rod
RS5F32A
1. I
Install striking rod, lever and interlock. When inserting striking rod into clutch housing, tape edges of striking rod to avoid damaging oil seal lip.
2. 3.
Install reverse check sleeve assembly. Install check balls, reverse check spring and reverse check plug.
Oil seal SMT586
SMT584
4. Suitable bar
Vice
SMT688
Check spring
Check reverse check force. Reverse check force: 4.9 - 7.4 N·m (50 - 75 kg-cm, 43 - 65 in-lb) I If not within specification, select another check plug having a different length and reinstall it. Available reverse check plugs: Refer to SDS MT-87. 5. Install selected reverse check plug. I Apply locking sealant to thread of plug before installing it. 6. 7.
Install check ball plug, shift check ball and check spring. Install oil pocket.
8. a.
Install gear components onto clutch housing. Install final drive assembly.
Shift check ball Check ball plug
SMT648A
SMT671B
MT-41
ASSEMBLY b. I I
RS5F32A
Install input shaft assembly with bearing retainer, mainshaft assembly and reverse idler gear. Be careful not to damage oil seal lip with splines of input shaft while shaft is being inserted into clutch housing. Be careful not to damage oil channel when inserting mainshaft into clutch housing.
.
SMT670B
c.
Install input shaft front bearing retainer.
9.
Apply grease to shifter caps, then install it to control bracket. Install control bracket with 1st & 2nd shift fork.
Bearing retainer .
SMT669B
SMT666
I
Ensure control bracket is seated correctly on clutch housing. 10. Install 3rd & 4th and 5th shift forks. Control bracket
Clutch housing SMT774B
11. Insert fork shaft. I Apply multi-purpose grease to support spring before installing. 12. Install reverse idler spacer.
SMT596
MT-42
ASSEMBLY Apply sealant continuously
RS5F32A
13. Apply recommended sealant to mating surface of clutch housing.
SMT587
14. Install transmission case on clutch housing.
SMT666B
15. Install mainshaft front bearing snap ring.
Snap ring
SMT665B
16. Tap mainshaft with a soft hammer to ensure mainshaft rear bearing snap ring contacts the surface of transmission case.
SMT758B
MT-43
ASSEMBLY
RS5F32A
17. Select case cover using the following procedure. a. Measure distance between case cover fitting surface and mainshaft rear bearing outer race. Clearance “C” between the end of case cover and main shaft rear bearing outer race (Main shaft end play): 0 - 0.1 mm (0 - 0.004 in) b. Select case cover so that clearance “C” will be specified clearance. Case cover: Refer to SDS MT-89.
Case cover
Thickness of cover
End play
SMT775B
18. Install O-ring and case cover on transmission case. I Apply recommended sealant to mating surface of transmission case.
Case cover
SMT664B
MT-44
NCMT0004
RS5F70A
DESCRIPTION
Cross-sectional View
Cross-sectional View
NCMT0004S01
Clutch housing 3rd input gear 3rd & 4th synchronizer 4th input gear 5th input gear Reverse idler gear Input shaft front bearing
Input shaft rear bearing
Input shaft
Mainshaft Mainshaft rear bearing .
Mainshaft front bearing
Sub-gear
Reverse main gear 5th & reverse synchronizer assembly 5th main gear 4th main gear
3rd main gear 2nd main gear Differential side bearing
1st & 2nd synchronizer assembly 1st main gear
Speedometer drive gear
Differential side bearing
Differential case Final gear
SMT834D
MT-45
DESCRIPTION
RS5F70A
Cross-sectional View (Cont’d)
DOUBLE-CONE SYNCHRONIZER 2nd main gear
NCMT0004S0101
Double-cone synchronizer is adopted for 1st and 2nd gears to reduce operating force of the shift lever.
Clutch gear coupling Sleeve Synchronizer hub
Outer baulk ring Synchronizer cone Inner baulk ring SMT837D
MT-46
NCMT0008
RS5F70A
MAJOR OVERHAUL
Transaxle Gear Control
Transaxle Gear Control
NCMT0008S01
4.4 - 5.9 (0.45 - 0.60, 39 - 52)
12 - 15 (1.2 - 1.5, 9 - 11) 22 - 29 (2.2 - 3.0, 16 - 22)
18 -24 (1.8 -2.4, 13 - 17)
12 - 15 (1.2 - 1.5, 9 - 11) Apply multi-purpose grease. N·m (kg-m, in-lb) N·m (kg-m, ft-lb)
29 - 37 (3.0 - 3.8, 21 - 27)
1. 2. 3. 4. 5. 6. 7.
Control lever knob Boot Finisher Control lever bracket Dust cover Socket Control lever
14 - 18 (1.4 - 1.8, 10 -13)
8. 9. 10. 11. 12. 13. 14.
O-ring O-ring Ring spring Bearing seat Seat Return spring Control rod
MT-47
SMT135D
15. 16. 17. 18. 19. 20. 21.
Bush Collar Bush Bracket Bush Collar Washer
RS5F70A
MAJOR OVERHAUL Case Components
Case Components
=NCMT0008S02
3.7 - 5.0 (0.38 - 0.51, 33 - 44)
16 - 22 (1.6 - 2.1, 12 - 16)
6.3 - 8.3 (0.64 - 0.85, 56 - 74)
23 - 33 (2.3 - 3.4, 17 - 25) 10 - 19 (1.0 - 2.0, 87 - 174)
7.4 - 9.7 (0.75 - 0.99, 65 - 86)
N·m (kg-m, in-lb) N·m (kg-m, ft-lb) Apply genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
29 - 33 (3.0 - 3.4, 22 - 25) 23 - 33 (2.3 - 3.4, 17 - 25)
7.4 - 9.7 (0.75 - 0.99, 65 - 86)
Apply locking sealant. Apply gear oil. Select with proper thickness.
25 - 34 (2.5 - 3.5, 18 - 25)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Clutch housing Welch plug Oil pocket Check plug Input shaft oil seal Oil channel Mainshaft front bearing Bearing retainer Magnet Reverse idler gear rear thrust washer 11. Reverse idler gear 12. Reverse idler gear bearing
13. Reverse idler gear front thrust washer 14. O-ring 15. Reverse idler gear shaft 16. Snap ring 17. Reverse switch 18. Filler plug 19. Side cover gasket 20. Side cover 21. Welch plug 22. Mainshaft bearing snap ring 23. Mainshaft bearing adjusting shim 24. O-ring
MT-48
SMT640D
25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38.
Rear cover Differential oil seal Drain plug PNP switch Transmission case Oil gutter Welch plug Magnet Boot Striking rod oil seal Welch plug Differential oil seal O-ring Speedometer pinion (If so equipped)
RS5F70A
MAJOR OVERHAUL
Gear Components
Gear Components
=NCMT0008S03
Apply gear oil. Select with proper thickness. SMT641D
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Reverse idler gear rear thrust washer Reverse idler gear Reverse idler gear bearing Reverse idler gear front thrust washer O-ring Reverse idler gear shaft Snap ring Input shaft front bearing Input shaft 3rd gear needle bearing 3rd input gear 3rd gear baulk ring Coupling sleeve Spread spring Shifting insert Coupling sleeve Spread spring 4th gear C-ring 4th gear needle bearing 4th gear baulk ring 4th input gear 5th gear front C-ring 5th input gear
24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.
5th gear rear C-ring C-ring holder Input shaft rear bearing Oil channel Input shaft rear bearing adjusting shim Mainshaft front bearing Mainshaft 1st gear needle bearing 1st main gear 1st inner baulk ring 1st synchronizer cone 1st outer baulk ring 1st & 2nd synchronizer hub Coupling sleeve Insert spring 2nd gear bushing 2nd gear needle bearing 2nd gear outer baulk ring 2nd gear synchronizer cone 2nd inner baulk ring 2nd main gear 3rd main gear Spacer
MT-49
47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69.
Mainshaft adjusting shim 4th main gear 5th gear bushing 5th gear needle bearing 5th main gear 5th gear baulk ring Spread spring Shifting insert 5th & reverse synchronizer hub Spread spring Coupling sleeve Reverse gear bush Reverse gear needle bearing Reverse gear baulk ring Reverse main gear Sub-gear Sub-gear washer Snap ring Mainshaft thrust washer Mainshaft rear bearing Mainshaft C-ring C-ring holder Snap ring
RS5F70A
MAJOR OVERHAUL Shift Control Components
Shift Control Components
=NCMT0008S04
16 - 21 (1.6 -2.1, 12 - 15)
N·m (kg-m, ft-lb) Apply genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
16 - 22 (1.6 - 2.2, 12 - 16)
16 - 21 (1.6 - 2.1, 12 - 15)
Apply gear oil.
16 - 21 (1.6 - 2.1, 12 - 15)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Clutch housing 3rd & 4th bracket 3rd & 4th shift fork Retaining pin Check ball Check pin Check spring Check plug Stopper ring 3rd & 4th fork rod Selector shaft pin Selector 5th & reverse bracket Reverse switch bracket Retaining pin 5th & reverse shift fork
17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
SMT642D
Interlock plunger Check ball Interlock pin Stopper ring 5th & reverse fork rod Striking lever Retaining pin 1st & 2nd bracket 1st & 2nd shift fork Check ball 1st & 2nd fork rod Transaxle case Check ball Check spring Check plug
MT-50
32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.
Reverse gate Return spring Steel ball Reverse gate Return bearing Selector arm Bushing Welch plug Selector shaft Striking yoke Retaining pin Striking rod Dust boot Striking rod oil seal Welch plug
RS5F70A
MAJOR OVERHAUL
Final Drive Components
Final Drive Components Apply locking sealant
=NCMT0008S05
98 - 108 (10.0 - 11.0, 72 - 80)
N·m (kg-m, ft-lb) Select with proper thickness.
SMT643D
1. 2. 3. 4. 5.
Differential shim Differential Differential Final gear Differential
side bearing adjusting side bearing outer race side bearing
6. 7. 8. 9. 10.
Speedometer drive gear Speedometer stopper Differential side bearing Differential side bearing outer race Pinion mate thrust washer
case
MT-51
11. 12. 13. 14. 15.
Pinion mate gear Side gear thrust washer Side gear Pinion mate shaft Lock pin
NCMT0009
DISASSEMBLY
RS5F70A
Transaxle Case
Transaxle Case
Reverse switch PNP switch
Filler plug
NCMT0009S01
1.
Remove reverse switch, PNP switch, drain plug, and filler plug from transaxle case.
2. 3. 4.
Remove snap rings from reverse idler shaft. Remove side cover and rear cover from case. Remove O-ring and mainshaft bearing adjusting shim.
5. a. b.
Remove reverse idler gear shaft. Attach bolt (M6) to thread of reverse idler gear shaft end. Pull out the attached bolt, and remove reverse idler gear shaft from case. Remove reverse idler gear, thrust washer, and bearing from case.
Drain plug SMT648D Snap ring
Rear cover
Side cover
SMT644D
Bolt (M6)
6.
SMT645D
7.
Remove snap ring of mainshaft bearing from case.
8.
Remove check plugs, springs, and check balls from case.
Flat-head screwdriver Mainshaft rear bearing snap ring
SMT646D
Check plug
SMT647D
MT-52
DISASSEMBLY
RS5F70A Transaxle Case (Cont’d)
Clutch housing
Transaxle case
9. Remove mounting bolts. 10. Remove input shaft rear bearing adjusting shim from transaxle case.
SMT649D
11. Remove oil gutter from case.
Oil gutter
SMT650D
12. Remove differential side bearing outer race and adjusting shim from case.
SMT651D
13. Remove differential oil seal from case.
SMT653D
14. Remove welch plugs from case.
SMT839D
MT-53
DISASSEMBLY
RS5F70A
Clutch Housing
Clutch Housing
NCMT0009S02
1. 2. 3.
Remove transaxle case from clutch housing. Remove magnet from housing. Remove check plugs, check springs, check pins, and check balls from housing.
4.
Remove 3rd & 4th bracket retaining pin.
5. 6. 7.
Remove 3rd & 4th shift fork stopper ring. Remove 3rd & 4th fork rod. Remove 3rd & 4th shift fork and bracket.
8. 9.
Remove interlock plunger and check ball. Remove 5th & reverse bracket stopper ring.
Check plug Clutch housing
SMT654D
3rd & 4th shift fork 3rd & 4th bracket
SMT656D
Stopper ring
3rd & 4th shift fork 3rd & 4th bracket
SMT655D
Stopper ring
5th & reverse bracket
Check ball Interlock plunger SMT658D
5th & reverse shift fork 5th & reverse bracket
10. Remove retaining pin from 5th & reverse shift fork and reverse switch bracket. 11. Remove 5th & reverse fork rod. 12. Remove interlock pin from 5th & reverse fork rod. 13. Remove reverse switch bracket and 5th & reverse bracket.
SMT657D
MT-54
RS5F70A
DISASSEMBLY
Clutch Housing (Cont’d) 1st & 2nd shift fork
14. 15. 16. 17.
Remove check ball from housing. Remove retaining pin for 1st & 2nd shift fork and bracket. Remove 1st & 2nd fork rod. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd bracket.
1st & 2nd bracket Check balls SMT659D
Mainshaft assembly
18. Remove both input shaft and mainshaft assemblies from housing.
Input shaft assembly SMT660D
Final drive assembly
Oil pocket
19. Remove final drive assembly from housing. 20. Remove oil pocket from housing.
SMT661D
21. Remove mainshaft bearing retainer from housing. 22. Cut off oil channel using a cutter as shown in the figure. Cut area Oil channel
Mainshaft bearing retainer
SMT662D
23. Remove mainshaft front bearing from housing.
Mainshaft front bearing
SMT663D
MT-55
DISASSEMBLY
RS5F70A
Clutch Housing (Cont’d)
24. Using a magnet or other suitable tool, remove retaining pin from selector shaft.
Selector Selector pin
SMT664D
25. Remove selector shaft and plug, then remove selector. Selector
Selector shaft
SMT665D
26. Remove reamer bolt, then remove selector leaf spring, return spring, steel ball, reverse gate, selector arm, bearing, and bushing. CAUTION: Be careful not to lose the steel ball.
Selector leaf spring
Return spring SMT666D
27. Remove retaining pin and plug from striking lever. 28. Remove striking rod, then striking lever from housing.
Striking lever
SMT667D
Flat-head screwdriver
29. Using a flat-head screwdriver or other suitable tool, remove dust seal, input shaft oil seal, and striking rod oil seal from housing. CAUTION: When removing dust and oil seals, be careful not to damage mounting surfaces of dust seal and oil seal.
Flat-head screwdriver
Input shaft oil seal Dust seal
SMT668D
MT-56
RS5F70A
DISASSEMBLY
Clutch Housing (Cont’d)
30. Remove differential oil seal from housing.
Differential oil seal
SMT669D
31. Remove differential side outer race from housing.
Differential side bearing outer race
SMT670D
MT-57
REPAIR FOR COMPONENT PARTS
RS5F70A
Input Shaft and Gears
Input Shaft and Gears
Feeler gauge
DISASSEMBLY 1.
I Input shaft assembly
SMT759D
2.
Remove oil channel from input shaft rear bearing.
3.
Press out input shaft rear bearing.
4. 5.
Remove C-ring holder. Remove 5th gear rear C-ring.
6. 7.
Remove 5th input gear from input shaft. Remove 5th gear front C-ring.
Oil channel
Input shaft SMT671D
Input shaft rear bearing
SMT672D
C-ring holder
Flat-head screwdriver 5th gear rear C-ring SMT673D
5th input gear
NCMT0010
Before disassembly, measure the end plays of 3rd and 4th input gears. Gear end play: Refer to SDS, MT-90. If end play is not within specification, disassemble and check the parts.
SMT674D
MT-58
RS5F70A
REPAIR FOR COMPONENT PARTS
Input Shaft and Gears (Cont’d)
8. 3rd & 4th synchronizer hub assembly
Remove 4th input gear, baulk ring, 4th gear needle bearing, and 4th gear C-ring from input shaft. 9. Press out both 3rd & 4th synchronizer hub assembly and 3rd input gear from input shaft. 10. Remove 3rd gear needle bearing.
3rd input gear SMT675D
11. Press out input shaft front bearing from input shaft. Input shaft front bearing
SMT676D
INSPECTION Gear and Shaft I I
NCMT0011 NCMT0011S01
Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.
SMT693D
Synchronizers I I I
NCMT0011S02
Check spline area of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for wear or deformation.
SMT637A
I
If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.
SMT867D
MT-59
RS5F70A
REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Cont’d)
I
Fixed
3rd & 4th coupling sleeve
Measure the movement (play, dimension “L”) of 3rd & 4th coupling sleeve with their end fixed and the other end lifted as shown in the figure. If the movement exceeds specification, replace the sleeve.
Coupling sleeve Dimension “L”
3rd & 4th
Length “L” 0 - 0.95 mm (0 - 0.0374 in)
SMT841D
I
Baulk ring to gear clearance
Measure clearance between baulk ring and gear. Clearance between baulk ring and gear: Refer to SDS, MT-90.
SMT140
Bearing I
NCMT0011S03
Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
SMT148A
ASSEMBLY 1. 2.
NCMT0012
Press on input shaft front bearing. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring bearing to input shaft.
Input shaft front bearing Input shaft
SMT696D
3.
Install spread spring, shifting insert, and 3rd & 4th synchronizer hub onto 3rd & 4th coupling sleeve. I Pay attention to the shape of spread spring and shifting insert for correct assembly. Do not install spread spring hook onto the same shifting insert. CAUTION: Do not reuse 3rd & 4th synchronizer hub.
Shifting insert (3rd & 4th) (5th & reverse)
Flat shape
R-shape
Spread spring
Shifting insert
SMT694D
MT-60
REPAIR FOR COMPONENT PARTS
RS5F70A Input Shaft and Gears (Cont’d)
I
Install synchronizer hub with its three grooves facing the front side (3rd input gear side).
I
Install 3rd & 4th coupling sleeve with its chamfered surface facing the 4th input gear side.
4.
Position bearing replacer to the front side of input shaft front bearing. Align grooves of shifting insert and 3rd gear baulk ring. Then, press it onto 3rd & 4th synchronizer hub assembly using a drift. Install 4th gear C-ring onto input shaft.
Front SMT695D
4th input gear
3rd input gear
SMT699D
3rd & 4th synchronizer hub assembly
I 5.
SMT698D
6. Feeler gauge 3rd & 4th synchronizer hub assembly
7.
Measure the end play of 3rd & 4th synchronizer hub, and check if it is within allowable specification below. End play specification: 0 - 0.06 mm (0 - 0.0024 in) If not within specification, adjust the end play by changing thickness of 4th gear C-ring. Available C-ring: Refer to SDS, MT-90.
4th gear C-ring SMT700D
8. 5th gear front C-ring 4th gear needle bearing
9.
Install 4th gear needle bearing, 4th gear baulk ring, and 5th gear front C-ring. Install 4th input gear.
4th gear baulk ring
SMT701D
MT-61
REPAIR FOR COMPONENT PARTS
RS5F70A
Input Shaft and Gears (Cont’d)
10. Position 5th input gear as shown in the figure, and install it on input shaft.
5th input gear
4th input gear
SMT703D
5th input gear 4th input gear
11. Install 5th input gear. CAUTION: Do not reuse 5th input gear. 12. Install 5th gear rear C-ring onto input shaft.
SMT702D
5th input gear
13. Measure the end play of 5th input gear, and check if it is within the allowable specification below. End play specification: 0 - 0.06 mm (0 - 0.0024 in) 14. If not within specification, adjust the end play by changing thickness of the 5th gear rear C-ring. Available C-ring: Refer to SDS, MT-90.
5th rear C-ring Feeler gauge
SMT704D
Input shaft rear bearing C-ring holder
15. Install C-ring holder onto 5th gear rear C-ring. CAUTION: Do not reuse C-ring holder. 16. Install input shaft rear bearing. CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.
SMT705D
17. Install oil channel onto input shaft. 18. Measure gear end play as a final check. Refer to, MT-58.
Oil channel
Input shaft SMT671D
MT-62
RS5F70A
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears
Mainshaft and Gears
Mainshaft assembly
DISASSEMBLY 1.
I
NCMT0013
Before disassembly, measure gear end play. Gear end play: Refer to SDS, MT-90. If end play is not within the specificed limit, disassemble and check the parts.
Feeler gauge SMT760D
2.
Remove snap ring.
3.
Remove C-ring holder and mainshaft C-ring.
4.
Press out mainshaft rear bearing from mainshaft.
5. 6.
Remove mainshaft thrust washer. Remove snap ring from mainshaft. Then, remove reverse main gear assembly, reverse gear needle bearing, and reverse gear baulk ring.
Snap ring
SMT677D
C-ring holder
Mainshaft C-ring
SMT678D
Mainshaft rear bearing
SMT679D
Mainshaft thrust washer
Reverse main gear assembly
SMT680D
MT-63
REPAIR FOR COMPONENT PARTS
RS5F70A
Mainshaft and Gears (Cont’d) Reverse gear bush 5th & reverse synchronizer hub assembly
7.
8.
Place bearing replacer between 5th & reverse synchronizer hub and 5th main gear, and press out both reverse gear bushing and 5th & reverse synchronizer assembly. Remove 5th main gear, 5th gear baulk ring, and 5th gear needle bearing.
SMT681D
9.
Place bearing replacer between 3rd and 4th main gears, and press out both 5th gear bushing and 4th main gear.
5th gear bush 4th main gear
SMT682D
10. Remove mainshaft adjusting shim and spacer. 11. Place bearing replacer between 2nd main gear and 1st & 2nd synchronizer hub, and press out both 3rd and 2nd main gears. 3rd main gear Bearing replacer 2nd main gear
SMT683D
2nd gear bush 1st & 2nd synchronizer hub
12. Remove 2nd double cone assembly, 2nd gear bushing, and coupling sleeve assembly. 13. Place bearing replacer on 1st gear front side, and press out all of 2nd gear bushing, 1st & 2nd synchronizer hub, 1st main gear, and 1st double cone. 14. Remove 1st gear needle bearing.
1st main gear SMT684D
INSPECTION Gear and Shaft I I
Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.
SMT693D
MT-64
NCMT0014 NCMT0014S01
RS5F70A
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont’d)
Synchronizers I I I
NCMT0014S02
Check spline area of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for wear or deformation.
SMT637A
I
If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.
I
Measure the movement (play, dimension “L”) of 1st & 2nd coupling sleeve and 5th & reverse coupling sleeve with their end fixed and the other end lifted as shown in the figure. If the movement exceeds specification, replace the sleeve.
SMT867D Fixed
1st & 2nd coupling sleeve
Dimension “L”
Coupling sleeve Fixed
5th & reverse coupling sleeve
Dimension “L”
Length “L”
1st & 2nd
0 - 0.68 mm (0 - 0.0268 in)
5th & Reverse
0 - 0.89 mm (0 - 0.0350 in)
SMT868D
I
Baulk ring to gear clearance
Measure clearance between baulk ring and gear. Clearance between baulk ring and gear: Refer to SDS, MT-90.
SMT140
Bearing I
NCMT0014S03
Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
SMT148A
MT-65
RS5F70A
REPAIR FOR COMPONENT PARTS Mainshaft and Gears (Cont’d)
Outer baulk ring Inner baulk ring
Synchronizer cone
Synchronizer cone
SMT714CB
I a) b)
I
Measure wear of 1st and 2nd baulk ring. Place baulk rings in position on synchronizer cone. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions “A” and “B”. Standard: A 0.6 - 0.8 mm (0.024 - 0.031 in) B 0.6 - 1.1 mm (0.024 - 0.043 in) Wear limit: 0.2 mm (0.008 in) If dimension “A” or “B” is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.
ASSEMBLY 1st gear needle bearing
1. 1st main gear
2.
NCMT0015
Install 1st gear needle bearing and 1st main gear onto mainshaft. Install 1st double cone assembly onto mainshaft.
Mainshaft SMT706D
3.
Install 1st & 2nd synchronizer hub with its three grooves facing the front side (1st main gear side) onto mainshaft. CAUTION: Do not reuse 1st & 2nd synchronizer hub.
Front SMT695D
MT-66
REPAIR FOR COMPONENT PARTS
RS5F70A Mainshaft and Gears (Cont’d)
4.
Install 1st & 2nd synchronizer hub.
5.
Install insert spring onto 1st & 2nd coupling sleeve.
6.
Install 1st & 2nd coupling sleeve with its chamfered surface facing the 1st main gear side onto 1st & 2nd synchronizer hub.
7.
Install 2nd gear bushing with its flange surface facing 1st & 2nd synchronizer hub side.
1st & 2nd synchronizer hub 1st gear double cone assembly
SMT707D
1st & 2nd coupling sleeve
SMT994BB
2nd main gear
1st main gear
1st & 2nd coupling sleeve
SMT708D
2nd gear bush
SMT709D
2nd main gear
8.
4th main gear 3rd main gear 2nd needle bearing
3rd main gear
2nd main gear
Install 2nd needle bearing, 2nd double cone assembly, and 2nd main gear onto mainshaft. 9. Position 3rd main gear as shown in the figure, and install it. CAUTION: Do not reuse 3rd main gear.
SMT710D
MT-67
REPAIR FOR COMPONENT PARTS
RS5F70A
Mainshaft and Gears (Cont’d)
10. Install spacer and mainshaft adjusting shim onto mainshaft. 11. Select a mainshaft adjusting shim suitable to satisfy the following specification of dimension “L” and install it onto mainshaft. Specification of dimension “L”: 151.35 - 151.45 mm (5.9586 - 5.9626 in) Available mainshaft adjusting shims: Refer to SDS, MT-91.
3rd main gear shim
151.35 - 151.45 mm (5.9586 - 5.9626 in)
Dimension “L”
SMT711D
12. Position 4th main gear as shown in the figure, and install it onto mainshaft. 5th main gear
3rd main gear
4th main gear
SMT713D
13. Install 4th main gear onto mainshaft. CAUTION: Do not reuse 4th main gear. 4th main gear
SMT712D
14. Install 5th gear bushing with its flange surface facing the 4th main gear side. 5th gear bush
SMT714D
MT-68
RS5F70A
REPAIR FOR COMPONENT PARTS
Mainshaft and Gears (Cont’d)
15. Install 5th needle bearing, 5th main gear, and 5th gear baulk ring onto mainshaft.
Reverse SMT761D
16. Being careful of the following points, install spread spring, shifting insert, and 5th & reverse synchronizer hub onto 5th & reverse coupling sleeve. I Pay attention to the shape of spread spring and shifting insert for correct assembly. Do not install spread spring hook onto the same shifting insert.
Shifting insert (3rd & 4th) (5th & reverse)
Flat shape
R-shape
Spread spring
Shifting insert
SMT694D
I
Install synchronizer hub with its three grooves facing the front side (5th main gear side). CAUTION: Do not reuse 5th & reverse synchronizer hub.
Front SMT695D
I
Reverse main gear
Install 5th & reverse coupling sleeve with its chamfered surface facing the reverse main gear side.
5th main gear
5th & reverse coupling sleeve
SMT716D
17. Install 5th & reverse synchronizer hub assembly.
5th & reverse synchronizer hub assembly
SMT715D
MT-69
REPAIR FOR COMPONENT PARTS
RS5F70A
Mainshaft and Gears (Cont’d)
Reverse gear bush
18. Install reverse gear baulk ring. 19. Install reverse gear bushing. 20. Install reverse gear needle bearing.
Reverse gear baulk ring
SMT717D
Reverse main gear
21. Install sub-gear, sub-gear washer, and snap ring onto reverse main gear. CAUTION: I Pay attention to direction of sub-gear washer. I Do not reuse snap ring.
Sub-gear washer
Sub-gear Reverse main gear
Sub-gear washer Snap ring
SMT718D
22. Install reverse main gear assembly onto mainshaft. 23. Select a thrust washer suitable to satisfy the following specification of dimension “M” (as shown in the figure), and install it onto mainshaft. Specification of dimension “M”: 244.20 - 244.30 mm (9.6142 - 9.6181 in) Available thrust washers: Refer to SDS, MT-92. 244.20 - 244.30 mm (9.6142 - 9.6181 in)
Thrust washer Dimension “M” SMT719D
24. Install mainshaft rear bearing.
Mainshaft rear bearing
SMT720D
MT-70
REPAIR FOR COMPONENT PARTS
RS5F70A Mainshaft and Gears (Cont’d)
Feeler gauge
Mainshaft C-ring
25. Install mainshaft C-ring. 26. Using feeler gauge, measure the end play of mainshaft rear bearing, and check if it satisfies the following specification. End play specification: 0 - 0.06 mm (0 - 0.0024 in) Available mainshaft C-rings: Refer to SDS, MT-91.
SMT721D
27. Install C-ring holder. C-ring holder
Mainshaft C-ring
SMT678D
28. Install snap ring. 29. Measure gear end play as a final check. Refer to, MT-63. CAUTION: I Do not reuse snap ring.
Snap ring
SMT677D
Final Drive
Dial gauge
PRE-INSPECTION I 1.
NCMT0036
Check the clearance between side gear and differential case as follows. Clean final drive assembly sufficiently to prevent side gear thrust washer, differential case, side gear, and other parts from sticking by gear oil.
SMT610AE
2. 3.
4. 5. SMT685D
Upright the differential case so that the side gear to be measured faces upward. Place final drive adapter and dial gauge onto side gear. Move side gear up and down, and measure the clearance. Clearance between side gear and differential case: 0.1 - 0.2 mm (0.004 - 0.008 in) If not within specification, adjust the clearance by changing thrust washer thickness. Turn differential case upside down, and measure the clearance between side gear and differential case on the other side in the same way.
MT-71
REPAIR FOR COMPONENT PARTS
RS5F70A
Final Drive (Cont’d)
DISASSEMBLY
Chamfer
1. 2. I
NCMT0016
Remove mounting bolts. Then, separate the final gear from differential case. Make a notch and remove speedometer drive gear using a scraper or other suitable tool. Bearing replacer cannot be positioned unless speedometer drive gear is removed.
SMT609A
Puller
Puller
3. 4. 5.
Remove differential side bearing of final gear side. Turn differential case upside down, and remove differential side bearing of speedometer drive gear side. Remove speedometer stopper.
6.
Remove lock pins from pinion mate shaft.
7. 8.
Remove pinion mate shaft. Rotate pinion mate gear, and remove pinion mate gear, pinion mate thrust washer, side gear, and side gear thrust washer from differential case.
SMT840D
SMT689D
SMT839
INSPECTION Gear, Washer, Shaft and Case I I
NCMT0017 NCMT0017S01
Check side gear, side gear thrust washer, pinion mate shaft, pinion mate gear, pinion mate gear washer, and differential case. Check washers for wear.
SMT083A
MT-72
RS5F70A
REPAIR FOR COMPONENT PARTS
Final Drive (Cont’d)
Bearing I I
NCMT0017S04
Make sure bearings roll freely and are free from noise, cracks, pitting or wear. When replacing tapered roller bearing, replace outer and inner race as a set.
SPD715
ASSEMBLY 1. 2. 3.
NCMT0018
Apply gear oil to sliding area of differential case, each gear, and thrust washer. Install side gear thrust washer and side gear into differential case. Position pinion mate gear and pinion mate thrust washer diagonally, and install them into differential case while rotating.
SMT062A
4.
Insert pinion mate shaft into differential case.
SMT087A
5.
SMT685D
Upright the differential case so that its side gear to be measured faces upward. 6. Place preload adapter and dial gauge onto side gear. Move side gear up and down, and measure the clearance. 7. Turn differential case upside down, and measure the clearance between side gear and differential case on the other side in the same way. Clearance of side gear and differential case: 0.1 - 0.2 mm (0.004 - 0.008 in) Available differential thrust washers: Refer to SDS, MT-92. 8. Hammer the retaining pin into pinion mate shaft. CAUTION: Do not reuse retaining pin.
SMT750D
MT-73
REPAIR FOR COMPONENT PARTS
RS5F70A
Final Drive (Cont’d)
9. Align and install speedometer drive gear into differential case. 10. Install speedometer stopper.
Speedometer drive gear
Installation direction
Alignment position
SMT842D
11. Install differential side bearing. 12. Turn differential case upside down, and install another differential side bearing on the other side in the same way. Speedometer drive gear
SMT751D
13. Install final gear into differential case. Apply sealant onto mounting bolts, and tighten them in order as shown in the figure with specified torque. Tightening torque: Refer to MT-48.
SMT752D
Shift Control Components INSPECTION I
NCMT0019
Check if the width of shift fork hook (sliding area with coupling sleeve) is within allowable specification below.
One-side wear One-side wear
One-side wear specification
Sliding width of new part
1st & 2nd
0.2 mm (0.008 in)
7.80 - 7.93 mm (0.3071 - 0.3122 in)
3rd & 4th
0.2 mm (0.008 in)
7.80 - 7.93 mm (0.3071 - 0.3122 in)
5th & reverse
0.2 mm (0.008 in)
7.80 - 7.93 mm (0.3071 - 0.3122 in)
Item Sliding width of new part SMT801D
MT-74
REPAIR FOR COMPONENT PARTS
RS5F70A Shift Control Components (Cont’d)
I
1st & 2nd fork rod
Check if shift check groove of fork rod or 5th & reverse check groove is worn, or has any other abnormalities.
5th & reverse fork rod
3rd & 4th fork rod
SMT692D
MT-75
NCMT0023
ASSEMBLY
RS5F70A
Clutch Housing
Clutch Housing
NCMT0023S01
1.
Hammer the striking rod oil seal into clutch housing as far as it will go. CAUTION: Do not reuse striking rod oil seal. Striking rod oil seal
SMT722D
2.
Hammer the differential oil seal into clutch housing until it becomes flush with clutch housing end face. CAUTION: Do not reuse differential oil seal.
Differential oil seal
SMT723D
3.
Hammer input shaft oil seal into clutch housing as far as it will go. CAUTION: Do not reuse input shaft oil seal.
Input shaft oil seal
SMT724D
4. Hammer the dust seal into clutch housing as far as it will go. CAUTION: Do not reuse dust seal.
Dust seal
SMT725D
5.
Install outer race of differential side bearing.
Differential side bearing outer race SMT726D
MT-76
ASSEMBLY
RS5F70A Clutch Housing (Cont’d)
6. Install new oil channel (mainshaft). CAUTION: Pay attention to installation direction of oil channel.
Oil channel
SMT727D
Notch on bearing
Transaxle case
7.
Align the notches on mainshaft front bearing and transaxle case. Then, install mainshaft front bearing.
8.
Install mainshaft bearing retainer, and tighten bolts with specified torque.
Mounting direction of bearing
Mainshaft front bearing SMT728D
Mainshaft bearing retainer 6.3 - 8.3 (0.64 - 0.85, 56 - 74)
N·m (kg-m, in-lb)
SMT729D
9.
Attach boot, striking rod, and striking lever to clutch housing. And install retaining pin for selector lever. CAUTION: I Before installing striking rod, wrap the end with a vinyl tape or the like to prevent oil seal from being damaged. I Do not reuse retaining pin. Striking lever
SMT667D
10. Hammer the welch plug (striking lever side) with a generalpurpose drift [OD: 12 mm (0.47 in)]. CAUTION: Do not reuse welch plug. Drift Welch plug drift depth
Welch plug
0 - 0.5 mm (0 - 0.020 in) Welch plug SMT730D
MT-77
ASSEMBLY
RS5F70A
Clutch Housing (Cont’d)
11. Install selector, selector shaft, and selector shaft pin into clutch housing.
Selector shaft pin Selector
Welch plug
Selector shaft
SMT731D
12. Hammer the welch plug (selector shaft side) with a generalpurpose drift [OD: 12 mm (0.47 in)]. CAUTION: Do not reuse welch plug.
Drift Welch plug drift depth
Welch plug
0 - 0.5 mm (0 - 0.020 in) Welch plug SMT732D
Reamer bolt (short) Reamer bolt (long)
Selector leaf spring Return spring
Bushing
Reverse gate
Return bearing
13. Install selector leaf spring, return spring, steel ball, reverse gate, selector arm, bushing, and return bearing. Then, tighten two reamer bolts with specified torque. CAUTION: Use correct reamer bolts for each installation point, because each bolt has a different length.
Selector arm SMT733D
Steel ball
N·m (kg-m, ft-lb) 16 - 21 (1.6 - 2.1, 12 - 15)
SMT734D
14. Install oil pocket.
Oil pocket
SMT735D
MT-78
RS5F70A
ASSEMBLY
Clutch Housing (Cont’d)
15. Install differential assembly, input shaft assembly, and mainshaft assembly into clutch housing. CAUTION: Be careful not to damage input shaft oil seal during installation of input shaft assembly.
SMT736D
1st & 2nd shift fork
16. Install 5th & reverse shift fork. 17. Install 1st & 2nd shift fork, bracket, and fork rod. 18. Install retaining pin for 1st & 2nd bracket. CAUTION: Do not reuse retaining pin. 19. Install two check balls.
1st & 2nd bracket Check balls SMT659D
5th & reverse shift fork 5th & reverse bracket
SMT657D
20. Install interlock pin into 5th & reverse fork rod. 21. Install reverse switch bracket, 5th & reverse bracket, and fork rod. 22. Install retaining pin for 5th & reverse shift fork and reverse switch bracket. CAUTION: Do not reuse retaining pin. 23. Install 5th & reverse bracket stopper ring. CAUTION: Do not reuse stopper pin. 24. Install check ball and interlock plunger. 25. Install 3rd & 4th shift fork, bracket, and fork rod. 26. Install 3rd & 4th bracket retaining pin. CAUTION: Do not reuse retaining pin.
3rd & 4th shift fork 3rd & 4th bracket
SMT656D
27. Install 3rd & 4th shift fork stopper ring. CAUTION: Do not reuse stopper ring. 28. Install check ball, check pin, and check spring, and apply Three Bond TB1215, Loctite Part No. 51813 or equivalent onto check plug. Then, tighten it with specified torque. Tightening torque: Refer to MT-48.
Stopper ring
3rd & 4th shift fork .
3rd & 4th bracket
SMT655D
MT-79
ASSEMBLY
RS5F70A
Transaxle Case
Transaxle Case
Differential oil seal
Drift
NCMT0023S02
1.
Insert differential oil seal into differential case until it becomes flush with case end face.
2.
Install welch plug into transaxle case.
3.
Calculate dimension “N” (thickness of adjusting shim) using the following procedure to satisfy specification of end play for differential side bearing. End play: 0.15 - 0.21 mm (0.0059 - 0.0083 in) Dimension “N” = (N1 − N2) + End play N : Thickness of adjusting shim N1: Distance between clutch housing case end face and mounting face of adjusting shim N2: Distance between differential side bearing and transaxle case Available differential side bearing adjusting shims: Refer to SDS, MT-92.
a.
Using dial gauge and scale, measure dimension “N1” between clutch housing case end face and mounting face of adjusting shim.
SMT737D
Welch plug drift depth Welch plug Welch plug 1.0 - 1.5 mm (0.039 - 0.059 in)
Outer race adjusting shim
SMT739D
Outer race
Transaxle case
SMT740D
Scale
SMT741D
MT-80
RS5F70A
ASSEMBLY
Transaxle Case (Cont’d) Scale
b.
c. Scale
Install outer race onto differential side bearing on final gear side. Holding lightly the outer race horizontally by hand, rotate final gear five times or more (for smooth movement of bearing roller). Using dial gauge and scale as shown in the figure, measure dimension “N2” between differential side bearing outer race and transaxle case end face.
SMT742D
4.
Install selected shim and bearing outer race.
5.
Measure turning torque of final drive assembly. Turning torque of final drive assembly (New bearing): 2.9 - 6.9 N⋅m (30 - 70 kg-cm, 26 - 61 in-lb) When old bearing is used again, turning torque will be slightly less than the above. Make sure torque is close to the specified range. Changes in turning torque of final drive assembly per revolution should be within 1.0 N⋅m (10 kg-cm, 8.7 in-lb) without binding.
Outer race SMT738D
I I I SMT600-D
6. Transaxle case Input shaft rear bearing
Input shaft rear bearing adjusting shim
Rear cover Dimension “O”
SMT743D
Calculate dimension “O” (thickness of adjusting shim) using the following procedure to satisfy specification of end play for input shaft rear bearing. End play: 0 - 0.06 mm (0 - 0.0024 in) Dimension “O” = (O1 − O2) + End play O : Thickness of adjusting shim O1: Distance between transaxle case end face and mounting face of adjusting shim O2: Distance between clutch housing case end face and end face of input shaft rear bearing Available input shaft rear bearing adjusting shims: Refer to SDS, MT-91.
MT-81
ASSEMBLY
RS5F70A
Transaxle Case (Cont’d)
a.
Using block gauge, scale, and dial gauge, measure dimension “O1” between transaxle case end face and mounting face of adjusting shim.
b.
Using gauge block, scale, and dial gauge as shown in the figure, measure dimension “O2” between clutch housing case end face and end face of input shaft rear bearing. Install selected input shaft rear bearing adjusting shim onto input shaft.
Scale Block gauge
SMT744D
Scale
7.
Block gauge
SMT745D
Oil gutter
8.
Install oil gutter into transaxle case.
9.
Install two magnets.
SMT650D
Magnets
SMT755D
10. Clean mating surfaces of clutch housing and transaxle case. Check for cracks and damage. Then, apply Three Bond TB1215, Loctite Part No. 51813 or equivalent.
SMT802D
MT-82
ASSEMBLY
RS5F70A Transaxle Case (Cont’d)
Clutch housing
Transaxle case
SMT649D
Reverse switch PNP switch
Filler plug
11. Install transaxle case onto clutch housing, and tighten mounting bolts with specified torque. Tightening torque: Refer to MT-48.
12. Apply Three Bond TB1215, Loctite Part No. 51813 or equivalent to threads of reverse switch, PNP switch, and drain plug, and install them. (Fill the case with oil before installation of filler plug.) 13. Install speedometer pinion assembly. CAUTION: Do not reuse O-ring.
Drain plug SMT648D
14. Install check springs and check balls. Apply sealant to the thread on the check plug, and install it. Check balls Check springs Check plugs 16 - 22 (1.6 -2.2, 12 -16) N·m (kg-m, ft-lb) SMT749D
Rear cover Mainshaft rear bearing adjusting shim Mainshaft rear bearing
Dimension “P”
SMT746D
15. Calculate thickness of adjusting shim using the following procedure to satisfy specification of end play for mainshaft rear bearing. End play: 0 - 0.06 mm (0 - 0.0024 in) Dimension “P” = (P1 − P2) + End play P : Thickness of adjusting shim P1: Distance between transaxle case end face and mainshaft rear bearing P2: Distance between adjusting shim end face of rear cover and transaxle mounting face Available mainshaft rear bearing adjusting shims: Refer to SDS, MT-92.
MT-83
ASSEMBLY
RS5F70A
Transaxle Case (Cont’d)
a.
Using dial gauge as shown in the figure, measure dimension “P1” between transaxle case end face and mainshaft rear bearing.
b.
Using dial gauge as shown in the figure, measure dimension “P2” between adjusting shim mounting face of rear cover and transaxle mounting face.
Mainshaft rear bearing SMT747D
Rear cover
SMT748D
16. Using snap ring pliers as shown in the figure, install snap ring. CAUTION: Do not reuse snap ring. 17. Install selected mainshaft adjusting shim.
Flat-head screwdriver Mainshaft rear bearing snap ring SMT646D
Reverse idler gear rear thrust washer Reverse idler gear Reverse idler gear bearing
18. Install reverse idler gear, O-ring, thrust washers (front, rear), and bearing onto reverse idler shaft. 19. Install snap ring into transaxle case using snap ring pliers. CAUTION: I Do not reuse snap ring. I Do not reuse O-ring. I Before installation, apply gear oil to O-ring.
Reverse idler gear front thrust washer O-ring Reverse idler gear shaft
Feeler gauge
SMT753D
20. Using feeler gauge, measure the end play of snap ring, and select a snap ring suitable to satisfy the following specification. End play: 0.05 - 0.25 mm (0.0020 - 0.0098 in) Available snap ring: Refer to SDS, MT-90.
Snap ring
SMT754D
MT-84
ASSEMBLY
RS5F70A Transaxle Case (Cont’d)
Snap ring
Rear cover
Side cover
SMT644D
21. Install selected snap ring. CAUTION: Do not reuse snap ring. 22. Apply gear oil to rear cover O-ring, and install rear cover, side cover gasket, and side cover. Then tighten mounting bolts with specified torque. Tightening torque: Refer to MT-48. CAUTION: Do not reuse mounting bolts for rear cover and side cover.
MT-85
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications — RS5F32A and RS5F70A
General Specifications — RS5F32A and RS5F70A TRANSAXLE Engine
CD20T
Transaxle model
QG16DE
QG18DE
RS5F32A
Transaxle model code number
SR20DE
RS5F70A
2J624
8E069
7J006
Number of speeds
5
Synchromesh type
Warner
6J016
Shift pattern
NMT031
Gear ratio
Number of teeth
1st
3.3333
3.3333
2nd
1.9545
1.9545
3rd
1.2857
1.2857
4th
0.9268
0.9268
5th
0.7333
0.7556
Reverse
3.2143
3.2143
Input gear
Main gear
1st
15
15
2nd
22
22
3rd
28
28
4th
41
41
5th
45
45
Rev.
14
14
1st
50
50
2nd
43
43
3rd
36
36
4th
38
38
5th
33
34
Rev.
45
Reverse idler gear Oil capacity (Reference) Oil level
(Imp pt) mm (in)
45
31
37
3.6 - 3.8 (6-3/8 - 6-3/4)
3.0 (5-1/4) 75.5 - 80.5 (2.972 - 3.169)
57 - 62 (2.244 - 2.441)
FINAL GEAR Engine
QG16DE
QG18DE/ SR20DE
CD20T
4.4375
4.1765
3.8888
Final gear/ Pinion
71/16
71/17
70/18
Side gear/ Pinion
16/10
14/10
14/10
Final gear ratio
Number of teeth
MT-86
56.5 - 61.0 (2.224 - 2.402)
RS5F32A
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment — RS5F32A
Inspection and Adjustment — RS5F32A GEAR END PLAY
AVAILABLE SNAP RINGS
Gear
Input shaft front bearing
End play mm (in)
1st main gear
0.18 - 0.31 (0.0071 - 0.0122)
2nd main gear
0.20 - 0.30 (0.0079 - 0.0118)
Thickness mm (in)
Part number
3rd main gear
0.20 - 0.30 (0.0079 - 0.0118)
1.27 (0.0500)
32204-M8004
4th main gear
0.20 - 0.30 (0.0079 - 0.0118)
1.33 (0.0524)
32204-M8005
5th input gear
0.18 - 0.31 (0.0071 - 0.0122)
1.39 (0.0547)
32204-M8006
1.45 (0.0571)
32204-M8007
Allowable clearance
CLEARANCE BETWEEN BAULK RING AND GEAR
0 - 0.1 mm (0 - 0.004 in)
Input shaft 5th synchronizer hub
1st, 4th, 5th baulk ring Unit: mm (in) Standard
Allowable clearance
0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in)
Part number
2.00 (0.0787)
32311-M8812
2.05 (0.0807)
32311-M8813
2.10 (0.0827)
32311-M8814
2.15 (0.0846)
32311-M8815
2.20 (0.0866)
32311-M8816
2.25 (0.0886)
32311-M8817
2.30 (0.0906)
32311-M8818
Wear limit
1st
0.95 - 1.45 (0.0374 - 0.0571)
4th
0.90 - 1.45 (0.0354 - 0.0571)
5th
0.90 - 1.50 (0.0354 - 0.0591)
0.7 (0.028)
2nd and 3rd baulk ring Outer baulk ring B
AVAILABLE C-RINGS Mainshaft C-ring
A
Allowable clearance
Inner baulk ring Synchronizer cone
0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in)
Part number
4.45 (0.1752)
32348-50J00
4.52 (0.1780)
32348-50J01
4.59 (0.1807)
32348-50J02
4.66 (0.1835)
32348-50J03
4.73 (0.1862)
32348-50J04
4.80 (0.1890)
32348-50J05
4.87 (0.1917)
32348-50J06
4.94 (0.1945)
32348-50J07
NMT026
Dimension
Standard
A
0.7 - 0.9 (0.028 - 0.035)
B
0.6 - 1.1 (0.024 - 0.043)
Wear limit
0.2 (0.008)
AVAILABLE CHECK PLUGS Reverse check plug Reverse check turning torque (At striking rod)
4.9 - 7.4 N·m (50 - 75 kg-cm, 43 - 65 in-lb)
Length mm (in)
Part number
8.3 (0.327)
32188-M8001*
7.1 (0.280)
32188-M8002
7.7 (0.303)
32188-M8003
8.9 (0.350)
32188-M8004 * Standard check plug
MT-87
RS5F32A
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment — RS5F32A (Cont’d)
AVAILABLE SPACERS
AVAILABLE SHIMS — DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM
Mainshaft bearing adjusting spacer
Bearing preload (Re-used bearing) Mainshaft rear bearing
Unit: mm (in) Mainshaft
Mainshaft adjusting spacing
Differential side bearing preload: T*
0.25 - 0.30 (0.0098 - 0.0118)
* Install shims which are “deflection of differential case” + “T” in thickness.
SMT693B
Turning torque (New bearing) Unit: N·m (kg-cm, in-lb)
230.15 - 230.25 mm (9.0610 - 9.0649 in)
Bearing distance: C
Final drive
2.9 - 6.9 (30 - 70, 26 - 61)
Thickness mm (in)
Part number
18.91 (0.7445)
32347-50J00
18.98 (0.7472)
32347-50J01
19.05 (0.7500)
32347-50J02
Thickness mm (in)
Part number
19.12 (0.7528)
32347-50J03
0.44 (0.0173)
38454-M8000
19.19 (0.7555)
32347-50J04
0.48 (0.0189)
38454-M8001
19.26 (0.7583)
32347-50J05
0.56 (0.0220)
38454-M8003
19.33 (0.7610)
32347-50J06
0.60 (0.0236)
38454-M8004
19.40 (0.7638)
32347-50J07
0.64 (0.0252)
38454-M8005
19.47 (0.7665)
32347-50J08
0.68 (0.0268)
38454-M8006
0.72 (0.0283)
38454-M8007
AVAILABLE WASHERS
0.76 (0.0299)
38454-M8008
Differential side gear thrust washer
0.80 (0.0315)
38454-M8009
0.84 (0.0331)
38454-M8010
0.88 (0.0346)
38454-M8011
Allowable clearance between side gear and differential case with washer
F32A
Differential side bearing adjusting shims
0.1 - 0.2 mm (0.004 - 0.008 in)
Thickness mm (in)
Part number
0.75 - 0.80 (0.0295 - 0.0315)
38424-D2111
0.80 - 0.85 (0.0315 - 0.0335)
38424-D2112
0.85 - 0.90 (0.0335 - 0.0354)
38424-D2113
0.90 - 0.95 (0.0354 - 0.0374)
38424-D2114
0.95 - 1.00 (0.0374 - 0.0394)
38424-D2115
MT-88
SERVICE DATA AND SPECIFICATIONS (SDS)
RS5F32A
Inspection and Adjustment — RS5F32A (Cont’d)
INPUT SHAFT BRAKING MECHANISM
1st & 2nd shifter Striking lever
Control bracket fitting surface
MAINSHAFT END PLAY Mainshaft end play (Clearance between end of case cover and mainshaft rear bearing outer race)
Reverse brake cam
0 - 0.1 mm (0 - 0.004 in)
SMT735B
Maximum height “H” between the control bracket fitting surface and 1-2 shifter mm (in)
67.16 - 67.64 (2.6441 - 2.6630)
Case cover
Reverse brake cam Striking lever
T
SMT760B
Thickness “T” mm (in)
Part No.
10.78 (0.4244)
32131-50J00
10.83 (0.4264)
32131-50J01
10.88 (0.4283)
32131-50J02
10.93 (0.4303)
32131-50J03
SMT736B
Clearance “C” between reverse brake cam and striking lever mm (in)
0.05 - 0.125 (0.0020 - 0.0049)
MT-89
10.98 (0.4323)
32131-50J04
11.03 (0.4343)
32131-50J05
RS5F70A
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment — RS5F70A
Inspection and Adjustment — RS5F70A GEAR END PLAY
NCMT0025
Unit: mm (in)
Gear
AVAILABLE SNAP RINGS Snap Ring
NCMT0028 NCMT0028S01
End play Allowable clearance
1st main gear 2nd main gear
0.05 - 0.25 mm (0.0020 - 0.0098 in)
Thickness
Part number*
1.45 mm (0.0571 in)
32204-6J000
Reverse main gear
1.55 mm (0.0610 in)
32204-6J001
3rd input gear
1.65 mm (0.0650 in)
32204-6J002
1.75 mm (0.0689 in)
32204-6J003
1.85 mm (0.0728 in)
32204-6J004
5th main gear
0.18 - 0.31 (0.0071 - 0.0122)
4th input gear
0.17 - 0.44 (0.0067 - 0.0173)
CLEARANCE BETWEEN BAULK RING AND GEAR NCMT0026 3rd, 4th, 5th, Reverse Baulk Ring NCMT0026S01 Unit: mm (in) Standard
Wear limit
*: Always check with the parts department for the latest information.
AVAILABLE C-RINGS 4th Input Gear C-ring
3rd
Allowable clearance
4th
0.90 - 1.45 (0.0354 - 0.0571) 0.7 (0.028)
5th Reverse
0.9 - 1.35 (0.0354 - 0.0531)
1st and 2nd Baulk Ring
NCMT0026S02
Unit: mm (in)
NCMT0029 NCMT0029S01
0 - 0.06 mm (0 - 0.0024 in)
Thickness
Part number*
3.00 mm (0.1181 in)
32205-6J000
3.03 mm (0.1193 in)
32205-6J001
3.06 mm (0.1205 in)
32205-6J002
3.09 mm (0.1217 in)
32205-6J003
Outer baulk ring
5th Input Gear Rear C-ring Allowable clearance
Inner baulk ring
NCMT0029S02
0 - 0.06 mm (0 - 0.0024 in)
Thickness
Part number*
2.59 mm (0.1020 in)
32205-6J005
2.62 mm (0.1031 in)
32205-6J006
2.65 mm (0.1043 in)
32205-6J007
2.68 mm (0.1055 in)
32205-6J008
2.71 mm (0.1067 in)
32205-6J009
2.74 mm (0.1079 in)
32205-6J010
Synchronizer cone SMT757C
Dimension
Standard
A
0.6 - 0.8 (0.024 0.031)
B
0.6 - 1.1 (0.024 0.043)
Wear limit
0.2 (0.008)
MT-90
RS5F70A
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment — RS5F70A (Cont’d)
Mainshaft C-ring Allowable clearance
NCMT0029S03
0 - 0.06 mm (0 - 0.0024 in)
AVAILABLE ADJUSTING SHIMS NCMT0037 Input Shaft Rear Bearing Adjusting Shim NCMT0037S01 Allowable clearance
0 - 0.06 mm (0 - 0.0024 in)
Thickness
Part number*
3.48 mm (0.1370 in)
32348-6J000
Thickness
Part number*
3.51 mm (0.1382 in)
32348-6J001
0.74 mm (0.0291 in)
32225-6J003
3.54 mm (0.1394 in)
32348-6J002
0.78 mm (0.0307 in)
32225-6J004
3.57 mm (0.1406 in)
32348-6J003
0.82 mm (0.0323 in)
32225-6J005
3.60 mm (0.1417 in)
32348-6J004
0.86 mm (0.0339 in)
32225-6J006
3.63 mm (0.1429 in)
32348-6J005
0.90 mm (0.0354 in)
32225-6J007
3.66 mm (0.1441 in)
32348-6J006
0.94 mm (0.0370 in)
32225-6J008
3.69 mm (0.1453 in)
32348-6J007
0.98 mm (0.0386 in)
32225-6J009
3.72 mm (0.1465 in)
32348-6J008
1.02 mm (0.0402 in)
32225-6J010
3.75 mm (0.1476 in)
32348-6J009
1.06 mm (0.0417 in)
32225-6J011
3.78 mm (0.1488 in)
32348-6J010
1.10 mm (0.0433 in)
32225-6J012
3.81 mm (0.1500 in)
32348-6J011
1.14 mm (0.0449 in)
32225-6J013
3.84 mm (0.1512 in)
32348-6J012
1.18 mm (0.0465 in)
32225-6J014
3.87 mm (0.1524 in)
32348-6J013
1.22 mm (0.0480 in)
32225-6J015
3.90 mm (0.1535 in)
32348-6J014
1.26 mm (0.0496 in)
32225-6J016
3.93 mm (0.1547 in)
32348-6J015
1.30 mm (0.0512 in)
32225-6J017
3.96 mm (0.1559 in)
32348-6J016
1.34 mm (0.0528 in)
32225-6J018
1.38 mm (0.0543 in)
32225-6J019
1.42 mm (0.0559 in)
32225-6J020
1.46 mm (0.0575 in)
32225-6J021
1.50 mm (0.0591 in)
32225-6J022
1.54 mm (0.0606 in)
32225-6J023
1.58 mm (0.0622 in)
32225-6J024
1.62 mm (0.0638 in)
32225-6J060
1.66 mm (0.0654 in)
32225-6J061
*: Always check with the parts department for the latest information.
Mainshaft Adjusting Shim Standard length “L”
NCMT0037S02
151.35 - 151.45 mm (5.9586 5.9626 in)
Thickness
Part number*
0.48 mm (0.0189 in)
32238-6J000
0.56 mm (0.0220 in)
32238-6J001
0.64 mm (0.0252 in)
32238-6J002
0.72 mm (0.0283 in)
32238-6J003
0.80 mm (0.0315 in)
32238-6J004
0.88 mm (0.0346 in)
32238-6J005
*: Always check with the parts department for the latest information.
MT-91
SERVICE DATA AND SPECIFICATIONS (SDS)
RS5F70A
Inspection and Adjustment — RS5F70A (Cont’d)
Mainshaft Rear Bearing Adjusting Shim NCMT0037S03
AVAILABLE WASHERS NCMT0031 Differential Side Gear Thrust Washer NCMT0031S01
Thickness
Part number*
2.99 mm (0.1177 in)
32238-6J010
3.03 mm (0.1193 in)
32238-6J011
3.07 mm (0.1209 in)
32238-6J012
Thickness mm (in)
Part number*
3.11 mm (0.1224 in)
32238-6J013
0.75 - 0.80 (0.0295 - 0.0315)
38424-D2111
3.15 mm (0.1240 in)
32238-6J014
0.80 - 0.85 (0.0315 - 0.0335)
38424-D2112
3.19 mm (0.1256 in)
32238-6J015
0.85 - 0.90 (0.0335 - 0.0354)
38424-D2113
3.23 mm (0.1272 in)
32238-6J016
0.90 - 0.95 (0.0354 - 0.0374)
38424-D2114
3.27 mm (0.1287 in)
32238-6J017
0.95 - 1.00 (0.0374 - 0.0394)
38424-D2115
3.31 mm (0.1303 in)
32238-6J018
3.35 mm (0.1319 in)
32238-6J019
3.39 mm (0.1335 in)
32238-6J020
3.43 mm (0.1350 in)
32238-6J021
3.47 mm (0.1366 in)
32238-6J022
3.51 mm (0.1382 in)
32238-6J023
AVAILABLE THRUST WASHER Mainshaft Thrust Washer
Allowable clearance between side gear and differential case with washer
0.1 - 0.2 mm (0.004 - 0.008 in)
AVAILABLE SHIMS — DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM NCMT0032 Bearing Preload NCMT0032S01 Unit: mm (in) Differential side bearing preload: T*
NCMT0038
0.15 - 0.21 (0.0059 - 0.0083)
* Install shims which are “deflection of differential case” + “T” in thickness.
NCMT0038S01
Differential Side Bearing Adjusting Shims NCMT0032S03
244.20 - 244.30 mm (9.6142 - 9.6181 in)
Thickness mm (in)
Part number*
0.44 (0.0173)
38454-M8000
0.48 (0.0189)
38454-M8001
0.52 (0.0205)
38454-M8002
0.56 (0.0220)
38454-M8003
0.60 (0.0236)
38454-M8004
0.64 (0.0252)
38454-M8005
SMT843D
0.68 (0.0268)
38454-M8006
244.20 - 244.30 mm (9.6142 9.6181 in)
0.72 (0.0283)
38454-M8007
Thickness
Part number*
0.76 (0.0299)
38454-M8008
6.04 mm (0.2378 in)
32246-6J000
0.80 (0.0315)
38454-M8009
6.12 mm (0.2409 in)
32246-6J001
0.84 (0.0331)
38454-M8010
6.20 mm (0.2441 in)
32246-6J002
0.88 (0.0346)
38454-M8011
6.28 mm (0.2472 in)
32246-6J003
6.36 mm (0.2504 in)
32246-6J004
Standard length “M”
*: Always check with the parts department for the latest information.
*: Always check with the parts department for the latest information.
MT-92
AUTOMATIC TRANSAXLE SECTION
AT
(H⋅CVT)
CONTENTS TROUBLE DIAGNOSIS - INDEX ....................................3 Alphabetical & P No. Index for DTC ...........................3 PRECAUTIONS ...............................................................5 Precautions for Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″ ......................................................5 Precautions for On Board Diagnostic (OBD) System of CVT and Engine.........................................5 Precautions ..................................................................5 Service Notice or Precautions .....................................6 Wiring Diagrams and Trouble Diagnosis.....................7 PREPARATION ...............................................................8 Special Service Tools ..................................................8 OVERALL SYSTEM ........................................................9 CVT Electrical Parts Location......................................9 Circuit Diagram ..........................................................10 Cross-sectional View - RE0F06A ..............................11 Control System ..........................................................12 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................15 Introduction ................................................................15 OBD Function for CVT System .................................15 OBD Diagnostic Trouble Code (DTC) .......................15 Malfunction Indicator (MI) ..........................................18 CONSULT-II ...............................................................18 TROUBLE DIAGNOSIS - INTRODUCTION..................29 Introduction ................................................................29 Work Flow..................................................................32 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........34 CVT Fluid Check .......................................................34 Stall Test ....................................................................34 Line Pressure Test.....................................................35 Road Test...................................................................36 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................41 TCM Terminals and Reference Value........................41
TROUBLE DIAGNOSIS FOR POWER SUPPLY..........45 Wiring Diagram - CVT - MAIN...................................45 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH .........................................................................48 Description .................................................................48 Wiring Diagram - AT - PNP/SW.................................50 Diagnostic Procedure ................................................51 Component Inspection...............................................53 DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT .........................................................................54 Description .................................................................54 Wiring Diagram - AT - FTS ........................................56 Diagnostic Procedure ................................................57 DTC P0715 PRIMARY SPEED SENSOR .....................59 Description .................................................................59 Wiring Diagram - AT - VSSA/T ..................................60 Diagnostic Procedure ................................................61 Component Inspection...............................................61 DTC P0720 VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) ................................62 Description .................................................................62 Wiring Diagram - AT - VSSA/T ..................................64 Diagnostic Procedure ................................................65 Component Inspection...............................................65 DTC P0725 ENGINE SPEED SIGNAL .........................66 Description .................................................................66 Wiring Diagram - AT - ENGSS ..................................67 Diagnostic Procedure ................................................68 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE........................................................69 Description .................................................................69 Wiring Diagram - AT - TCV........................................71 Diagnostic Procedure ................................................72 Component Inspection...............................................73 DTC P0745 LINE PRESSURE SOLENOID VALVE .....74 Description .................................................................74
AT
CONTENTS Wiring Diagram - AT - LPSV......................................76 Diagnostic Procedure ................................................77 Component Inspection...............................................78 DTC P1705 THROTTLE POSITION SENSOR .............79 Description .................................................................79 Wiring Diagram - AT - TPS........................................81 Diagnostic Procedure ................................................82 Component Inspection...............................................85 DTC P1777 STEP MOTOR - CIRCUIT .........................86 Description .................................................................86 Wiring Diagram - AT - STM .......................................88 Diagnostic Procedure ................................................89 Component Inspection...............................................90 DTC P1778 STEP MOTOR - FUNCTION .....................91 Description .................................................................91 Diagnostic Procedure ................................................93 DTC P1791 CVT FLUID PRESSURE SENSOR ...........94 Description .................................................................94 Wiring Diagram - AT - FPS........................................96 Diagnostic Procedure ................................................97 Component Inspection...............................................98 CVT SAFE FUNCTION..................................................99 Description .................................................................99 Diagnostic Procedure ..............................................100 CONTROL UNIT (RAM), CONTROL UNIT (ROM).....101 Description ...............................................................101
(Cont’d)
Diagnostic Procedure ..............................................102 CONTROL UNIT (EEPROM) .......................................103 Description ...............................................................103 Diagnostic Procedure ..............................................104 TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS...........................................................................105 PNP Switch, Stop Lamp Switch and Throttle Position Switch ........................................................105 Wiring Diagram - AT - NONDTC .............................110 ON-VEHICLE SERVICE ..............................................114 Control Cable Adjustment........................................114 Park/Neutral Position (PNP) Switch Adjustment .....114 Differential Side Oil Seal Replacement ...................114 REMOVAL AND INSTALLATION ...............................116 Removal...................................................................116 Inspection.................................................................116 Installation................................................................117 Air Breather Hose ....................................................118 CVT Fluid Cooler (Hyper CVT-M6) .........................118 Components.............................................................119 SERVICE DATA AND SPECIFICATIONS (SDS) .......120 General Specifications.............................................120 Stall Revolution........................................................120 Line Pressure...........................................................120 Removal and Installation .........................................120
AT-2
TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC
Alphabetical & P No. Index for DTC
NCAT0001
ALPHABETICAL INDEX FOR DTC
NCAT0001S01
DTC Items (CONSULT-II screen terms)
CONSULT-II GST*2
Reference page
ECM*1
ATF TEMP SEN/CIRC
0710
P0710
AT-54
ENG SPEED SIG
0725
P0725
AT-66
LINE PRESSURE SEN
1791
P1791
AT-94
L/PRESS SOL/CIRC
0745
P0745
AT-74
PNP SW/CIRC
0705
P0705
AT-48
PRI SPEED SIG/CIRC
0715
P0715
AT-59
STEP MOTOR/CIRC
1777
P1777
AT-86
STEP MOTOR/FNCTN
1778
P1778
AT-91
TP SEN/CIRC A/T*3
1705
P1705
AT-79
TCC SOLENOID/CIRC
0740
P0740
AT-69
VEH SPD SEN/CIR A/T
0720
P0720
AT-62
*1: In Diagnostic Test Mode II (Self-diagnostic results), these numbers are controlled by NISSAN. *2: These numbers are prescribed by ISO15031-6. *3: When the fail-safe operation occurs, the MI illuminates.
AT-3
TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC (Cont’d)
P NO. INDEX FOR DTC
=NCAT0001S02
DTC Items (CONSULT-II screen terms)
Reference page
CONSULT-II GST*2
ECM*1
P0705
0705
PNP SW/CIRC
AT-48
P0710
0710
ATF TEMP SEN/CIRC
AT-54
P0715
0715
PRI SPEED SIG/CIRC
AT-59
P0720
0720
VEH SPD SEN/CIR AT
AT-62
P0725
0725
ENG SPEED SIG
AT-66
P0740
0740
TCC SOLENOID/CIRC
AT-69
P0745
0745
L/PRESS SOL/CIRC
AT-74
P1705
1705
TP SEN/CIRC A/T*3
AT-79
P1777
1777
STEP MOTOR/CIRC
AT-86
P1778
1778
STEP MOTOR/FNCTN
AT-91
P1791
1791
LINE PRESSURE SEN
AT-94
*1: In Diagnostic Test Mode II (Self-diagnostic results), these numbers are controlled by NISSAN. *2: These numbers are prescribed by ISO15031-6. *3: When the fail-safe operation occurs, the MI illuminates.
AT-4
PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
NCAT0002
The Supplemental Restraint System “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: I 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 dealer. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors).
Precautions for On Board Diagnostic (OBD) System of CVT and Engine
NCAT0198
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: I Be sure to turn the ignition switch “OFF” and disconnect the negative battery terminal before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. I Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MI to light up due to an open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) I Be sure to route and secure the harnesses properly after work. Interference of the harness with a bracket, etc. may cause the MI to light up due to a short circuit. I Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MI to light up due to a malfunction of the EGR system or fuel injection system, etc. I Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and ECM before returning the vehicle to the customer.
Precautions I
NCAT0003
Before connecting or disconnecting the TCM harness connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the TCM. Because battery voltage is applied to TCM even if ignition switch is turned off.
SEF289H
AT-5
PRECAUTIONS Precautions (Cont’d)
I
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.
I
Before replacing TCM, perform TCM input/output signal inspection and make sure whether TCM functions properly or not. (See page AT-41.)
I
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.
I
It is very important to perform functional tests whenever they are indicated. Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling. When the CVT drain plug is removed, only some of the fluid is drained. Old CVT fluid will remain in torque converter and CVT fluid cooling system. Always follow the procedures under “Changing CVT Fluid” in the MA section when changing CVT fluid.
SEF291H
Perform TCM input/output signal inspection before replacement.
MEF040DA
SAT652J
I I
Service Notice or Precautions FAIL-SAFE
NCAT0004 NCAT0004S01
The TCM has an electronic Fail-Safe (limp home 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 even with a shift lever position of “L” or “D”. The customer may complain of sluggish or poor acceleration. When the ignition key is turned “ON” following Fail-Safe operation, CVT or SPORT indicator lamp blinks for about 8 seconds. [For “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”, refer to AT-25.] Fail-Safe may occur without electrical circuit damage if the vehicle is driven under extreme conditions (such as excessive wheel spin followed by sudden braking). To recover normal shift pattern, turn the ignition key “OFF” for 5 seconds, then “ON”.
AT-6
PRECAUTIONS Service Notice or Precautions (Cont’d)
The blinking of the CVT or SPORT indicator lamp for about 8 seconds will appear only once and be cleared. The customer may resume normal driving conditions. Always follow the “WORK FLOW” (Refer to AT-32). 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.
OBD SELF-DIAGNOSIS
NCAT0004S04
I
CVT self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through the blinking pattern of the CVT or SPORT indicator. Refer to the table on AT-19 for the indicator used to display each self-diagnostic result. I The self-diagnostic results indicated by the MI are automatically stored in both the ECM and TCM memories. Always perform the procedure “HOW TO ERASE DTC” on AT-16 to complete the repair and avoid unnecessary blinking of the MI. For details of OBD, refer to EC section (“ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”). I 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 EL section, “Description”, “HARNESS CONNECTOR”.
Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the followings: I “HOW TO READ WIRING DIAGRAMS” in GI section I “POWER SUPPLY ROUTING” for power distribution circuit in EL section When you perform trouble diagnosis, refer to the followings: I “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” in GI section I “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” in GI section
AT-7
NCAT0005
PREPARATION Special Service Tools
Special Service Tools Tool number Tool name ST2505S001 Oil pressure gauge set 1 ST25051001 Oil pressure gauge 2 ST25052000 Hose 3 ST25053000 Joint pipe 4 ST25054000 Adapter 5 ST25055000 Adapter
NCAT0006
Description Measuring line pressure and governor pressure
NT097
KV31103000 Drift
Installing differential side oil seal (Use with ST35325000) a: 59 mm (2.32 in) dia. b: 49 mm (1.93 in) dia. NT105
ST35325000 Drift
Installing differential side oil seal (Use with KV31103000) a: 215 mm (8.46 in) b: 25 mm (0.98 in) dia. c: M12 x 1.5P
NT417
AT-8
OVERALL SYSTEM CVT Electrical Parts Location
CVT Electrical Parts Location
Steering column
NCAT0008
Throttle position sensor and throttle position switch
Indicator C/U
Front
TCM
SPORT indicator lamp
CVT indicator lamp
Secondary speed sensor PNP switch Control valve connector
SPORT mode switch
Dropping resistor
Inside control valve Fluid temperature sensor Fluid pressure sensor Lock-up solenoid Line pressure solenoid Step motor Manual mode switch
Primary speed sensor
SAT671J
AT-9
OVERALL SYSTEM Circuit Diagram
Circuit Diagram
NCAT0009
YAT250
AT-10
OVERALL SYSTEM Cross-sectional View — RE0F06A
Cross-sectional View — RE0F06A
NCAT0011
Converter housing Reverse brake
Primary pulley
Planet carrier
Oil pump
Forward clutch
Torque converter
Steel belt
Sun gear Input shaft Side cover
Internal gear
Parking gear Output gear Taper roller bearing
Reduction gear
Idler gear
Speedometer drive gear Secondary pulley
Differential case Final gear
SAT668J
AT-11
OVERALL SYSTEM Control System
Control System
=NCAT0014
OUTLINE
NCAT0014S01
The CVT senses vehicle operating conditions through various sensors. It always controls the optimum shift position and reduces shifting and lock-up shocks. SENSORS
TCM
PNP switch Throttle position sensor Closed throttle position switch Wide open throttle position switch Engine speed signal CVT fluid temperature sensor CVT fluid pressure sensor Primary speed sensor Secondary speed sensor Stop lamp switch Sport mode switch (Hyper CVT only) Indicator control unit (Hyper CVT M6 only) ABS control unit
Shift control Line pressure control Lock-up control Fail-safe control Self-diagnosis CONSULT-II communication line control Duet-EU control On board diagnosis
E
AT-12
ACTUATORS
E
Step motor CVT indicator (warning) lamp (Hyper CVT M6 only) Torque converter clutch solenoid valve Line pressure solenoid valve SPORT indicator lamp (Hyper CVT only)
OVERALL SYSTEM Control System (Cont’d)
CONTROL SYSTEM
NCAT0014S02
Transaxle
Wheel
Differential gear
Belt and Pulley
Final gear
Forward and reverse change
Torque converter
Engine
Oil pump
Parking system Oil pressure control
Control device
Electrical control
Sport mode SW or manual mode SW Control valve
Engine speed sensor Primary pulley speed and secondary pulley speed sensor
[Hyper CVT-M6]
Position indicator
Indicator C/U
Throttle opening sensor
CVT indicator (warning) lamp or SPORT indicator lamp
TCM
ECM
Mechanical system Oil system Electrical system
ABS C/U Stop lamp SW
PNP switch
NAT310
AT-13
OVERALL SYSTEM Control System (Cont’d)
TCM FUNCTION
=NCAT0014S03
The function of the TCM is to: I Receive input signals sent from various switches and sensors. I Determine required line pressure, shifting point and lock-up operation. I Send required output signals to the step motor and the respective solenoids.
INPUT/OUTPUT SIGNAL OF TCM
NCAT0014S04
Sensors and actuators
Input
Output
Function
PNP switch
Detects select lever position and sends a signal to TCM.
Throttle position sensor
Detects throttle valve position and sends a signal to TCM.
Closed throttle position switch
Detects throttle valve’s fully-closed position and sends a signal to TCM.
Wide open throttle position switch
Detects a throttle valve position of greater than 1/2 of full throttle and sends a signal to TCM.
Engine speed signal
From ECM.
CVT fluid temperature sensor
Detects transmission fluid temperature and sends a signal to TCM.
CVT fluid pressure sensor
Detects transmission fluid pressure and sends a signal to TCM.
Primary speed sensor
Detects primary pulley rpm and sends a signal to TCM.
Secondary speed sensor
Detects secondary pulley rpm and sends a signal to TCM.
Stop lamp switch
Sends a signal to the TCM relaying the operation condition of the brake pedal.
Sport mode switch
Sends a signal to the TCM relaying the operation condition of the sport mode switch.
Indicator control unit*1
Sends a signal to the TCM operation condition of the manual mode switch in control device.
ABS control unit
Sends a signal to the TCM operation condition of the ABS.
Step motor
Regulates pulley position in relation to a signal sent from TCM.
Line pressure solenoid valve
Regulates (or decreases) line pressure suited to driving conditions in relation to a signal sent from TCM.
Torque converter clutch solenoid valve
Regulates (or decreases) lock-up pressure suited to driving conditions in relation to a signal sent from TCM.
CVT indicator (warning) lamp*2
Shows TCM faults, when CVT control components malfunction.
SPORT indicator lamp*3
Shows the operation condition of the SPORT mode switch. *3
Indicator control unit *1
Receives the information of gear position on manual mode from TCM, and sends a signal to indicator.
*1: Hyper CVT M6 models only *2: Hyper CVT M6 models *3: Hyper CVT models
AT-14
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Introduction
Introduction
NCAT0017
The CVT system has two self-diagnostic systems. The first is the emission-related on board diagnostic system (OBD) performed by the TCM in combination with the ECM. The malfunction is indicated by the MI (malfunction indicator) 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 CVT indicator (warning) lamp or SPORT indicator lamp. The malfunction is stored in the TCM memory. The detected items are overlapped with OBD selfdiagnostic items. For detail, refer to AT-26.
OBD Function for CVT System
NCAT0018
The ECM provides emission-related on board diagnostic (OBD) functions for the CVT system. One function is to receive a signal from the TCM used with OBD-related parts of the CVT 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 MI (malfunction indicator) on the instrument panel. Sensors, switches and solenoid valves are used as sensing elements. The MI automatically illuminates in Two Trip Detection Logic when a malfunction is sensed in relation to CVT system parts.
OBD Diagnostic Trouble Code (DTC) HOW TO READ DTC AND 1ST TRIP DTC
NCAT0020 NCAT0020S01
DTC and 1st trip DTC can be read by the following methods. 1. ( No Tools) The number of blinks of the malfunction indicator in the Diagnostic Test Mode II (Self-Diagnostic Results) Examples: 0705, 0710, 0715, 0720, etc. For details, refer to EC section [“Malfunction Indicator (MI)”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”]. These DTCs are controlled by NISSAN. GST) CONSULT-II or GST (Generic Scan Tool) Examples: P0705, P0710, 2. ( with CONSULT-II or P0720, P0725, etc. These DTCs are prescribed by ISO15031-6. (CONSULT-II also displays the malfunctioning component or system.) I 1st trip DTC No. is the same as DTC No. I 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, using CONSULT-II (if available) is recommended. A sample of CONSULT-II display for DTC is shown at left. 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.
SAT651J
If the DTC is being detected currently, the time data will be “0”.
AT-15
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD Diagnostic Trouble Code (DTC) (Cont’d)
SAT581J
If a 1st trip DTC is stored in the ECM, the time data will be “1t”.
SAT582J
Freeze Frame Data and 1st Trip Freeze Frame Data
NCAT0020S0101
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 section (“CONSULT-II”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”). 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/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
Items Freeze frame data
2 3
Misfire — DTC: P0300 - P0306 (0300 - 0306) Fuel Injection System Function — DTC: P0171 (0171), P0172 (0172), P0174 (0174), P0175 (0175) Except the above items (Includes CVT related items)
1st trip freeze frame data
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased.
HOW TO ERASE DTC
NCAT0020S02
The diagnostic trouble code can be erased by CONSULT-II, GST or ECM DIAGNOSTIC TEST MODE as described following. I If the battery terminal is disconnected, the diagnostic trouble code will be lost within 24 hours. I When you erase the DTC, using CONSULT-II or GST is easier and quicker than switching the mode selector on the ECM.
AT-16
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD Diagnostic Trouble Code (DTC) (Cont’d)
The following emission-related diagnostic information is cleared from the ECM memory when erasing DTC related to OBD. For details, refer to EC section (“Emission-related Diagnostic Information”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”). I Diagnostic trouble codes (DTC) I 1st trip diagnostic trouble codes (1st trip DTC) I Freeze frame data I 1st trip freeze frame data I System readiness test (SRT) codes I Test values I Distance traveled while MI is activated I Others
HOW TO ERASE DTC (WITH CONSULT-II)
NCAT0020S03
I If a DTC is displayed for both ECM and TCM, it needs to be erased for both ECM and TCM. 1. 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. 2. Turn CONSULT-II “ON” and touch “CVT”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. (The DTC in the TCM 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.) How to erase DTC (With CONSULT-II) 1. 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.
.
2. Turn CONSULT-II “ON”, and touch “CVT”.
3. Turn “SELF DIAGNOSIS”.
4. Touch “ERASE”. (The DTC in the TCM will be erased.) Touch “BACK”
Touch “BACK”
.
5. Touch “ENGINE”.
6. Touch “SELF DIAGNOSIS”.
7. Touch “ERASE”. (The DTC in the ECM will be erased.) SAT681J
AT-17
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD Diagnostic Trouble Code (DTC) (Cont’d)
HOW TO ERASE DTC (WITH GST)
NCAT0020S04
1. 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. 2. Perform “OBD SELF-DIAGNOSTIC PROCEDURE (No Tools)”. Refer to AT-25. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) 3. Select Mode 4 with Generic Scan Tool (GST). For details, refer to EC section “Generic Scan Tool (GST)”.
HOW TO ERASE DTC (NO TOOLS)
NCAT0020S05
1. 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. 2. Perform “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”. Refer to AT-25. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) 3. Change the diagnostic test mode from Mode II to Mode I by turning the mode selector on the ECM. Refer to EC section “HOW TO SWITCH DIAGNOSTIC TEST MODES”.
Malfunction Indicator (MI) 1. I
2. SAT652J
NCAT0021
The malfunction indicator will light up when the ignition switch is turned ON without the engine running. This is for checking the lamp. If the malfunction indicator does not light up, refer to EL section (“Warning Lamps/System Description”, “WARNING LAMPS AND CHIME”). (Or see MI & Data Link Connectors in EC section.) When the engine is started, the malfunction indicator should go off. If the lamp remains on, the on board diagnostic system has detected an emission-related (OBD) malfunction. For detail, refer to EC section (“ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”).
CONSULT-II
NCAT0022
After performing “SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)” (AT-19), place check marks for results on the “DIAGNOSTIC WORKSHEET”, AT-31. Reference pages are provided following the items. NOTICE: I Additional CONSULT-II information can be found in the Operation Manual supplied with the CONSULT-II unit.
AT-18
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)
SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)
NCAT0022S02
1.
Turn on CONSULT-II and touch “ENGINE” for OBD detected items or touch “CVT” for TCM self-diagnosis. If CVT is not displayed, check TCM power supply and ground circuit. Refer to AT-41. If result is NG, refer to EL section (“POWER SUPPLY ROUTING”).
2.
Touch “SELF DIAGNOSIS”. Display shows malfunction experienced since the last erasing operation. CONSULT-II performs REAL-TIME SELF-DIAGNOSIS. Also, any malfunction detected while in this mode will be displayed at real time.
SAT651J
SAT584J
SELF-DIAGNOSTIC RESULT TEST MODE
NCAT0022S03
TCM self-diagnosis
OBD (DTC)
Available by CVT or SPORT indicator lamp “CVT” on CONSULT-II
Available by malfunction indicator lamp*2, “ENGINE” on CONSULT-II or GST
—
P0705
I TCM does not receive the proper voltage signal from the sensor.
X
P0715
I TCM does not receive the proper voltage signal from the sensor.
X
P0720
X
P0740
X
P0745
X
P1705
Detected items (Screen terms for CONSULT-II, “SELF DIAGNOSIS” test mode) Malfunction is detected when ...
“CVT”
“ENGINE”
PNP switch circuit PNP SW/CIRCUIT
PNP SW/CIRC
Primary speed sensor I/P PULLY SPD SIG
PRI SPEED SIG/ CIRC
Secondary speed sensor VEHICLE SPEED SIG
VEH SPD SEN/CIR A/T
T/C clutch solenoid valve T/C CLUTCH SOL/V
TCC SOLENOID/ CIRC
Line pressure solenoid valve LINE PRESSURE S/V
L/PRESS SOL/ CIRC
Throttle position sensor, Throttle position switch THROTTLE POSI SEN
I TCM does not receive the correct voltage signal (based on the gear position) from the switch.
I TCM detects an improper voltage drop when it tries to operate the solenoid valve. I TCM detects an improper voltage drop when it tries to operate the solenoid valve. I TCM receives an excessively low or high voltage from the sensor.
TP SEN/CIRC A/T
AT-19
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) TCM self-diagnosis
OBD (DTC)
Available by CVT or SPORT indicator lamp “CVT” on CONSULT-II
Available by malfunction indicator lamp*2, “ENGINE” on CONSULT-II or GST
I TCM does not receive the proper voltage signal from the ECM.
X
P0725
I TCM receives an excessively low or high voltage from the sensor.
X
P0710
I Not proper voltage change of the TCM terminal when operating step motor.
X
P1777
I Step motor is not operating according to the TCM.
X
P1778
I TCM receives an excessively low or high voltage from the sensor.
X
P1791
X
—
I TCM memory (RAM) is malfunctioning.
—
—
I TCM memory (ROM) is malfunctioning.
—
—
I TCM memory (EEP ROM) is malfunctioning.
—
—
X
—
X
X
Detected items (Screen terms for CONSULT-II, “SELF DIAGNOSIS” test mode) Malfunction is detected when ...
“CVT”
“ENGINE”
Engine speed signal ENGINE SPEED SIG CVT fluid temperature sensor BATT/FLUID TEMP SEN
ATF TEMP SEN/ CIRC
Stepping motor circuit STEP MOTOR
STEP MOTOR/ CIRC
Stepping motor function —
STEP MOTOR/ FNCTN
CVT fluid pressure sensor LINE PRESSURE SEN
LINE PRESS SEN
I TCM is malfunctioning.
CVT SAFE FUNCTION CVT SAFE FUNCTION
—
TCM (RAM) CONTROL UNIT (RAM)
—
TCM (ROM) CONTROL UNIT (ROM)
—
TCM (EEP ROM) CONT UNIT (EEP ROM)
—
Initial start *INITIAL START*
—
No failure (NO SELF DIAGNOSTIC FAILURE INDICATED FURTHER TESTING MAY BE REQUIRED**)
I This is not a malfunction message (Whenever shutting off a power supply to the TCM, this message appears on the screen.) I No failure has been detected.
X: Applicable —: Not applicable *1: These malfunctions cannot be displayed by MI if another malfunction is assigned to MI. *2: Refer to EC section [“Malfunction Indicator (MI)”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”].
AT-20
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)
DATA MONITOR MODE (CVT)
NCAT0022S04
Monitor item Item
Display
Vehicle speed sensor VHCL SPEED (Secondary speed sensor) SE [km/h] or [mph]
Throttle position sensor
CVT fluid temperature sensor
THRTL POS SEN [V] FLUID TEMP SE [V]
Battery voltage
BATTERY VOLT [V]
Engine speed
ENGINE SPEED [rpm]
P/N position switch
R position switch
D position switch
Sport mode switch
L position switch
Closed throttle position switch
N POSITION SW [ON/OFF] R POSITION SW [ON/OFF] D POSITION SW [ON/OFF] S POSITION SW [ON/OFF] L POSITION SW [ON/OFF] CLOSED THL/SW [ON/OFF]
Wide open throttle position W/O THRL/ switch P-SW [ON/OFF]
TCM input signals
Main signals
Description
Remarks
I Vehicle speed computed from signal of revolution sensor is displayed.
When racing engine in “N” or “P” position with vehicle stationary, CONSULT-II data may not indicate 0 km/h (0 mph).
X
—
X
—
I Throttle position sensor signal voltage is displayed.
—
X
—
I CVT fluid temperature sensor signal voltage is displayed. I Signal voltage lowers as fluid temperature rises.
—
X
—
I Source voltage of TCM is displayed.
—
X
X
I Engine speed, computed from engine speed signal, is displayed.
Engine speed display may not be accurate under approx. 800 rpm. It may not indicate 0 rpm even when engine is not running.
—
I ON/OFF state computed from signal of P/N position SW is displayed.
—
—
I ON/OFF state computed from signal of R position SW is displayed.
—
—
I ON/OFF state computed from signal of D position SW is displayed.
—
X
—
I ON/OFF status, computed from signal of Sport mode SW, is displayed.
—
X
—
I ON/OFF status, computed from signal of L position SW, is displayed.
—
—
I ON/OFF status, computed from signal of closed throttle position SW, is displayed.
—
—
I ON/OFF status, computed from signal of wide open throttle position SW, is displayed.
—
X
X
X
X
X
AT-21
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Monitor item Item
Gear position
Display
Description
Remarks
X
I Gear position (when use manual mode) data used for computation by TCM, is displayed.
—
—
X
I Selector lever position I A specific value used for data, used for computacontrol is displayed if failtion by TCM, is dissafe is activated due to played. error.
—
X
I Vehicle speed data, used for computation by TCM, is displayed.
X
I A specific value used for I Throttle position data, used for computation by control is displayed if failsafe is activated due to TCM, is displayed. error.
X
I Control value of line pressure solenoid valve, computed by TCM from each input signal, is displayed.
—
X
I Control value of torque converter clutch solenoid valve, computed by TCM from each input signal, is displayed.
—
TCM input signals
GEAR —
Selector lever position
Vehicle speed
Throttle position
Line pressure duty
Torque converter clutch solenoid valve duty
Main signals
SLCT LVR POSI
VEHICLE SPEED [km/h] or [mph] THROTTLE POSI [/8] LINE PRES DTY [%]
—
—
TCC S/V DUTY [%] —
Self-diagnosis display lamp (SPORT or CVT indicator lamp)
PAT MONI LAMP [ON/OFF]
CVT fluid pressure sensor
LINE PRESSURE [V]
I Control status of SPORT or CVT indicator lamp is displayed.
—
—
X
X
—
I CVT fluid pressure sensor signal voltage is displayed.
—
X
I Primary pulley speed computed from signal of primary pulley speed sensor is displayed.
—
—
—
I Secondary pulley speed computed from signal of secondary speed sensor is displayed.
—
—
Primary pulley speed sensor
I/P PULLY SPD [rpm]
Secondary pulley speed sensor
O/P PULLY SPD [rpm]
Stop lamp switch
BRAKE SW [ON/OFF]
X
—
I ON/OFF position signal of stop lamp switch is displayed.
—
CLSD THL POSI [ON/OFF]
—
—
I Idle status judged from throttle position sensor signal is displayed.
—
ABS SIGNAL [ON/OFF]
X
—
I ABS operation signal (ON/OFF) from ABS control unit is displayed.
—
MANU MODE SW [ON/OFF]
X
—
I ON/OFF position signal of manual mode switch is displayed.
—
Idle judgement
ABS signal
Manual mode switch
X
AT-22
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Monitor item Item
Non-manual mode switch
Up switch
Down switch
Step motor coil A
Step motor coil B
Step motor coil C
Step motor coil D
Display
I ON/OFF position signal of non-manual mode switch is displayed.
—
X
—
I ON/OFF position signal of up switch is displayed.
—
X
—
I ON/OFF position signal of down switch is displayed.
—
—
I Control valve of step motor coil A, computed by TCM from each input signal is displayed.
—
—
I Control valve of step motor coil B, computed by TCM from each input signal is displayed.
—
—
I Control valve of step motor coil C, computed by TCM from each input signal is displayed.
—
—
—
I Control valve of step motor coil D, computed by TCM from each input signal is displayed.
—
—
X
I Real CVT ratio operated TCM is displayed.
—
—
X
I Step motor position is displayed.
—
—
X
I Real line pressure calculated from line pressure sensor voltage with TCM is displayed.
—
—
—
I Target primary pulley speed operated with TCM is displayed.
—
—
—
I Target changing the speed ratio operated with TCM is displayed.
—
—
—
I Target step motor position operated with TCM is displayed.
—
X
UP SW [ON/OFF] DOWN SW [ON/OFF] S/M COIL [A] [ON/OFF]
S/M COIL [B] [ON/OFF]
S/M COIL [C] [ON/OFF]
S/M COIL [D] [ON/OFF]
Step
PLY CONT STEP [step]
Line pressure
LINE PRESSURE [MPa]
Step 2
—
NON M MODE SW [ON/OFF]
CVT RATIO [—]
CVT ratio 2
Remarks
Main signals
CVT ratio
Pulley rpm⋅in 2
Description
TCM input signals
—
—
—
T RPM [rpm]
T RATIO [—]
T STEP [step]
X: Applicable —: Not applicable
AT-23
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)
WORK SUPPORT MODE WITH CONSULT-II
Data link connector
1. 2. 3.
Turn ignition switch “OFF”. Connect CONSULT-II to Data link connector. Data link connector is located in left side dash panel. Turn ignition switch “ON”.
4.
Touch “START”.
5.
Touch “CVT”.
6.
Touch “WORK SUPPORT”.
7. 8.
Touch “ENGINE BRAKE ADJUSTMENT”. Touch “START”.
NRS071
SAT586J
SAT651J
SAT732J
SAT933J
AT-24
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)
9.
SAT934J
Set “ENGINE BRAKE LEVEL” by touching “UP” or “DOWN”. ENGINE BRAKE LEVEL 0: Initial set value (Engine brake level control is activated) OFF: Engine brake level control is disactivated. 10. Turn ignition switch “OFF”, wait at least 5 seconds and then turn ignition switch “ON”. 11. Engine brake level set is completed. CAUTION: Mode of “+1” “0” “-1” “-2” “OFF” can be selected by pressing the “UP” “DOWN” on CONSULT screen. However, do not select mode other than “0” and “OFF”. If the “+1” or “-1” or “-2” is selected, that might cause the abnormality of drivability.
DIAGNOSTIC PROCEDURE WITHOUT CONSULT-II NCAT0022S07 OBD Self-diagnostic Procedure (With GST) NCAT0022S0701 Refer to EC section [“Generic Scan Tool (GST)”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”].
OBD Self-diagnostic Procedure (No Tools)
NCAT0022S0702
Refer to EC section [“Malfunction Indicator (MI)”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”].
TCM Self-diagnostic Procedure (No Tools)
=NCAT0022S0703
Preparation 1. Turn ignition switch to “OFF” position. 2. Disconnect the throttle position switch harness connector. 3. Turn ignition switch to “ON” position. 4. Check continuity of the closed throttle position switch. Continuity should exist. (If continuity does not exist, check throttle opener and closed throttle position switch. Then increase vacuum until closed throttle position switch shows continuity.) 5. Connect the throttle position switch harness connector. 6. Warm up the engine. 7. Turn the ignition switch from ON to OFF two more times, and then turn to OFF. 8. In the “P” position of the selector lever, turn the ignition switch ON, and verify that the CVT warning lamp turns on for about 2 seconds. 9. Turn the ignition switch OFF. 10. Press the brake pedal, and shift the selector lever to the “D” position. 11. Turn the ignition switch ON. 12. Release the brake, and shift the selector lever to the “L” position. 13. Fully depress both brake and accelerator pedals all the way to the floor. Without releasing the brake and accelerator pedals, shift the selector lever to the “D” position. 14. Read the display from the CVT warning lamp to complete the diagnosis.
AT-25
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)
Judgement of Self-diagnosis Code
NCAT0022S0704
CVT or SPORT indicator lamp* All judgement flickers are the same.
1st judgement flicker is longer than others.
Self diagnosis start Start signal 10 judgement flickers
Light
Light
Shade
Shade
SAT436FA
SAT437FA
All circuits that can be confirmed by self-diagnosis are OK.
Secondary speed sensor (VEHICLE SPEED SENSOR CVT) circuit is short-circuited or disconnected. ⇒ Go to VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) (DTC: 0720), AT-62.
2nd judgement flicker is longer than others.
3rd judgement flicker is longer than others.
Light Light Shade Shade
SAT439FA
SAT441FA
Primary speed sensor circuit is short-circuited or disconnected. ⇒ Go to PRIMARY SPEED SENSOR (DTC: 0715), AT-59.
Throttle position sensor circuit is short-circuited or disconnected. ⇒ Go to THROTTLE POSITION SENSOR (DTC: 1705), AT-79.
4th judgement flicker is longer than others.
5th judgement flicker is longer than others.
Self diagnosis start Light
Light Shade
Shade
SAT443FA
Step motor circuit is short-circuited or disconnected. ⇒ Go to STEP MOTOR (DTC: 1777), AT-86.
SAT445FA
CVT fluid pressure sensor circuit is short-circuited or disconnected. ⇒ Go to CVT FLUID PRESSURE SENSOR (DTC: 1791), AT-94.
AT-26
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) CVT or SPORT indicator lamp* 7th judgement flicker is longer than others.
6th judgement flicker is longer than others.
Light
Light
Shade
Shade SAT447FA
SAT449FA
Line pressure solenoid valve circuit is short-circuited or disconnected. ⇒ Go to LINE PRESSURE SOLENOID VALVE (DTC: 0745), AT-74.
Lock up solenoid valve circuit is short-circuited or disconnected. ⇒ Go to TORQUE CONVERTER CLUTCH SOLENOID VALVE (DTC: 0740), AT-69.
8th judgement flicker is longer than others.
9th judgement flicker is longer than others.
Self diagnosis start Light
Light
Shade
Shade
SAT451FA
SAT453FA
CVT fluid temperature sensor is disconnected or TCM power source circuit is damaged. ⇒ Go to CVT FLUID TEMPERATURE SENSOR (DTC: 0710) AND TCM POWER SOURCE, AT-54.
Engine speed signal circuit is short-circuited or disconnected. ⇒ Go to ENGINE SPEED SIGNAL (DTC: 0725), AT-66.
10th judgement flicker is longer than others.
Flickers as shown below.
Light Light Shade
Shade
SAT455FA
I When “4th judgement flicker” and/or “6th judgement flicker” is displayed, inspect “STEP MOTOR (DTC: 1777)” and/or “LINE PRESSURE SOLENOID VALVE (DTC: 0745)”. I When neither “4th judgement flicker” nor “6th judgement flicker” are displayed, replace TCM. ⇒ Go to CVT SAFE FUNCTION, AT-99.
SAT457FA
Battery voltage is low. Battery has been disconnected for a long time. Battery is connected conversely. (When reconnecting TCM connectors — This is not a problem)
AT-27
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) CVT or SPORT indicator lamp* Lamp does not come on.
Self diagnosis start Light
Shade SAT653J
PNP switch, stop lamp switch or throttle position switch circuit is disconnected or TCM is damaged. ⇒ Go to TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS, AT-105. t1 = 2.5 seconds t2 = 2.0 seconds t3 = 1.0 second *CVT indicator lamp: Hyper CVT M6 SPORT indicator lamp: Hyper CVT
t4 = 1.0 second
AT-28
TROUBLE DIAGNOSIS — INTRODUCTION Introduction
Introduction Sensors
TCM
Solenoid valves
ECM
SAT631IA
CAUSE INFO.
SAT632I
NCAT0023
The TCM receives a signal from the vehicle speed sensor, throttle position sensor or PNP switch and provides shift control or lock-up control via step motor and CVT solenoid valves. The TCM also communicates with the ECM by means of a signal sent from sensing elements used with the OBD-related parts of the CVT system for malfunction-diagnostic purposes. The TCM is capable of diagnosing malfunctioning parts while the ECM can store malfunctions in its memory. Input and output signals must always be correct and stable in the operation of the CVT system. The CVT 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 problem that occurs intermittently rather than continuously. Most intermittent problems 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 problems. A road test with CONSULT-II (or GST) or a circuit tester connected should be performed. Follow the “Work Flow”. Refer to AT-32. 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 problems, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “Diagnostic Worksheet” like the example (AT-31) should be used. Start your diagnosis by looking for “conventional” problems first. This will help troubleshoot driveability problems on an electronically controlled engine vehicle. Also check related Service bulletins for information.
SEF234G
AT-29
TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d)
DIAGNOSTIC WORKSHEET Information from Customer KEY POINTS WHAT ..... Vehicle & CVT model WHEN..... Date, Frequencies WHERE..... Road conditions HOW..... Operating conditions, Symptoms Customer name
MR/MS
Model & Year
VIN
Trans. model
Engine
Mileage
Incident Date
Manuf. Date
In Service Date
Frequency
l Continuous
l Intermittent
l Vehicle does not move. Symptoms
(
times a day)
( l Any position l Particular position)
l Lockup malfunction l Shift point too high or too low. l Shift shock or slip
(lN,D
l Lockup
l Noise or vibration l No pattern select l Others (
)
SPORT indicator lamp or CVT indicator (warning) lamp
Blinks for about 8 seconds. l Continuously lit
l Not lit
Malfunction indicator (MI)
l Continuously lit
l Not lit
AT-30
l Any drive position)
=NCAT0023S01 NCAT0023S0101
TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d)
Diagnostic Worksheet
=NCAT0023S0102
1.
l Read the Fail-safe and listen to customer complaints.
AT-6
2.
l CHECK CVT FLUID
AT-34
l Leakage (Follow specified procedure) l Fluid condition l Fluid level 3.
l Perform STALL TEST and LINE PRESSURE TEST.
AT-34, 35
l Stall test — Mark possible damaged components/others. l Forward clutch
l Reverse brake l Engine l Line pressure is low
l Line Pressure test — Suspected parts: 4.
l Perform all ROAD TEST and mark required procedures.
AT-36
4-1. Check before engine is started.
AT-37
l SELF-DIAGNOSTIC PROCEDURE — Mark detected items. l l l l l l l l l l l l l l l
PNP switch, AT-48. CVT fluid temperature sensor, AT-54. Vehicle speed sensor (Secondary speed sensor), AT-62. Engine speed signal, AT-66. Torque converter clutch solenoid valve, AT-69. Line pressure solenoid valve, AT-74. Step motor, AT-86, 91. CVT fluid pressure sensor, AT-94. Throttle position sensor, AT-79. Stop lamp and throttle position switches. CVT fluid temperature sensor and TCM power source, AT-54. Primary speed sensor, AT-59. PNP switch, stop lamp switch, throttle position switch AT-105. Battery Others
5.
l For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts.
AT-19
6.
l Perform all ROAD TEST and re-mark required procedures.
AT-36
7.
l 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-41 AT-54
8.
l Erase DTC from TCM and ECM memories.
AT-16
AT-31
TROUBLE DIAGNOSIS — INTRODUCTION Work Flow
Work Flow HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR
=NCAT0024 NCAT0024S01
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about a problem. It is important to fully understand the symptoms or conditions for a customer complaint. Make good use of the two sheets provided, “INFORMATION FROM CUSTOMER” (AT-30) and “DIAGNOSTIC WORKSHEET” (AT-31), to perform the best troubleshooting possible.
AT-32
TROUBLE DIAGNOSIS — INTRODUCTION Work Flow (Cont’d)
WORK FLOW CHART
=NCAT0024S02
CHECK IN H
LISTEN TO CUSTOMER COMPLAINTS AND FILL OUT “INFORMATION FROM CUSTOMER”, *1
F
Refer to FAIL-SAFE Service Notice or Precautions, *3.
F
Refer to CVT Fluid Check, *4.
F
Refer to Stall Test and Line Pressure Test, *5.
F
Follow ROAD TEST procedure, *6.
H
CHECK, PRINT OUT OR WRITE DOWN (1ST TRIP) DTC AND FREEZE FRAME DATA. (PRE-CHECK) THEN ERASE. PASTE IT IN REPAIR ORDER SHEET. ALSO CHECK RELATED SERVICE BULLETINS. H
CHECK A/T FLUID LEVEL AND CONDITION. IF NG, PLACE CHECK ON THE DIAGNOSTIC WORKSHEET, *2. H
PERFORM STALL TEST AND LINE PRESSURE TEST. H
PERFORM “DTC CONFIRMATION PROCEDURE” IF THE (1ST TRIP) DTC IS AVAILABLE. PERFORM ROAD TEST AND PLACE CHECKS FOR NG ITEMS ON THE DIAGNOSTIC WORKSHEET.
NG items including OBD No NG item or NG items (1st trip) DTC or TCM selfnot including any OBD diagnostic item DTC or TCM self-diagnostic H items ● FOR OBD or TCM SELF-DIAGNOSIS NG ITEMS: F -INSPECT EACH COMPONENT. -REPAIR/REPLACE. ● PERFORM DTC CONFIRMATION PROCEDURE OR ROAD TEST AND PLACE CHECKS FOR NG ITEMS ON THE DIAGNOSTIC WORKSHEET AGAIN.
E
●
●
Refer to CONSULT-II, *7. Perform ROAD TEST for all items. Proceed if self-diagnosis detects no malfunction. (Non-self-diagnostic items, especially those that require CVT removal, should be repaired in the following steps.)
H
H ●
● ●
FOR ALL REMAINING MALFUNCTIONS: F -INSPECT EACH COMPONENT. -REPAIR/REPLACE. PERFORM ROAD TEST AND CONFIRM ALL MALFUNCTIONS ARE ELIMINATED.
Refer to ● ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION, *8 - *9. ● TROUBLE DIAGNOSIS FOR DTC, *10 - *11. ● TROUBLE DIAGNOSES FOR SYMPTOMS, *12.
H
ERASE DTC FROM TCM AND ECM MEMORIES.
F
Refer to HOW TO ERASE DTC, *13.
F
Refer to DTC CONFIRMATION PROCEDURE. *14 - *15.
H
NG
FINAL CHECK Confirm that the incident is completely fixed by performing BASIC INSPECTION and DTC CONFIRMATION PROCEDURE. Then, erase the unnecessary (already fixed) 1st trip DTCs in ECM and TCM.
OK E
CHECK OUT SAT086JC
*1: *2: *3: *4: *5:
AT-30 AT-31 AT-6 AT-34 AT-34, 35
*6: *7: *8: *9: *10:
*11: *12: *13: *14: *15:
AT-36 AT-18 AT-15 AT-26 AT-48
AT-33
AT-94 AT-110 AT-16 AT-49 AT-95
TROUBLE DIAGNOSIS — BASIC INSPECTION CVT Fluid Check
CVT Fluid Check
NCAT0025
FLUID LEAKAGE CHECK 1.
NCAT0025S01
3.
Clean area suspected of leaking. — for example, mating surface of converter housing and transmission case. Start engine, apply foot brake, place selector lever in “D” position and wait a few minutes. Stop engine.
4.
Check for fluid leakage.
2.
SAT767B
Fluid leakage
SAT288G
FLUID CONDITION CHECK Fluid color
NCAT0025S02
Suspected problem
Dark or black with burned odor
Wear of frictional material
Milky pink
Water contamination — Road water entering through filler tube or breather
Varnished fluid, light to dark brown and Oxidation — Over or under filling, — tacky Overheating SAT638A
FLUID LEVEL CHECK
NCAT0025S03
Refer to MA section (“Checking CVT Fluid”, “CHASSIS AND BODY MAINTENANCE”).
Stall Test STALL TEST PROCEDURE 1. 2.
NCAT0026 NCAT0026S01
Check CVT fluid and engine oil levels. If necessary, add. Drive vehicle for approx. 10 minutes or until engine oil and CVT fluid reach operating temperature. CVT fluid operating temperature: 50 - 80°C (122 - 176°F)
SAT647B
AT-34
TROUBLE DIAGNOSIS — BASIC INSPECTION Stall Test (Cont’d)
3. 4. I
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.
5.
Start engine, apply foot brake, and place selector lever in D position. Accelerate to wide open throttle gradually while applying foot brake. Quickly note the engine stall revolution and immediately release throttle. During test, never hold throttle wide open for more than 5 seconds. Stall revolution: 2,350 - 2,850 rpm
SAT513G
6. 7.
Less than 5 sec.
I
SAT514G
8. 9. I
Move selector lever to “N” position. Cool off CVT fluid. Run engine at idle for at least one minute.
SAT771B
Line Pressure Test LINE PRESSURE TEST PORTS
NCAT0027 NCAT0027S01
Location of line pressure test ports are shown in the illustration. I Always replace pressure plugs as they are self-sealing bolts.
Line pressure test port
SAT670J
LINE PRESSURE TEST PROCEDURE 1. 2.
NCAT0027S02
Check CVT fluid and engine oil levels. If necessary, add fluid or oil. Drive vehicle for approx. 10 minutes or until engine oil and CVT fluid reach operating temperature. CVT fluid operating temperature: 50 - 80°C (122 - 176°F)
SAT647B
AT-35
TROUBLE DIAGNOSIS — BASIC INSPECTION Line Pressure Test (Cont’d)
3.
Install pressure gauge to corresponding line pressure port.
4. I
Set parking brake and block wheels. Continue to depress brake pedal fully while line pressure test is being performed at stall speed.
SAT513G
5. I
Start engine and measure line pressure at idle and stall speed. When measuring line pressure at stall speed, follow the stall test procedure. Line pressure: Refer to SDS, AT-120.
SAT493G
Road Test
ROAD TEST PROCEDURE
DESCRIPTION I
1. Check before engine is started.
I 1. 2.
NCAT0028 NCAT0028S01
The purpose of the test is to determine overall performance of CVT and analyze causes of problems. The road test consists of the following three parts: Check before engine is started Cruise test
2. Cruise test. SAT692J
I I
Before road test, familiarize yourself with all test procedures and items to check. Conduct tests on all items until specified symptom is found. Troubleshoot items which check out No Good after road test. Refer to “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION” and “TROUBLE DIAGNOSIS FOR SYMPTOMS”, AT-15, AT-26 and AT-110.
SAT496G
AT-36
TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)
1. CHECK BEFORE ENGINE IS STARTED 1
=NCAT0028S02
CHECK SPORT OR CVT INDICATOR LAMP
1. Park vehicle on flat surface. 2. Move selector lever to “P” position.
SPORT or CVT
SAT967IA
3. Turn ignition switch to “OFF” position. Wait at least 5 seconds. 4. Turn ignition switch to “ON” position. (Do not start engine.) 5. Does CVT or SPORT indicator lamp come on for about 2 seconds? Yes or No Yes
©
GO TO 2.
No
©
Stop ROAD TEST.
2
CHECK CVT OR SPORT INDICATOR LAMP
Does CVT or SPORT indicator lamp flicker for about 8 seconds? Yes or No Yes
©
Perform self-diagnosis and check NG items on the DIAGNOSTIC WORKSHEET, AT-31. Refer to TCM SELF-DIAGNOSIS PROCEDURE (NO TOOLS), AT-25.
No
©
1. Turn ignition switch to “OFF” position. 2. Perform self-diagnosis and note NG items. Refer to TCM SELF-DIAGNOSIS PROCEDURE (NO TOOLS), AT-25.
3
TEST DRIVE
Drive the vehicle and verify that there are no abnormalities.
©
TEST END
2. CRUISE TEST I
With CONSULT-II I I
NCAT0028S04
Check all items listed in Parts 1 through 3. NCAT0028S0401
Using CONSULT-II, conduct a cruise test and record the result. Print the result and ensure that shifts and lock-ups take place as per Shift Schedule.
SAT601J
AT-37
TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)
CONSULT-II Setting Procedure
Data link connector
NCAT0028S0402
1. 2.
Turn ignition switch “OFF”. Connect CONSULT-II to Data link connector. Data link connector is located in left side dash panel.
3. 4.
Turn ignition switch “ON”. Touch “START”.
5.
Touch “CVT”.
6.
Touch “DATA MONITOR”.
7. 8.
Touch “MAIN SIGNALS” to set recording condition. See “Numerical Display”, “Barchart Display” or “Line Graph Display”. Touch “START”.
NRS071
SAT586J
SAT651J
SAT732J
9.
PAT902H
AT-38
TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)
10. When performing cruise test, touch “Store Data”.
PAT071H
11. After finishing cruise test part 1, touch “STOP”.
PAT072H
12. Touch “STORE”.
PAT301C
13. Touch “DISPLAY”.
SAT608J
SAT609J
AT-39
TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)
14. Touch “PRINT”. 15. Check the monitor data printed out. 16. Continue cruise test part 2 and 3.
SAT610J
Without CONSULT-II I
NCAT0028S0403
Throttle position sensor can be checked by voltage across terminals 41 and 42 of TCM. Refer to “Road Test”, AT-36.
SAT417J
AT-40
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value
TCM Terminals and Reference Value
NCAT0030
PREPARATION I
NCAT0030S01
Measure voltage between each terminal and terminal 25 or 48 by following “TCM INSPECTION TABLE”.
Terminal 25 or p 48 p SAT216J
TCM HARNESS CONNECTOR TERMINAL LAYOUTNCAT0030S02
SAT403J
TCM INSPECTION TABLE
NCAT0030S03
(Data are reference values.) Terminal No.
1
2
3
Wire color
OR/L
P/B
GY/R
Item
Judgement standard
Condition When releasing accelerator pedal after warming up engine.
Line pressure solenoid valve
Approx. 2.8V
When depressing accelerator pedal Approx. 1.4V fully after warming up engine. When releasing accelerator pedal after warming up engine.
Line pressure solenoid valve (with dropping resistor)
Approx. 11.0V
When depressing accelerator pedal Approx. 4.0V fully after warming up engine.
Torque converter clutch solenoid valve
When CVT performs lock-up.
Approx. 12.0V
When CVT does not perform lockup.
Approx. 0V
5 *1
W/L
DT1
—
—
6 *1
W/PU
DT2
—
—
7 *1
R/W
DT3
—
—
8 *1
L/R
DT5
—
—
9 *1
LG/B
DT4
—
—
10
G/W
When turning ignition switch to “ON”.
Battery voltage
When turning ignition switch to “OFF”.
Approx. 0V
Power source
AT-41
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No.
Wire color
11
PU
12
L/W
13
15 *1
16
17
OR/B
Item Step motor A Step motor B
Y
LG
Approx. 0V
ABS control unit
When driving slowly.
Change 0 Battery voltage
Same as No. 10
L/Y
Step motor C
21
P/L
Step motor D
27
L/OR
—
When releasing accelerator pedal after warming up engine.
20
B
—
When depressing accelerator pedal more than half-way after warming Battery voltage up engine.
Power source
25
Battery voltage
Wide open throttle position switch (in throttle position switch)
G/W
BR/Y
When CVT or SPORT indicator lamp does not illuminate
When releasing accelerator pedal after warming up engine.
19
23
Approx. 0V
Closed throttle position switch (in throttle position switch)
SB
GY
When CVT or SPORT indicator lamp illuminates
—
18
22
Within 2 seconds after key switch “ON”, the time measurement by 30.0 msec using the pulse width measurement function (Hi level) of CONSULT-II. I CONSULT-II cable connected to data link connector. 10.0 msec I This inspection cannot be measured by circuit tester.
CVT or SPORT indicator lamp
PU/Y
Judgement standard
Condition
Battery voltage
When depressing accelerator pedal Approx. 0V after warming up engine.
Within 2 seconds after key switch “ON”, the time measurement by 30.0 msec using the pulse width measurement function (Hi level) of CONSULT-II. I CONSULT-II cable connected to data link connector. 10.0 msec. I This inspection cannot be measured by circuit tester. When SPORT mode switch in “ON” Approx. 0V position.
Sport mode switch
When SPORT mode switch in “OFF” position.
Approx. 10V
When ABS operates.
Approx. 0V
When ABS does not operate.
5.6 - 10.0V
ABS control unit
Ground
— When setting selector lever to “L” position.
PNP switch “L” position
— Battery voltage
When setting selector lever to other Approx. 0V positions.
AT-42
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No.
28
Wire color
W/L
Item
Power source (Memory backup)
Judgement standard
Condition When turning ignition switch to “OFF”.
Battery voltage
When turning ignition switch to “ON”.
Battery voltage
or
When driving (D position, 20 km/h), the pulse measurement by Secondary speed using the pulse measurement function of CONSULT-II. sensor I CONSULT-II cable connected to data link connector. I This inspection cannot be measured by circuit tester.
29
G/R
30 *2
G/B
—
—
—
31 *2
GY/L
—
—
—
32
33
34
35
36
37
G
Throttle position sensor (Power source)
PU/W
Indicator control unit
LG
PNP switch “D” position
G/W
G/R
W/G
Approx. 600 Hz
When turning ignition switch to “ON”
4.5 - 5.5V
When turning ignition switch to “OFF”
Approx. 0V
When setting selector lever to any position.
1.5 - 2.0V
When setting selector lever to “D” position.
Battery voltage
When setting selector lever to other Approx. 0V positions. When setting selector lever to “R” position.
PNP switch “R” position
Battery voltage
When setting selector lever to other Approx. 0V positions. When setting selector lever to “N” or “P” position.
PNP switch “N” or “P” position
Battery voltage
When setting selector lever to other Approx. 0V positions. When engine runs at idle speed.
Approx. 1.0V
When engine runs at stall speed.
Approx. 4.0V
CVT fluid pressure sensor
38
G/Y
Primary speed sensor
39
L/OR
Engine speed signal
When driving (L position, 20 km/h), the pulse measurement by using the pulse measurement function of CONSULT-II. I CONSULT-II cable connected to data link connector. I This inspection cannot be measured by circuit tester.
When engine runs at idle speed.
AT-43
Approx. 900 Hz
0.5 - 1.5V
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No.
Wire color
Item
41
GY
Throttle position sensor
42
B/W
Throttle position sensor (Ground)
45
R/G
Stop lamp switch
46
47
48
P/L
Y/PU
B
Judgement standard
Condition
Fully-closed throttle: When depressing accelerator pedal Approximately slowly after warming up engine. 0.3V (Voltage rises gradually in response Fully-open to throttle position.) throttle: Approximately 3V — When depressing brake pedal
Battery voltage
When releasing brake pedal
Approx. 0V
CVT fluid pressure sensor (Power source)
—
CVT fluid temperature sensor
4.5 - 5.5V
When CVT fluid temperature is 20°C (68°F).
Approximately 1.5V
When CVT fluid temperature is 80°C (176°F).
Approximately 0.5V
Ground
—
*1: This terminal is connected to the ECM. *2: These terminals are connected to the Data link connector for CONSULT-II.
AT-44
—
—
TROUBLE DIAGNOSIS FOR POWER SUPPLY Wiring Diagram — CVT — MAIN
Wiring Diagram — CVT — MAIN
NCAT0031
BATTERY
FUSE BLOCK (J/B)
Refer to EL-POWER.
: Detectable line for DTC : Non-detectable line for DTC : LHD models ENGINE CONTROL MODULE RELAY
: RHD models
OFF
ON
STOP LAMP SWITCH
STOP LAMP SWITCH OFF
ON
FUSE BLOCK (J/B)
TCM (TRANSMISSION CONTROL MODULE)
ECM
Refer to last page (foldout page).
YAT201
AT-45
TROUBLE DIAGNOSIS FOR POWER SUPPLY Wiring Diagram — CVT — MAIN (Cont’d)
TCM TERMINALS AND REFERENCE VALUE
NCAT0031S01
Remarks: Specification data are reference values. Terminal No.
10
Wire color
G/W
19
G/W
25
B
28
48
W/L
B
Item
When turning ignition switch to “ON”.
Battery voltage
When turning ignition switch to “OFF”.
Approx. 0V
Power source
Power source
Same as No. 10
Ground
—
Power source (Memory backup)
—
When turning ignition switch to “OFF”.
Battery voltage
When turning ignition switch to “ON”.
Battery voltage
or
Ground
—
DIAGNOSTIC PROCEDURE 1
Judgement standard
Condition
—
NCAT0031S03
CHECK TCM POWER SOURCE
1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 10, 19, 28 and ground. Voltage: Battery voltage 3. Turn ignition switch to “OFF” position. 4. Check voltage between TCM terminal 28 and ground. Voltage: Battery voltage
SAT332J
OK or NG OK
©
GO TO 2.
NG
©
Check the following items: I Harness for short or open between ignition switch and TCM terminals 10, 19 and 25 (Main harness) I Ignition switch and fuse Refer to EL section (“POWER SUPPLY ROUTING”).
AT-46
TROUBLE DIAGNOSIS FOR POWER SUPPLY Wiring Diagram — CVT — MAIN (Cont’d)
2
CHECK TCM GROUND CIRCUIT
1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check continuity between terminals 25, 48 and ground. Continuity should exist.
SAT333J
If OK, check harness for short to ground and short to power. OK or NG OK
©
INSPECTION END
NG
©
Repair open circuit or short to ground or short to power in harness or connectors.
AT-47
DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Description
Description I I
NCAT0032
The PNP switch assembly includes a transmission range switch. The transmission range switch detects the selector lever position and sends a signal to the TCM.
TCM TERMINALS AND REFERENCE VALUE
NCAT0032S01
Remarks: Specification data are reference values. Terminal No.
27
Wire color
L/OR
34
LG
35
G/W
36
G/R
Item
Judgement standard
Condition
PNP switch “L” position
PNP switch “D” position
PNP switch “R” position
PNP switch “N” or “P” position
When setting selector lever to “L” position.
Battery voltage
When setting selector lever to other positions.
Approx. 0V
When setting selector lever to “D” position.
Battery voltage
When setting selector lever to other positions.
Approx. 0V
When setting selector lever to “R” position.
Battery voltage
When setting selector lever to other positions.
Approx. 0V
When setting selector lever to “N” or “P” position.
Battery voltage
When setting selector lever to other positions.
Approx. 0V
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
Check items (Possible cause)
: PNP SW/CIRC : P0705
TCM does not receive the correct voltage signal from the switch based on the gear position.
: MI Code No. 0705
AT-48
I Harness or connectors (The PNP switch circuit is open or shorted.) I PNP switch
NCAT0032S02
DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Description (Cont’d)
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0032S03
SAT651J
CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)
SAT654J
3) 4)
Turn ignition switch “ON” and select “DATA MONITOR” mode for “CVT” with CONSULT-II. Make sure that output voltage of CVT fluid temperature snesor is within the range below. FLUID TEMP SEN: 0.5 - 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 “DATA MONITOR” mode for “ENGINE” with CONSULTII. Start engine and maintain the following conditions for at least 15 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3V Selector lever: D position ENG SPEED: 450 rpm or more If the check result is “NG”, go to “Diagnostic Procedure”, AT-51. With GST
Follow the procedure “With CONSULT-II”.
AT-49
DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Wiring Diagram — AT — PNP/SW
Wiring Diagram — AT — PNP/SW
NCAT0199
YAT251
AT-50
DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Diagnostic Procedure
Diagnostic Procedure 1
NCAT0033
CHECK PNP SWITCH CIRCUIT (With CONSULT-II) With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II.
SAT651J
3. Read out “P/N”, “R”, “D” and “L” position switches moving selector lever to each position. Check the signal of the selector lever position is indicated properly. OK or NG OK
©
GO TO 3.
NG
©
Check the following items: I PNP switch Refer to “Component Inspection”, AT-53. I Harness for short or open between ignition switch and PNP switch (Main harness) I Harness for short or open between PNP switch and TCM (Main harness) I Ignition switch and fuse Refer to EL section (“POWER SUPPLY ROUTING”). I Diode (P, N positions)
2
CHECK PNP SWITCH CIRCUIT (Without CONSULT-II) Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 27, 34, 35, 36 and ground while moving selector lever through each position. Voltage: B: Battery voltage 0: 0V Terminal No. Lever position
MTBL0312 OK or NG
OK
©
GO TO 3.
NG
©
Check the following items: I PNP switch Refer to “Component Inspection”, AT-53. I Harness for short or open between ignition switch and PNP switch (Main harness) I Harness for short or open between PNP switch and TCM (Main harness) I Ignition switch and fuse Refer to EL section (“POWER SUPPLY ROUTING”). I Diode (P, N positions)
AT-51
DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Diagnostic Procedure (Cont’d)
3
CHECK DTC
Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-49. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
AT-52
DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Component Inspection
Component Inspection
=NCAT0034
PARK/NEUTRAL POSITION SWITCH 1.
Check continuity between terminals 1 and 2 and between terminals 3 and 5, 6, 7, 8, 9 while moving manual shaft through each position. Lever position
2. 3. 4. 5. 6.
NCAT0034S01
Terminal No.
P
3—7
R
3—8
N
3—9
D
3—6
L
3—5
1—2
1—2
If NG, check again with control cable disconnected from manual shaft of CVT assembly. Refer to step 1. If OK on step 2, adjust control cable. Refer to AT-114. If NG on step 2, remove PNP switch from CVT and check continuity of PNP switch terminals. Refer to step 1. If OK on step 4, adjust PNP switch. Refer to AT-114. If NG on step 4, replace PNP switch.
AT-53
DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT Description 2.5
Description
2.0
The CVT fluid temperature sensor detects the CVT fluid temperature and sends a signal to the TCM.
NCAT0035
1.5 1.0 0.5 °C (°F)
0
(-40) (-4) (32) (68) (104) (140) (176) (212) (248) (284) (320)
SAT021J
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0035S01 Remarks: Specification data are reference values. Monitor item CVT fluid temperature sensor
Condition
Specification
Cold [20°C (68°F)] " Hot [80°C (176°F)]
Approximately 1.5V " Approximately 0.5V
TCM TERMINALS AND REFERENCE VALUE
NCAT0035S02
Remarks: Specification data are reference values. Terminal No.
Wire color
42
B
47
Y/PU
Item
Judgement standard
Condition
Throttle position sensor (Ground)
—
CVT fluid temperature sensor
—
When CVT fluid temperature is 20°C (68°F).
Approximately 1.5V
When CVT fluid temperature is 80°C (176°F).
Approximately 0.5V
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
NCAT0035S03
Check items (Possible cause)
: ATF TEMP SEN/CIRC : P0710
TCM receives an excessively low or high voltage from the sensor.
: MI Code No. 0710
AT-54
I Harness or connectors (The sensor circuit is open or shorted.) I CVT fluid temperature sensor
DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT Description (Cont’d)
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0035S04
SAT651J
CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1)
SAT654J
Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. 2) Start engine and maintain the following conditions for at least 10 minutes (Total). (It is not necessary to maintain continuously.) ENG SPEED: 450 rpm or more VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3 V Selector lever: D position If the check result is NG, go to “Diagnostic Procedure”, AT-57. With GST Follow the procedure “With CONSULT-II”.
AT-55
DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT Wiring Diagram — AT — FTS
Wiring Diagram — AT — FTS
NCAT0200
CONTROL VALVE (CVT FLUID TEMPERATURE SENSOR)
: Detectable line for DTC : Non-detectable line for DTC
TCM (TRANSMISSION CONTROL MODULE)
ECM
YAT203
AT-56
DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT Diagnostic Procedure
Diagnostic Procedure 1
NCAT0036
CHECK CVT FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY
1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminals 6 and 7 when CVT is cold. Resistance: Cold [20°C (68°F)] Approximately 2.5 kΩ
SAT419JA
4. Reinstall any part removed. OK or NG OK (With CONSULT-II)
©
GO TO 2.
OK (Without CONSULT-II)
©
GO TO 3.
NG
©
Replace CVT assembly
2
CHECK INPUT SIGNAL OF CVT FLUID TEMPERATURE SENSOR (With CONSULT-II) With CONSULT-II
1. Start engine. 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “FLUID TEMP SE”. Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V OK or NG OK
©
GO TO 4.
NG
©
Check the following item: I Harness for short to ground or short to power or open between TCM, ECM and terminal cord assembly (Main harness) I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).
AT-57
DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT Diagnostic Procedure (Cont’d)
3
CHECK INPUT SIGNAL OF CVT FLUID TEMPERATURE SENSOR (Without CONSULT-II) Without CONSULT-II
1. Start engine. 2. Check voltage between TCM terminal 47 and ground while warming up CVT. Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V
SAT420JA
3. Turn ignition switch to “OFF” position. 4. Disconnect TCM harness connector. 5. Check continuity between terminal 42 and ground. Continuity should exist.
SAT421J
If OK, check harness for short to ground and short to power. OK or NG OK
©
GO TO 4.
NG
©
Check the following item: I Harness for short to ground or short to power or open between TCM, ECM and terminal cord assembly (Main harness) I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).
4
CHECK DTC
Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-55. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
AT-58
DTC P0715 PRIMARY SPEED SENSOR Description
Description
NCAT0220
The primary speed sensor detects the primary pulley revolution speed and sends a signal to the ECM.
TCM TERMINALS AND REFERENCE VALUE
NCAT0220S01
Remarks: Specification data are reference values. Terminal No.
Wire color
38
G/Y
Item
Judgement standard
Condition
Primary speed sensor
When driving (L position, 20 km/h), the pulse measurement by using the pulse measurement function of CONSULT-II.
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Approx. 900 Hz
NCAT0220S02
Malfunction is detected when ...
Check items (Possible cause)
TCM does not receive the proper voltage signal from the sensor.
I Harness or connectors (The sensor circuit is open or shorted.) I Primary speed sensor
: PRI SPEED SIG/CIRC : P0715 : MI Code No. 0715
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0220S03
SAT651J
CAUTION: I Always drive vehicle at a safe speed. I Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)
SAT971J
Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 5 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3V Selector lever: D position ENG SPEED: 450 rpm or more 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 “Diagnostic Procedure”, AT-61. With GST
Follow the procedure “With CONSULT-II”.
SAT654J
AT-59
DTC P0715 PRIMARY SPEED SENSOR Wiring Diagram — AT — VSSA/T
Wiring Diagram — AT — VSSA/T PRIMARY SPEED SENSOR
NCAT0221
: Detectable line for DTC : Non-detectable line for DTC
TCM (TRANSMISSION CONTROL MODULE)
ECM
YAT204
AT-60
DTC P0715 PRIMARY SPEED SENSOR Diagnostic Procedure
Diagnostic Procedure 1
NCAT0222
CHECK PRIMARY SPEED SENSOR
Refer to “Component Inspection” AT-65. OK or NG OK (With CONSULT-II)
©
GO TO 2.
OK (Without CONSULT-II)
©
GO TO 3.
NG
©
Repair or replace primary speed sensor.
2
CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II
1. Start engine. 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “I/P PULLY SPD” while driving. Check the value changes according to driving speed. (Almost same value as engine speed) OK or NG OK
©
GO TO 4.
NG
©
Check the following items: I Harness for short or open between TCM, ECM and primary speed sensor (Main harness) I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).
3
CHECK DTC
Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-62. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
Component Inspection REVOLUTION SENSOR 1. 2.
NCAT0223 NCAT0223S01
Jacking up the vehicle. Check pulse by using the pulse measurement function of CONSULT-II when front wheel rotating. I CONSULT-II cable connected to data link connector. At front wheel rotating (L position, 20 km/h): Approx. 900 Hz
CONSULT-II
To data link connector
DDL
PULSE
NAT314
AT-61
DTC P0720 VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) Description
Description
NCAT0038
The vehicle speed sensor CVT secondary speed 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.
TCM TERMINALS AND REFERENCE VALUE
NCAT0038S01
Remarks: Specification data are reference values. Terminal No.
Wire color
29
G/R
42
B
Item
Judgement standard
Condition
Secondary speed sensor
When driving (D position, 20 km/h), the pulse measurement by using the pulse measurement function of CONSULT-II. I CONSULT-II cable connected to data link connector. I This inspection cannot be measured by circuit tester.
Throttle position sensor (Ground)
—
Approx. 600 Hz
—
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
NCAT0038S02
Check items (Possible cause)
: VEH SPD SEN/CIR AT : P0720
TCM does not receive the proper voltage signal from the sensor.
I Harness or connectors (The sensor circuit is open or shorted.) I Secondary speed sensor
: MI Code No. 0720
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0038S03
SAT651J
CAUTION: I Always drive vehicle at a safe speed. I Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated.
AT-62
DTC P0720 VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) Description (Cont’d)
With CONSULT-II 1) 2)
SAT971J
Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 12 consecutive seconds. THRTL POS SEN: More than 1.3V Selector lever: 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 “DIAGNOSTIC PROCEDURE”, AT-65. With GST
Follow the procedure “With CONSULT-II”.
SAT654J
AT-63
DTC P0720 VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) Wiring Diagram — AT — VSSA/T
Wiring Diagram — AT — VSSA/T SECONDARY SPEED SENSOR
NCAT0201
: Detectable line for DTC : Non-detectable line for DTC
TCM (TRANSMISSION CONTROL MODULE)
ECM
YAT205
AT-64
DTC P0720 VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) Diagnostic Procedure
Diagnostic Procedure 1
NCAT0039
CHECK SECONDARY SPEED SENSOR
Refer to “Component Inspection” AT-65. OK or NG OK (With CONSULT-II)
©
GO TO 2.
OK (Without CONSULT-II)
©
GO TO 3.
NG
©
Repair or replace secondary speed sensor.
2
CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II
1. Start engine. 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “VEHICLE SPEED” while driving. Check the value changes according to driving speed. OK or NG OK
©
GO TO 4.
NG
©
Check the following items: I Harness for short or open between TCM, ECM and secondary speed sensor (Main harness) I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).
3
CHECK DTC
Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-62. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
Component Inspection SECONDARY SPEED SENSOR 1. 2.
NCAT0040 NCAT0040S01
Jacking up the vehicle. Check pulse by using the pulse measurement function of CONSULT-II when front wheel rotating. I CONSULT-II cable connected to data link connector. At front wheel rotating (D position, 20 km/h): Approx. 600 Hz
CONSULT-II
To data link connector
DDL
PULSE
NAT315
AT-65
DTC P0725 ENGINE SPEED SIGNAL Description
Description
NCAT0041
The engine speed signal is sent from the ECM to the TCM.
TCM TERMINALS AND REFERENCE VALUE
NCAT0041S01
Remarks: Specification data are reference values. Terminal No.
Wire color
39
L/OR
Item
Judgement standard
Condition
Engine speed signal
When engine runs at idle speed.
0.5 - 1.5V
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
NCAT0041S02
Check item (Possible cause)
: ENGINE SPEED SIG : P0725
TCM does not receive the proper voltage I Harness or connectors signal from ECM. (The sensor circuit is open or shorted.)
: MI Code No. 0725
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0041S03
SAT651J
CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)
SAT654J
Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 10 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3V Selector lever: D position If the check result is “NG”, go to “Diagnostic Procedure”, AT-68. With GST
Follow the procedure “With CONSULT-II”.
AT-66
DTC P0725 ENGINE SPEED SIGNAL Wiring Diagram — AT — ENGSS
Wiring Diagram — AT — ENGSS
NCAT0202
ECM
: Detectable line for DTC : Non-detectable line for DTC
TCM (TRANSMISSION CONTROL MODULE)
YAT206
AT-67
DTC P0725 ENGINE SPEED SIGNAL Diagnostic Procedure
Diagnostic Procedure 1
NCAT0042
CHECK DTC WITH ECM
Perform diagnostic test mode II (self-diagnostic results) for engine control. Check ignition signal circuit condition. OK or NG OK (With CONSULT-II)
©
GO TO 2.
OK (Without CONSULT-II)
©
GO TO 3.
NG
©
Check ignition signal circuit for engine control. Refer to EC section (IGNITION SIGNAL).
2
CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II
1. Start engine. 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “ENGINE SPEED”. Check engine speed changes according to throttle position. OK or NG OK
©
GO TO 4.
NG
©
Check the following items: I Harness for short or open between TCM and ECM I Resistor and ignition coil Refer to EC section (IGNITION SIGNAL).
3
CHECK INPUT SIGNAL (Without CONSULT-II) Without CONSULT-II
1. Start engine. 2. Check voltage between TCM terminal 39 and ground. Voltage (Idle speed): 0.5 - 1.5V
SAT424JA
OK or NG OK
©
GO TO 4.
NG
©
Check the following items: I Harness for short or open between TCM and ECM I Resistor and ignition coil Refer to EC section (IGNITION SIGNAL).
4
CHECK DTC
Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-66. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
AT-68
DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Description
Description
NCAT0055
The torque converter clutch solenoid valve is activated, by the TCM in response to signals sent from the vehicle speed and throttle position sensors. Lock-up piston operation will then be controlled. Lock-up operation, however, is prohibited when CVT fluid temperature is too low. When the accelerator pedal is depressed (less than 2/8) in lock-up condition, the engine speed should not change abruptly. If there is a big jump in engine speed, there is no lock-up.
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0055S01 Remarks: Specification data are reference values. Monitor item Torque converter clutch solenoid valve duty
Condition
Specification
Lock-up “OFF” " Lock-up “ON”
Approximately 4% " Approximately 94%
TCM TERMINALS AND REFERENCE VALUE
NCAT0055S02
Remarks: Specification data are reference values. Terminal No.
3
Wire color
GY/R
Item
Judgement standard
Condition
Torque converter clutch solenoid valve
When CVT performs lock-up.
Approx. 12.0V
When CVT does not perform lockup.
Approx. 0V
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
NCAT0055S03
Check items (Possible cause)
: TCC SOLENOID/CIRC : P0740
TCM detects an improper voltage drop when it tries to operate the solenoid valve.
I Harness or connectors (The solenoid circuit is open or shorted.) I T/C clutch solenoid valve
: MI Code No. 0740
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0055S04 NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. SAT651J
AT-69
DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Description (Cont’d)
With CONSULT-II 1) 2)
Turn ignition switch “ON”. Select “DATA MONITOR” mode for “ENGINE” with CONSULT-II and wait at least 10 seconds. If the check result is “NG”, go to “Diagnostic Procedure”, AT-72. With GST
Follow the procedure “With CONSULT-II”. SAT654J
AT-70
DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Wiring Diagram — AT — TCV
Wiring Diagram — AT — TCV
NCAT0207
AT-TCV-01
LU DUTY SOL 3
TCM (TRANSMISSION CONTROL MODULE)
M48
GY/R : Detectable line for DTC : Non-detectable line for DTC
GY/R M53 21 F102 GY/R
GY/R 9
CONTROL VALVE (TORQUE CONVERTER CLUTCH SOLENOID VALVE)
F71
5 4 3 2 1 10 9 8 7 6
6 7 8 9 10 1 2 3 4 5 F102 11 12 13 14 15 16 17 18 19 20 21 22 23 24 W
F71 G
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
M48 W YAT149
AT-71
DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Diagnostic Procedure
Diagnostic Procedure 1
NCAT0056
CHECK GROUND CIRCUIT
1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal 9 and ground. Resistance: 10 - 20Ω OK or NG OK
©
GO TO 2.
NG
©
Replace CVT assembly
2
CHECK POWER SOURCE CIRCUIT
1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check continuity between terminal 9 and TCM harness connector terminal 3. Continuity should exist.
SAT683J
If OK, check harness for short to ground and short to power. 4. Reinstall any part removed. 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 DTC
Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-69. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
AT-72
DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Component Inspection
Component Inspection
NCAT0057
TORQUE CONVERTER CLUTCH SOLENOID VALVENCAT0057S01 I To torque converter clutch solenoid valve
For removal, refer to AT-116.
Resistance Check I
NCAT0057S0101
Check resistance between two terminals. Solenoid valve
Torque converter clutch solenoid valve
Terminal No.
9
Ground of TCC solenoid valve
Resistance (Approx.) 10 - 16Ω
SAT684J
Operation Check I
NCAT0057S0102
Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground of TCC solenoid valve.
To torque converter clutch solenoid valve
SAT685J
AT-73
DTC P0745 LINE PRESSURE SOLENOID VALVE Description
Description
NCAT0061
The line pressure solenoid valve regulates the oil pump discharge pressure to suit the driving condition in response to a signal sent from the TCM. The line pressure duty cycle value is not consistent 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 IN DATA MONITOR MODE NCAT0061S01 Remarks: Specification data are reference values. Monitor item
Line pressure solenoid valve duty
Condition
Specification
Small throttle opening (Low line pressure) " Large throttle opening (High line pressure)
Approximately 4% " Approximately 94%
NOTE: The line pressure duty cycle value is not consistent 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”.
TCM TERMINALS AND REFERENCE VALUE
NCAT0061S02
Remarks: Specification data are reference values. Terminal No.
1
2
Wire color
Item
OR/L
Line pressure solenoid valve
P/B
Judgement standard
Condition When releasing accelerator pedal after warming up engine.
Approx. 2.8V
When depressing accelerator pedal Approx. 1.4V fully after warming up engine. When releasing accelerator pedal after warming up engine.
Line pressure solenoid valve (with dropping resistor)
Approx. 11.0V
When depressing accelerator pedal Approx. 4.0V fully after warming up engine.
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
NCAT0061S03
Check items (Possible cause)
: L/PRESS SOL/CIRC : P0745
TCM detects an improper voltage drop when it tries to operate the solenoid valve.
: MI Code No. 0745
AT-74
I Harness or connectors (The solenoid circuit is open or shorted.) I Line pressure solenoid valve
DTC P0745 LINE PRESSURE SOLENOID VALVE Description (Cont’d)
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0061S04 NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. SAT651J
With CONSULT-II 1) 2)
Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Depress accelerator pedal completely and wait at least 5 seconds. If the check result is “NG”, go to “Diagnostic Procedure”, AT-77. With GST
Follow the procedure “With CONSULT-II”. SAT654J
AT-75
DTC P0745 LINE PRESSURE SOLENOID VALVE Wiring Diagram — AT — LPSV
Wiring Diagram — AT — LPSV TCM (TRANSMISSION CONTROL MODULE)
PL DUTY SOL (DR) 2
PL DUTY SOL 1
P/B
OR/L
P/B 20
F102
P/B
AT-LPSV-01
M48
OR/L M53
NCAT0209
: Detectable line for DTC
22
: Non-detectable line for DTC
OR/L
P/B 2 DROPPING RESISTOR
F86 1 OR/L
OR/L 8 CONTROL VALVE (LINE PRESSURE SOLENOID VALVE)
F71
1 2
F86 GY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
5 4 3 2 1 10 9 8 7 6
F71 G
1 2 3 4 5 6 7 8 9 10 F102 11 12 13 14 15 16 17 18 19 20 21 22 23 24 W
M48 W YAT150
AT-76
DTC P0745 LINE PRESSURE SOLENOID VALVE Diagnostic Procedure
Diagnostic Procedure 1
NCAT0062
CHECK GROUND CIRCUIT
1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal 8 and ground. Resistance: 2.5 - 5Ω OK or NG OK
©
GO TO 2.
NG
©
Check the following items: I Line pressure solenoid valve Refer to “Component Inspection”, AT-78. I Harness of terminal cord assembly for short or open
2
CHECK POWER SOURCE CIRCUIT
1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check resistance between terminal 8 and TCM harness connector terminal 2. Resistance: 11.2 - 12.8Ω OK or NG OK
©
GO TO 3.
NG
©
Check the following items: I Dropping resistor Refer to “Component Inspection”, AT-78. I Harness for short or open between TCM terminal 2 and terminal cord assembly (Main harness)
3
CHECK POWER SOURCE CIRCUIT
1. Turn ignition switch to “OFF” position. 2. Check continuity between terminal 8 and TCM harness connector terminal 1. Continuity should exist. If OK, check harness for short to ground and short to power. 3. 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 Diagnostic Trouble Code (DTC) confirmation procedure, AT-75. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
AT-77
DTC P0745 LINE PRESSURE SOLENOID VALVE Component Inspection
Component Inspection
=NCAT0063
LINE PRESSURE SOLENOID VALVE I
Resistance Check I To line pressure solenoid valve
NCAT0063S01
For removal, refer to AT-116. NCAT0063S0101
Check resistance between two terminals. Solenoid valve
Line pressure solenoid valve
Terminal No.
8
Ground of line pressure solenoid valve
Resistance (Approx.) 2.5 - 5Ω
SAT686J
Operation Check I
NCAT0063S0102
Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground of line pressure solenoid valve.
To line pressure solenoid valve
SAT687J
DROPPING RESISTOR I
Check resistance between two terminals. Resistance: 11.2 - 12.8Ω
SAT444J
AT-78
NCAT0063S02
DTC P1705 THROTTLE POSITION SENSOR Description
Description
Throttle position sensor and throttle position switch
I I
SAT413J
NCAT0070
Throttle position sensor The throttle position sensor detects the throttle valve position and sends a signal to the TCM. Throttle position switch Consists of a wide open throttle position switch and a closed throttle position switch. The wide open throttle position switch sends a signal to the TCM when the throttle valve is open at least 1/2 of the full throttle position. The closed throttle position switch sends a signal to the TCM when the throttle valve is fully closed.
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0070S01 Remarks: Specification data are reference values. Monitor item
Condition
Specification
Fully-closed throttle
Approximately 0.5V
Fully-open throttle
Approximately 4V
Throttle position sensor
TCM TERMINALS AND REFERENCE VALUE
NCAT0070S02
Remarks: Specification data are reference values. Terminal No.
16
17
32
Wire color
Item
Y
Closed throttle position switch (in throttle position switch)
LG
G
When releasing accelerator pedal after warming up engine.
When depressing accelerator pedal more than half-way after warming Battery voltage up engine.
Throttle position sensor (Power source)
GY
Throttle position sensor
42
B
Ground (Throttle position sensor)
Battery voltage
When depressing accelerator pedal Approx. 0V after warming up engine.
Wide open throttle position switch (in throttle position switch)
41
Judgement standard
Condition
When releasing accelerator pedal after warming up engine.
Approx. 0V
When turning ignition switch to “ON”.
4.5 - 5.5V
When turning ignition switch to “OFF”.
Approx. 0V
Fully-closed throttle: When depressing accelerator pedal Approximately 0.3V slowly after warming up engine. (Voltage rises gradually in Fully-open throttle: response to throttle position.) Approximately 3V —
AT-79
—
DTC P1705 THROTTLE POSITION SENSOR Description (Cont’d)
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
NCAT0070S03
Check items (Possible cause)
: TP SEN/CIRC A/T : P1705
I TCM receives an excessively low or high voltage from the sensor. I I
Harness or connectors (The sensor circuit is open or shorted.) Throttle position sensor Throttle position switch
: MI Code No. 1705
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0070S04
SAT651J
CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)
Acceleratr pedal condition
THRTL POS SEN
CLOSED THL/SW
W/O THRL/P⋅SW
Fully released
Less than 0.5V
ON
OFF
Partially depressed
0.5 - 1.9V
OFF
OFF
Fully depressed
1.9 - 4.0V
OFF
ON
SAT971J
3) 4)
SAT654J
Turn ignition switch “ON” and select “DATA MONITOR” mode for “CVT” with CONSULT-II. Check the following.
If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-82. If the check result is OK, go to following step. Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 5 consecutive seconds. Then release accelerator pedal completely. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POSI SEN: Approximately 3V or less Selector lever: D position If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-82. With GST
Follow the procedure “With CONSULT-II”.
AT-80
DTC P1705 THROTTLE POSITION SENSOR Wiring Diagram — AT — TPS
Wiring Diagram — AT — TPS
NCAT0212
YAT252
AT-81
DTC P1705 THROTTLE POSITION SENSOR Diagnostic Procedure
Diagnostic Procedure 1
NCAT0071
CHECK DTC WITH ECM
Perform diagnostic test mode II (self-diagnostic results) for engine control. Refer to EC section [“Malfunction Indicator (MI)”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”]. OK or NG OK (With CONSULT-II)
©
GO TO 2.
OK (Without CONSULT-II)
©
GO TO 3.
NG
©
Check throttle position sensor circuit for engine control. Refer to EC section (“DTC P0120 THROTTLE POSITION SENSOR”).
2
CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “THRTL POS SEN”. Voltage: Fully-closed throttle: Approximately 0.5V Fully-open throttle: Approximately 4V OK or NG OK
©
GO TO 4.
NG
©
Check harness for short or open between ECM and TCM regarding throttle position sensor circuit. (Main harness)
3
CHECK INPUT SIGNAL (Without CONSULT-II) Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 41 and 42 while accelerator pedal is depressed slowly. Voltage: Fully-closed throttle valve: Approximately 0.5V Fully-open throttle valve: Approximately 4V (Voltage rises gradually in response to throttle position)
SAT453J
OK or NG OK
©
GO TO 5.
NG
©
Check harness for short or open between ECM and TCM regarding throttle position sensor circuit. (Main harness)
AT-82
DTC P1705 THROTTLE POSITION SENSOR Diagnostic Procedure (Cont’d)
4
CHECK THROTTLE POSITION SWITCH CIRCUIT (With CONSULT-II) With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal. Check the signal of throttle position switch is indicated properly.
Accelerator pedal condition
Data monitor CLOSED THL/SW
W/O THRL/P-SW
Released
ON
OFF
Fully depressed
OFF
ON
OK or NG
MTLB0011
OK
©
GO TO 6.
NG
©
Check the following items: I Throttle position switch — Refer to “Components Inspection”, AT-85. I Harness for short or open between ignition switch and throttle position switch (Main harness) I Harness for short or open between throttle position switch and TCM (Main harness)
AT-83
DTC P1705 THROTTLE POSITION SENSOR Diagnostic Procedure (Cont’d)
5
CHECK THROTTLE POSITION SWITCH CIRCUIT (Without CONSULT-II) Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 16, 17 and ground while depressing, and releasing accelerator pedal slowly. (After warming up engine) Voltage
Accelerator pedal condition
Terminal No. 16
Terminal No. 17
Released
Battery voltage
1V or less
Fully depressed
1V or less
Battery voltage MTBL0137
SAT454J
OK or NG OK
©
GO TO 6.
NG
©
Check the following items: I Throttle position switch — Refer to “Components Inspection”, AT-85. I Harness for short or open between ignition switch and throttle position switch (Main harness) I Harness for short or open between throttle position switch and TCM (Main harness)
6
CHECK DTC
Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-80. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
AT-84
DTC P1705 THROTTLE POSITION SENSOR Component Inspection
Component Inspection
=NCAT0072
THROTTLE POSITION SWITCH Closed Throttle Position Switch (Idle position) I
Throttle position switch harness connector
SAT688J
I
Throttle position switch harness connector
NCAT0072S0101
Check continuity between terminals 5 and 6. Accelerator pedal condition
Continuity
Released
Yes
Depressed
No
To adjust closed throttle position switch, refer to EC section (“Basic Inspection”, “TROUBLE DIAGNOSIS — Basic Inspection”).
Wide Open Throttle Position Switch I
NCAT0072S01
NCAT0072S0102
Check continuity between terminals 5 and 4. Accelerator pedal condition
Continuity
Released
No
Depressed
Yes
SAT689J
AT-85
DTC P1777 STEP MOTOR — CIRCUIT Description
Description I
NCAT0224
The step motor is ON/OFF of 4 aspects changes according to the signal from TCM. As a result, the flow of line pressure to primary pulley is changed and pulley ratio is controlled.
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0224S01 Remarks: Specification data are reference values. Monitor item Step motor
Condition
Specification
The vehicle runs a safe condition and press/depress accelerator pedal.
ON/OFF
TCM TERMINALS AND REFERENCE VALUE
NCAT0224S02
Remarks: Specification data are reference values. Terminal No.
Wire color
11
PU
12
L/W
20
L/Y
21
P/L
Item
Step motor
Judgement standard
Condition
30.0 msec Within 2 seconds after key switch “ON”, the time measurement by using the pulse width measurement function (Hi level) of CON10.0 msec SULT-II. 30.0 msec I CONSULT-II cable connect to data link connector. I This inspection cannot be measured by circuit tester. 10.0 msec
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
NCAT0224S03
Check items (Possible cause)
: STEP MOTOR/CIRC : P1777
When in operating step motor ON and OFF, there is no proper change in the voltage of the terminal TCM which corresponds to it.
: MI Code No. 1777
AT-86
I Harness or connectors (The step motor circuit is open or shorted.) I Step motor
DTC P1777 STEP MOTOR — CIRCUIT Description (Cont’d)
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0224S04
SAT651J
CAUTION: I Always drive vehicle at a safe speed. I Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)
SAT654J
Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Drive vehicle for at least 5 consecutive seconds. If the check result is “NG”, go to “Diagnostic Procedure”, AT-89. With GST
Follow the procedure “With CONSULT-II”.
AT-87
DTC P1777 STEP MOTOR — CIRCUIT Wiring Diagram — AT — STM
Wiring Diagram — AT — STM
NCAT0225
TCM (TRANSMISSION CONTROL MODULE) : Detectable line for DTC : Non-detectable line for DTC
CONTROL VALVE (STEP MOTOR)
YAT208
AT-88
DTC P1777 STEP MOTOR — CIRCUIT Diagnostic Procedure
Diagnostic Procedure 1 1. 2. 3. 4. 5. 6.
NCAT0226
CHECK POWER SOURCE CIRCUIT Turn ignition switch to “ON” position. Check “SELF-DIAGNOSIS” with CONSULT-II. If “CVT SAFE FUNCTION” activate, refer to “CVT SAFE FUNCTION” AT-99. Turn ignition switch to “OFF” position. Disconnect TCM harness connector. Check continuity between terminal 2, 3, 4, 5 and TCM harness connector terminal 11, 12, 20, 21. Continuity should exist.
Step motor connector
SAT655J
If OK, check harness for short to ground and short to power. 7. Reinstall any part removed. 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 DTC
Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-91. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
AT-89
DTC P1777 STEP MOTOR — CIRCUIT Component Inspection
Component Inspection
=NCAT0227
STEP MOTOR Resistance Check CVT fluid pressure sensor connector
I
NCAT0227S01 NCAT0227S0101
Check resistance between terminals. Control valve
Terminal No.
Resistance (Approx.)
2 and 3 28Ω 4 and 5 SAT690J
2 and ground Step motor 3 and ground 14Ω 4 and ground 5 and ground
AT-90
DTC P1778 STEP MOTOR — FUNCTION Description
Description I
I I
NCAT0228
The step motor is ON/OFF of 4 aspects changes according to the signal from TCM. As a result, the flow of line pressure to primary pulley is changed and pulley ratio is controlled. This diagnosis item detects when electrical system is OK but, mechanical system is NG. This diagnosis item detects when the state that the changing the speed mechanism in unit does not operate normally.
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0228S01 It is monitoring whether “CVT RATIO: 2.32 - 0.47” changes similarly to “PLY CONT STEP: 3 - 200” by DATA MONITOR mode.
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
NCAT0228S03
Check items (Possible cause)
: STEP MOTOR/FNCTN : P1778
When not changing the speed according to the instruction of TCM.
I Step motor
: MI Code No. 1778
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0228S04
SAT651J
CAUTION: I Always drive vehicle at a safe speed. I Be careful not to rev engine into the red zone on the tachometer. I Before start “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, confirm “Hi” or “Mid” or “Low” fixation by “I/P PULLY SPD” and “VHCL SPEED SE” on “DATA MONITOR MODE”. I If hi-geared fixation, go to diagnostic procedure soon. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1)
Turn ignition switch “ON” and select “DATA MONITOR” mode for “CVT” with CONSULT-II.
SAT971J
AT-91
DTC P1778 STEP MOTOR — FUNCTION Description (Cont’d)
2)
3) 4)
SAT654J
Make sure that output voltage of CVT fluid temperature snesor is within the range below. FLUID TEMP SEN: 0.5 - 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 “ENGINE” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 30 consecutive seconds. TEST START FROM 0 km/h (0 MPH) CONSTANT ACCELERATION: Keep 30 sec or more VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3V Selector lever: D position ENG SPEED: 450 rpm or more If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-93. With GST
Follow the procedure “With CONSULT-II”.
AT-92
DTC P1778 STEP MOTOR — FUNCTION Diagnostic Procedure
Diagnostic Procedure 1
CHECK STEP MOTOR
I It is monitoring whether “CVT ratio: 2.32 - 0.47” changes similarly to “PLY CONT STEP: -3 - 200” by DATA MONITOR mode. I If no CONSULT-II, inspect the engine speed (rise and descend) about vehicle speed and throttle opening angle, and check shift change. OK or NG OK
©
INSPECTION END
NG
©
Replace CVT assembly.
AT-93
NCAT0230
DTC P1791 CVT FLUID PRESSURE SENSOR Description
Description I
NCAT0232
The CVT fluid pressure sensor detects line pressure of CVT, and sends TCM the signal.
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0232S01 Remarks: Specification data are reference values. Monitor item
CVT fluid pressure sensor
Condition
Specification
Throttle valve fully closed (PL Duty: 4%) " Throttle valve fully depressed (PL Duty: 94%)
Approx. 1.0 V " Approx. 4.0 V
TCM TERMINALS AND REFERENCE VALUE
NCAT0232S02
Remarks: Specification data are reference values. Terminal No.
Wire color
37
Item
Judgement standard
Condition
When engine runs at idle speed.
Approx. 1.0 V
When engine runs at stall speed.
Approx. 4.0V
W/G CVT fluid pressure sensor
42
B
—
—
46
P/L
—
4.5 - 5.5 V
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
NCAT0232S03
Check items (Possible cause)
: LINE PRESS SEN : P1791
TCM receives an excessively low or high voltage from the step motor.
: MI Code No. 1791
AT-94
I Harness or connectors (The sensor circuit is open or shorted.) I CVT fluid pressure sensor
DTC P1791 CVT FLUID PRESSURE SENSOR Description (Cont’d)
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0232S04
SAT651J
CAUTION: I Always drive vehicle at a safe speed. I Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)
SAT971J
3) 4)
SAT654J
Turn ignition switch “ON” and select “DATA MONITOR” mode for “CVT” with CONSULT-II. Make sure that output voltage of CVT fluid temperature snesor is within the range below. FLUID TEMP SEN: 0.5 - 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 “DATA MONITOR” mode for “ENGINE” with CONSULTII. Start engine and maintain the following conditions for at least 5 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: 1.3V Selector lever: D position ENG SPEED: 450 rpm or more If the check result is NG, go to “Diagnostic Procedure”, AT-97. With GST
Follow the procedure “With CONSULT-II”.
AT-95
DTC P1791 CVT FLUID PRESSURE SENSOR Wiring Diagram — AT — FPS
Wiring Diagram — AT — FPS CONTROL VALVE (CVT FLUID PRESSURE SENSOR)
NCAT0233
: Detectable line for DTC : Non-detectable line for DTC
TCM (TRANSMISSION CONTROL MODULE)
ECM
YAT209
AT-96
DTC P1791 CVT FLUID PRESSURE SENSOR Diagnostic Procedure
Diagnostic Procedure 1
NCAT0234
CHECK PRESSURE SENSOR
Refer to “Component Inspection”, AT-98. OK or NG OK (With CONSULT-II)
©
GO TO 2.
OK (Without CONSULT-II)
©
GO TO 3.
NG
©
Repair or replace pressure sensor.
2
CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II
1. Start engine. 2. Select “ECU Input Item Parameter List” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “LINE PRES SEN” while driving. I Throttle valve fully closed (PL Duty: 4%): Approx. 1.0V I Throttle valve fully depressed (PL Duty: 94%): Approx. 4.0V OK or NG OK
©
GO TO 4.
NG
©
Check the following items: I Harness for short or open between TCM, ECM and CVT fluid pressure sensor (Main harness) I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).
3
CHECK INPUT SIGNAL (Without CONSULT-II) Without CONSULT-II
Refer to “Component Inspection”, AT-98. OK or NG OK
©
GO TO 4.
NG
©
Check the following items: I Harness for short or open between TCM, ECM and CVT fluid pressure sensor (Main harness). I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).
4
CHECK DTC
Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-95. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
AT-97
DTC P1791 CVT FLUID PRESSURE SENSOR Component Inspection
Component Inspection
=NCAT0235
CVT FLUID PRESSURE SENSOR CVT fluid pressure sensor connector
I I
NCAT0235S01
Start engine. Check voltage between terminals 1 and 6, 6 and 10. Terminal No.
Voltage
1
6
Approx. 0.5 - 4.5V
6
10
Approx. 4.5 - 5.5V
SAT691J
AT-98
CVT SAFE FUNCTION Description
Description “CVT SAFE FUNCTION” is function to protect CVT.
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code
Malfunction is detected when ...
Check items (Possible cause)
: CVT SAFE FUNCTION TCM is malfunctioning
TCM
: 10th judgement flicker
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE With CONSULT-II 1) 2) 3)
Turn ignition switch “ON” and select “DATA MONITOR” mode for CVT with CONSULT-II. Start engine. Run engine for at least 2 seconds at idle speed. Without CONSULT-II
SAT651J
1) 2)
Start engine. Perform self-diagnosis. Refer to SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II), AT-25.
SAT971J
Light
Shade
SAT455FA
AT-99
CVT SAFE FUNCTION Diagnostic Procedure
Diagnostic Procedure 1
CHECK INPUT SIGNAL (With CONSULT-II)
1. Turn ignition switch to “ON” and select “SELF DIAG RESULTS” mode for CVT with CONSULT-II. 2. Touch “ERASE”. Perform “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”. See previous page. Is the “CVT SAFE FUNCTION” displayed again? YES
©
Replace TCM
NO
©
INSPECTION END
AT-100
CONTROL UNIT (RAM), CONTROL UNIT (ROM) Description
Description
NCAT0239
The TCM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the CVT.
SAT574J
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : CONTROL UNIT (RAM) : CONTROL UNIT (ROM)
Malfunction is detected when ... TCM memory (RAM) or (ROM) is malfunctioning.
NCAT0239S01
Check item (Possible cause)
TCM
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0239S02 NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. With CONSULT-II 1) SAT651J
2) 3)
Turn ignition switch “ON” and select “DATA MONITOR” mode for CVT with CONSULT-II. Start engine. Run engine for at least 2 seconds at idle speed.
SAT971J
AT-101
CONTROL UNIT (RAM), CONTROL UNIT (ROM) Diagnostic Procedure
Diagnostic Procedure 1
CHECK DTC With CONSULT-II
1. Turn ignition switch “ON” and select “SELF DIAG RESULTS” mode for CVT with CONSULT-II. 2. Touch “ERASE”. PERFORM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE. See previous page. Is the “CONTROL UNIT (RAM) or CONTROL UNIT (ROM)” displayed again? Yes
©
Replace TCM.
No
©
INSPECTION END
AT-102
=NCAT0240
CONTROL UNIT (EEPROM) Description
Description
NCAT0241
The TCM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the CVT.
SAT574J
ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : CONT UNIT (EEPROM)
Malfunction is detected when ... TCM memory (EEPROM) is malfunctioning.
NCAT0241S01
Check item (Possible cause) TCM
DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0241S02 NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. With CONSULT-II 1) SAT651J
2) 3)
Turn ignition switch “ON” and select “DATA MONITOR” mode for CVT with CONSULT-II. Start engine. Run engine for at least 2 seconds at idle speed.
SAT971J
AT-103
CONTROL UNIT (EEPROM) Diagnostic Procedure
Diagnostic Procedure 1
CHECK DTC With CONSULT-II
1. Turn ignition switch “ON” and select “SELF DIAG RESULTS” mode for CVT with CONSULT-II. 2. Move selector lever to “R” position. 3. Depress accelerator pedal (Full throttle position). 4. Touch “ERASE”. 5. Turn ignition switch “OFF” position for 10 seconds. PERFORM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE. See previous page. Is the “CONT UNIT (EEPROM)” displayed again? Yes
©
Replace TCM.
No
©
INSPECTION END
AT-104
=NCAT0242
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS PNP Switch, Stop Lamp Switch and Throttle Position Switch
PNP Switch, Stop Lamp Switch and Throttle Position Switch
NAAT0204
SYMPTOM: CVT or SPORT indicator lamp does not come on in TCM selfdiagnostic procedure even the lamp circuit is good.
DESCRIPTION I I I I
NAT0204S01
PNP switch The PNP switch assemble includes a transmission range switch. The transmission range switch detects the selector position and sends a signal to the TCM. Stop lamp switch Detects the stop lamp switch position (ON or OFF) and sends a signal to the TCM Throttle position switch. Consists of a wide open throttle position switch and a closed throttle position switch. The wide open throttle position switch sends a signal to the TCM when the throttle valve is open at least 1/2 of the full throttle position. The closed throttle position switch sends a signal to the TCM when the throttle valve is fully closed.
AT-105
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS PNP Switch, Stop Lamp Switch and Throttle Position Switch (Cont’d)
1
CHECK PNP SWITCH CIRCUIT (With CONSULT-II)
With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II.
SAT651J
3. Read out “P/N”, “R”, “D” and “L” position switches moving selector lever to each position. Check the signal of the selector lever position is indicated properly. OK or NG OK
©
GO TO 3.
NG
©
Check the following items: I PNP switch Refer to “Component Inspection”, AT-53. I Harness for short or open between ignition switch and PNP switch (Main harness) I Harness for short or open between PNP switch and TCM (Main harness) I Ignition switch and fuse Refer to EL section (“POWER SUPPLY ROUTING”). I Diode (P, N positions)
2
CHECK PNP SWITCH CIRCUIT (Without CONSULT-II)
With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 27, 34, 35, 36 and ground while moving selector lever through each position. Voltage: B: Battery voltage 0: 0V Lever position P,N R D L
36 B 0 0 0
Terminal No. 35 34 0 0 B 0 0 B 0 0
27 0 0 0 B MTBL0312
OK or NG OK
©
GO TO 3.
NG
©
Check the following items: I PNP switch Refer to “Component Inspection”, AT-53. I Harness for short or open between ignition switch and PNP switch (Main harness) I Harness for short or open between PNP switch and TCM (Main harness) I Ignition switch and fuse Refer to EL section (“POWER SUPPLY ROUTING”). I Diode (P, N positions)
AT-106
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS PNP Switch, Stop Lamp Switch and Throttle Position Switch (Cont’d)
3
CHECK PNP SWITCH CIRCUIT (With CONSULT-II)
With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II.
SAT651J
3. Read out “BRAKE SW” moving brake pedal to each position. Check the signal of the brake pedal is indicated properly. OK or NG OK
©
GO TO 5.
NG
©
Check the following items: I Harness for short or open between fuse block and PNP switch harness terminal 3 I Fuse I Ignition switch (Refer to EL section.)
4
CHECK STOP LAMP SWITCH CIRCUIT (Without CONSULT-II)
1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between stop lamp switch harness terminal 1 and ground. Refer to “Wiring Diagram — CVT — MAIN”, AT-45.
Stop lamp switch LHD models RHD models
SAT733J
Does battery voltage exist? OK
©
GO TO 5.
NG
©
Check the following items: I Harness for short or open between battery and stop lamp switch harness terminal 1 I Fuse I Ignition switch (Refer to EL section.)
AT-107
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS PNP Switch, Stop Lamp Switch and Throttle Position Switch (Cont’d)
5
CHECK THROTTLE POSITION SWITCH CIRCUIT (With CONSULT-II)
With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal. Check the signal of throttle position switch is indicated properly.
Accelerator pedal condition
Data monitor CLOSED THL/SW
W/O THRL/P-SW
Released
ON
OFF
Fully depressed
OFF
ON MTLB0011
OK or NG OK
©
GO TO 7.
NG
©
Check the following items: I Throttle position switch — Refer to “Components Inspection”, AT-85. I Harness for short or open between ignition switch and throttle position switch (Main harness) I Harness for short or open between throttle position switch and TCM (Main harness)
AT-108
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS PNP Switch, Stop Lamp Switch and Throttle Position Switch (Cont’d)
6
CHECK THROTTLE POSITION SWITCH CIRCUIT (Without CONSULT-II)
Without CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 16, 17 and ground while depressing, and releasing accelerator pedal slowly. (After warming up engine) Voltage
Accelerator pedal condition
Terminal No. 16
Terminal No. 17
Released
Battery voltage
1V or less
Fully depressed
1V or less
Battery voltage MTBL0137
SAT454J
OK or NG OK
©
GO TO 7.
NG
©
Check the following items: I Throttle position switch — Refer to “Components Inspection”, AT-85. I Harness for short or open between ignition switch and throttle position switch (Main harness) I Harness for short or open between throttle position switch and TCM (Main harness)
7
CHECK DTC
Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-103. OK or NG OK
©
INSPECTION END
NG
©
1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
AT-109
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS Wiring Diagram — AT — NONDTC
Wiring Diagram — AT — NONDTC MODELS BEFORE VIN - P11U0548750 BATTERY
NCAT0237
IGNITION SWITCH ON or START
FUSE BLOCK (J/B)
Refer to EL-POWER.
TCM (TRANSMISSION CONTROL MODULE)
Detectable line for DTC Non-detectable line for DTC Hyper CVT models Hyper CVT M6 models SPORT indicator lamp CVT warning lamp
UNIFIED METER CONTROL UNIT
COMBINATION METER
INDICATOR CONTROL UNIT
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YAT155
AT-110
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS Wiring Diagram — AT — NONDTC (Cont’d)
MODELS AFTER VIN - P11U0548750
YAT253
AT-111
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS Wiring Diagram — AT — NONDTC (Cont’d)
YAT254
AT-112
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS Wiring Diagram — AT — NONDTC (Cont’d)
YAT255
AT-113
ON-VEHICLE SERVICE Control Cable Adjustment
Control Cable Adjustment
Control cable
Lock nut
Manual shaft SAT658J
Park/Neutral Position (PNP) Switch Adjustment
Pin
NCAT0112
PNP switch
Manual shaft (N range)
NCAT0111
Move selector lever from the “P” position to the “L” 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. 2. Loosen control cable lock nut and place manual shaft in “P” position. CAUTION: Turn wheels more than 1/4 rotations and apply the park lock. 3. Tighten control cable lock nut. : 12 - 14 N⋅m (1.2 - 1.5 kg-m, 9 - 10 ft-lb) 4. Move selector lever from “P” to “L” position again. Make sure that selector lever moves smoothly. 5. Apply grease to contacting areas of selector lever and control cable. Install any part removed.
1. 2. 3.
Remove control cable end from manual shaft. Set manual shaft in “N” position. Loosen PNP switch fixing bolts.
4. a. b.
Use a 4 mm (0.157 in) pin for this adjustment. Insert the pin straight into the manual shaft adjustment hole. Rotate PNP switch until the pin can also be inserted straight into hole in PNP switch. Tighten PNP switch fixing bolts. : 4.9 - 6.8 N⋅m (0.5 - 0.7 kg-m, 44 - 60 in-lb) Remove pin from adjustment hole after adjusting PNP switch. Reinstall any part removed. Adjust control cable. Refer to “Control Cable Adjustment”. Check continuity of PNP switch. Refer to AT-53.
SAT659J
5. 6. 7. 8. 9.
Differential Side Oil Seal Replacement 1. 2.
NCAT0113
Remove drive shaft assemblies. Refer to FA section (“Drive Shaft”, “FRONT AXLE”). Remove oil seals.
Oil seal
SAT660J
AT-114
ON-VEHICLE SERVICE Differential Side Oil Seal Replacement (Cont’d)
3. I I
Install oil seals. Apply CVT fluid to oil seal surface before installing. Install oil seals so that dimensions “A” and “B” are within specifications. Unit: mm (in)
Left side
Right side SAT661J
4.
A
B
5.5 - 6.5 (0.217 - 0.256)
−0.5 to 0.5 (−0.020 to 0.020)
Reinstall any part removed.
AT-115
REMOVAL AND INSTALLATION Removal
Removal
SAT664J
NCAT0115
CAUTION: Before separating transaxle from engine, remove the crankshaft position sensor (OBD) from transaxle. Be careful not to damage sensor. 1. Remove battery and bracket. 2. Remove air duct between throttle body and air cleaner. 3. Disconnect control valve harness connector, PNP switch harness connector, secondary speed sensor harness connector, dropping resistor harness connector, primary speed sensor harness connector and body earth harness connector. 4. Remove crankshaft position sensor (OBD) from transaxle. 5. Drain CVT fluid from transaxle. 6. Disconnect control cable from transaxle. 7. Remove exhaust front tube. Refer to FE section (“EXHAUST SYSTEM”). 8. Remove drive shafts. Refer to FA section (“Drive Shaft”, “FRONT AXLE”). 9. Disconnect oil cooler hoses. 10. Remove starter motor from transaxle. Tighten bolts to specified torque. : 41 - 52 N⋅m (4.2 - 5.3 kg-m, 30 - 38 ft-lb) 11. Support transaxle with a jack. 12. Remove center member. I Tighten center member fixing bolts to specified torque, Refer to EM section (“ENGINE REMOVAL”). 13. Remove rear plate cover. 14. Remove torque converter bolts. Rotate crankshaft to gain access to securing bolts. 15. Support engine with a jack. 16. Remove transaxle mount bolt. Refer to EM section (“ENGINE REMOVAL”). 17. Remove oil cooler tube (outlet side). 18. Remove transaxle.
Inspection I
NCAT0236
When connecting torque converter to transaxle, measure distance “A” to be certain that they are correctly assembled. Distance “A”: 15.9 mm (0.626 in) or more
SAT665J
AT-116
REMOVAL AND INSTALLATION Installation : Transaxle to engine
Installation
: Engine to transaxle
1.
SAT666J
NCAT0116
Tighten bolts fixing transaxle. Bolt No.
Tightening torque N⋅m (kg-m, ft-lb)
Bolt length “” mm (in)
1
70 - 79 (7.1 - 8.1, 51 - 59)
40 (1.57)
2
31 - 36 (3.1 - 3.7, 23 - 26)
35 (1.38)
3
31 - 36 (3.1 - 3.7, 23 - 26)
47 (1.85)
4
70 - 79 (7.1 - 8.1, 52 - 58)
65 (2.56)
2. I
Install torque converter to drive plate. With converter installed, rotate crankshaft several turns to check that transaxle rotates freely without binding.
3. 4. 5. 6. 7.
Reinstall any part removed. Adjust control cable. Refer to AT-114. Check continuity of PNP switch. Refer to AT-53. Refill transaxle with CVT fluid and check fluid level. Move selector lever through all positions to be sure that transaxle operates correctly. With parking brake applied, idle engine. A slight shock should be felt through the hand gripping the selector each time the transaxle is shifted. Perform road test. Refer to AT-36.
8. SAT638A
AT-117
REMOVAL AND INSTALLATION Air Breather Hose
Air Breather Hose SR20DE Air breather hose Engine harness
Air duct Clip Control cable Air conditioner tube
Paint mark upside More than 17 mm insert Front
NAT312
CVT Fluid Cooler (Hyper CVT-M6) SEC. 310
Radiator core support (lower) Hose
Radiator 4.5 - 5.7 (0.45 - 0.59)
Tube
Bumper retainer Front Radiator shroud Hose Upper bracket
Side member
Lower bracket
CVT fluid hydraulic circuit
Tube
Radiator CVT fluid cooler Fluid cooler 4.5 - 5.7 (0.45 - 0.59)
Hose
4.5 - 5.7 (0.45 - 0.59)
: N·m (kg-m)
NAT313
AT-118
REMOVAL AND INSTALLATION Components
Components SEC. 310⋅311⋅312⋅319
5.0 - 6.8 (0.5 - 0.7, 44 - 60)
5.0 - 6.8 (0.5 - 0.7, 44 - 60) PNP SW
Fluid level gauge
Fluid charging pipe Dropping resistor
Secondary pulley speed sensor 5.0 - 6.8 (0.5 - 0.7, 44 - 60)
4.5 - 5.7 (0.45 - 0.59, 40 - 50) O-ring
Speedometer pinion
5.0 - 6.8 (0.5 - 0.7, 44 - 60)
Differential oil seal O-ring
O-ring
Primary pulley speed sensor
O-ring
40 - 58 (4.0 - 6.0, 30 - 43) Copper washer 4.5 - 5.7 (0.45 - 0.59, 40 - 50)
Differential oil seal
Tube (outlet) 4.5 - 5.7 (0.45 - 0.59, 40 - 50) Oil pump oil seal
Torque converter
Copper washer Input shaft O-ring 40 - 58 (4.0 - 6.0, 30 - 43)
CVT assy Oil pan gasket
Oil pan installation bolt (18)
Tube (inlet)
Gasket
6.9 - 8.8 (0.7 - 0.9, 61 - 78)
Drain bolt 30 - 39 (3.0 - 4.0, 22 - 29) Magnet : N·m (kg-m, in-lb)
4.5 - 5.7 (0.45 - 0.59, 40 - 50)
Oil pan
: N·m (kg-m, ft-lb) : CVT fluid NS-1 NAT311
AT-119
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications
General Specifications
NCAT0179
Engine
SR20DE
Automatic transaxle model
RE0F06A
Automatic transaxle assembly
Transaxle gear ratio
Model code number
8E020
D range
Variable
Reverse
1.586
Final drive
5.473
Recommended fluid
Nissan CVT fluid NS-1*1
Fluid capacity
8.1 (7-1/8 Imp qt)
*1: Refer to MA section (“Fluids and Lubricants”, “RECOMMENDED FLUIDS AND LUBRICANTS”). Any other fluid will damage the CVT.
Stall Revolution Engine
NCAT0181
Stall revolution
(SR20DE)
rpm
2,350 - 2,850
Line Pressure
NCAT0182 2
Engine speed rpm
Line pressure MPa (kg/cm , psi) R position
D position
Idle
0.6 (6.1, 87)
Stall
4.1 (42, 595)
L position
Removal and Installation
NCAT0197
Unit: mm (in) Distance between end of converter housing and torque converter
AT-120
15.9 (0.626) or more
FRONT AXLE & FRONT SUSPENSION SECTION
FA
CONTENTS PRECAUTIONS AND PREPARATION.......................... 2 Precautions ................................................................ 2 Special Service Tools ................................................ 2 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................... 3 NVH Troubleshooting Chart....................................... 3 FRONT SUSPENSION SYSTEM .................................. 4 ON-VEHICLE SERVICE ................................................ 5 Front Axle and Front Suspension Parts .................... 5 Front Wheel Bearing.................................................. 6 Front Wheel Alignment .............................................. 6 Drive Shaft ................................................................. 8
FRONT AXLE ................................................................ 9 Wheel Hub and Knuckle...........................................11 Drive shaft................................................................ 15 FRONT SUSPENSION ................................................ 26 Coil Spring and Shock Absorber ............................. 28 Third Link and Upper Link ....................................... 29 Transverse Link and Lower Ball Joint ..................... 32 Stabilizer Bar ........................................................... 32 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 34 General Specifications............................................. 34 Inspection and Adjustment ...................................... 35
FA
PRECAUTIONS AND PREPARATION Precautions ●
● GG94310000
SBR500
● ●
When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. When removing each suspension part, check wheel alignment and adjust if necessary. Use Tool when removing or installing brake tubes. Always torque brake lines when installing.
Special Service Tools Tool number Tool name
Description
HT72520000 Ball joint remover
Removing tie-rod outer end and lower ball joint a: 33 (1.30) b: 50 (1.97) v: 11.5 (0.453)
Unit: mm (in)
NT546
HT71780000 Spring compressor
Removing and installing coil spring
NT144
GG94310000 Flare nut torque wrench
Removing and installing brake piping
NT406
a: 10 mm (0.39 in)
KV38106700 KV38106800 Differential side oil seal protector
Installing drive shaft
LH : KV38106700 NT147
RH : KV38106800
IM23600800 Attachment Wheel alignment
Measure wheel alignment a: Screw M24 x 1.5 b: 35 (1.38) dia. c: 65 (2.56) dia. d: 56 (2.20) NT148
e: 12 (0.47)
ST35652000 Strut attachment
Fixing strut assembly
NT145
FA-2
Unit: mm (in)
DRIVE SHAFT
FRONT AXLE AND FRONT SUSPENSION
Symptom
TIRES
ROAD WHEEL
Noise, Vibration Shake Noise Shake Vibration Shimmy Judder Poor quality ride or handling Noise Shake Vibration Shimmy Judder Poor quality ride or handling Noise Shake Shimmy, Judder Poor quality ride or handling X X X X X X X X X X X X X X X X X X X X X X
X X X X X
X: Applicable
FA-3
—
X X
X X X X
X X
X X
X X
X X X
X
X X
X X X
X X
X X X X X
X X
X X
X
X
X
X
X
X
X X X
X X X
X X X
X X X
X
X
X
X
X X X X
Refer to FRONT AXLE AND FRONT SUSPENSION in this chart. Refer to TIRES in this chart. Refer to ROAD WHEEL in this chart. NVH in RA section NVH in BR section NHV in ST section
TIRES ROAD WHEEL REAR AXLE AND REAR SUSPENSION BRAKES STEERING
—
Incorrect tire size
Refer to DRIVE SHAFT in this chart.
—
Non-uniformity
FRONT AXLE AND FRONT SUSPENSION
—
DRIVE SHAFT
—
Deformation or damage
Out-of-round
—
FA-6
Wheel bearing damage
Uneven tire wear
FA-6
Stabilizer bar fatigue
Incorrect air pressure
FA-6 FA-32
Incorrect wheel alignment
FA-5
Spring fatigue Suspension looseness
—
FA-29, FA-29
Parts interference
Bushing or mounting deterioration
FA-29
Shock absorber deformation, damage or deflection
— FA-5
Improper installation, looseness
Imbalance
— FA-21
Possible cause and SUSPECTED PARTS Joint sliding resistance
Reference page
Excessive joint angle
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart
Use the chart below to help you find 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 X X
X X X X X
X X
X X
X X X X X
X
X
X
X X X X X X X X X
X X X X X X X
X X X X X
X X X
X X X
X X X
X
X
X
X X X X
X X
X X
X X X X X X X
X X
X X X X X
X X X
X X X
FRONT SUSPENSION SYSTEM SEC. 391⋅400⋅401 When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
Shock absorber mounting insulator Coil spring
88 - 123 (9.0 - 12.5, 65 - 90)
18 - 21 (1.9 - 2.1, 14 - 15)
Upper link bracket
93 - 123 (9.5 - 12.5, 69 - 90)
Front suspension member
61 - 80 (6.3 - 8.1, 45 - 59)
Shock absorber Upper link
Third link
40 - 49 (4.1 - 4.9, 30 - 36)
Stay
Knuckle
98 - 114 (10.0 - 11.6, 73 - 84)
Front
Drive shaft
118 - 147 (12 - 14, 87 - 108)
Transverse link
118 - 147 (12 - 14, 87 - 108)
42 - 49 (4.3 - 4.4, 31 - 36)
Stabilizer bar
42 - 49 (4.3 - 4.9, 31 - 36)
: N·m (kg-m, ft-lb)
NFA028
FA-4
ON-VEHICLE SERVICE Front Axle and Front Suspension Parts Check front axle and front suspension parts for excessive play, cracks, wear or other damage. ● Shake each front wheel to check for excessive play. ● Ensure that new cotter pins are used, and are correctly fitted.
SMA525A
●
Retighten all axle and suspension nuts and bolts to the specified torque. Tightening torque: Refer to FRONT SUSPENSION, FA-26.
●
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. If ball joint dust cover is cracked or damaged, replace transverse link.
SMA614
NFA029
SMA113
.
SFA911A SFA911A
FA-5
ON-VEHICLE SERVICE Front Axle and Front Suspension Parts (Cont’d)
Transverse link Brake caliper Dial indicator
Pry bar
Lower ball joint SFA504A
● Check suspension ball joint end play. a. Jack up front of vehicle and set the stands. b. Clamp dial indicator onto transverse link and place indicator tip on lower edge of brake caliper. c. Make sure front wheels are straight and brake pedal is depressed. d. Place a pry bar between transverse link and inner rim of road wheel. e. While raising and releasing pry bar, observe maximum dial indicator value. Vertical end play: 0 mm (0 in) f. If ball joint vertical end play exists, remove transverse link and recheck the ball joint. Refer to “FRONT SUSPENSION”, FA-32.
Front Wheel Bearing ● ●
●
Check that wheel bearings operate smoothly. Check axial end play. Axial end play: 0.05 mm (0.0020 in) or less If axial end play is not within specification or wheel bearing does not turn smoothly, replace wheel bearing assembly. Refer to “Wheel Hub and Knuckle”, “FRONT AXLE”, FA-FA11.
SFA912A
Front Wheel Alignment Before checking front wheel alignment, be sure to make a preliminary inspection (Unladen*). *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. Lateral runout
Radial runout SFA975B
PRELIMINARY INSPECTION 1. Check tires for wear and improper inflation. 2. Check wheels for deformation, cracks and other damage. If deformed, remove tire and check wheel runout. Wheel runout: Refer to SDS, FA-35. 3. Check front wheel bearings for looseness. 4. Check front suspension for looseness. 5. Check steering linkage for looseness. 6. Check that front shock absorbers work correctly by using the standard bounce test. 7. Check vehicle posture (Unladen).
FA-6
ON-VEHICLE SERVICE Front Wheel Alignment (Cont’d) CAMBER, CASTER AND KINGPIN INCLINATION Attachment IM23600800
Alignment gauge
SRA096A
Camber, caster and kingpin inclination are preset at factory and cannot be adjusted. 1. Measure camber, caster and kingpin inclination of both right and left wheels with a suitable alignment gauge. Camber, Caster and Kingpin inclination: Refer to SDS, FA-35. 2. If camber, caster and kingpin inclination are not within specification, inspect front suspension parts. Replace any damaged or worn out parts.
TOE-IN Front
Hub center height
Base line Measuring point
SFA614B
Lines parallel to center line of body
Toe-in = A − B Total toe-in angle = 2 θ SFA234A
Front
Measure toe-in using following procedure: WARNING: ● Always perform following procedure on a flat surface. ● Ensure the way in front of the vehicle is clear before pushing it. 1. Bounce front of vehicle up and down to stabilize the posture. 2. Push the vehicle straight ahead for about 5 m (16 ft). 3. Put a mark on base line of the tread (rear side) of both tires at the same height as hub center. These are measuring points. 4. Measure distance “A” (rear tires). 5. Push the vehicle slowly forwards to rotate the wheels 180 degrees (1/2 turn). If the wheels have passed 180 degrees, try the above procedure again from the beginning. Never push vehicle backward. 6. Measure distance “B” (front tires). Toe-in (A − B): Refer to SDS, FA-35.
7. Adjust toe-in by varying the length of steering tie-rods. a. Loosen lock nuts.
Lock nut
.
SFA913A
FA-7
ON-VEHICLE SERVICE Front Wheel Alignment (Cont’d) b. Adjust toe-in by screwing tie-rods in and out. Standard length “L”: Refer to ST section (“General Specifications”, “SDS”). c. Tighten lock nuts to specified torque. : 38 - 47 N·m (3.9 - 4.7 kg-m, 28 - 34 ft-lb)
Lock nut
SFA486A
FRONT WHEEL TURNING ANGLE
SFA439B
1. Set wheels in straight-ahead position. Then move vehicle forward until front wheels rest on turning radius gauge properly. 2. Rotate steering wheel all the way right and left; measure turning angle. ● On power steering models, turn steering wheel to full lock and apply force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine at idle. Do not hold the steering wheel at full lock for more than 15 seconds. Wheel turning angle (Full turn): Refer to SDS, FA-35.
Drive Shaft Check for grease leakage or other damage.
.
SFA914A
FA-8
FRONT AXLE MODELS BEFORE VIN - P11U0559000 SEC. 400
Drive shaft Front
98 - 118 (10 - 12, 73 - 87)
Baffle plate Inner grease seal Wheel bearing assembly
Snap ring
Snap ring Knuckle .
18 - 24 (1.8 - 2.4, 13 - 17)
ABS sensor
Wheel bolt
Disc rotor
Outer grease seal Wheel hub Plain washer Wheel bearing lock nut 255 - 333 (26 - 34, 188 - 246) Cotter pin Wheel nut 98 - 118 (10 - 12, 73 - 87)
: N·m (kg-m, ft-lb) : Apply grease
NFA056
FA-9
FRONT AXLE MODELS AFTER VIN - P11U0559000
YFA001
FA-10
FRONT AXLE Wheel Hub and Knuckle REMOVAL CAUTION: Before removing front axle assembly, disconnect ABS wheel sensor from assembly and move it from front axle assembly area. Failure to do so may result in damage to sensor wires and the sensor becoming inoperative. 1. Remove wheel bearing lock nut. SFA897A
2. Remove brake caliper assembly and rotor. Brake hose need not be disconnected from brake caliper. In this case, suspend the caliper assembly with a wire so as not to stretch the brake hose. Be careful not to depress the brake pedal, to prevent the piston from popping out. Make sure brake hose is not twisted.
SFA898A
3. Separate tie-rod from knuckle with tool. Install stud nut inverted on stud bolt to prevent damage to stud bolt.
HT72520000 SFA899A
4. Remove kingpin cap and securing nut. Separate kingpin from knuckle.
SFA907A
5. Separate drive shaft from knuckle with drift. When removing drive shaft, cover drive shaft boots with waste cloth to prevent damage to them.
Wood SFA900A
FA-11
FRONT AXLE Wheel Hub and Knuckle (Cont’d) ●
Remove ball joint securing nut. Separate from knuckle using Tool (as for tie-rod).
HT72520000 SFA901A
INSTALLATION ● ●
●
Install knuckle with wheel hub. Tighten wheel bearing lock nut. : 236 - 313 N·m (24 - 32 kg-m, 174 - 230 ft-lb) Check that wheel bearings operate smoothly.
SFA906A
●
Check wheel bearing axial end play. Axial end play: 0.05 mm (0.0020 in) or less.
SFA902A
DISASSEMBLY CAUTION: When removing wheel hub or wheel bearing from knuckle, replace wheel bearing assembly (outer race, inner races and grease seals) with a new one.
Suitable tool
Wheel Hub Drive out hub with inner race (outside) from knuckle with a suitable tool. SFA903A
Wheel Bearing Suitable tool
When replacing wheel bearing, replace complete wheel bearing assembly (including inner and outer races). ● Remove bearing inner race (outside), then remove outer grease seal.
SFA654A
FA-12
FRONT AXLE Wheel Hub and Knuckle (Cont’d) ●
Remove inner grease seal from knuckle.
●
Remove inner and outer snap rings.
●
Press out bearing outer race.
SFA904A Suitable tool
SFA685
Suitable tool
SFA905A
INSPECTION Wheel Hub and Knuckle Check wheel hub and knuckle for cracks by using a magnetic exploration or dyeing test.
Snap Ring Check snap ring for wear or cracks. Replace if necessary.
ASSEMBLY Suitable tool Wheel bearing assembly Knuckle Inner snap ring Suitable tool SFA655A
1. Install inner snap ring into groove of knuckle. 2. Press new wheel bearing assembly into knuckle until it contacts snap ring. Maximum load P: 49 kN (5 t, 5.5 US ton, 4.9 lmp ton) CAUTION: ● Do not press inner race of wheel bearing assembly. ● Do not apply oil or grease to mating surfaces of wheel bearing outer race and knuckle. 3. Install outer snap ring into groove of knuckle.
FA-13
FRONT AXLE Wheel Hub and Knuckle (Cont’d) 4. Pack grease seal lip with multi-purpose grease.
Inner side SFA747
5. Install outer grease seal. Maximum load P: 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton) Suitable tool Grease seal
SFA656A
6. Install inner grease seal. Maximum load P: 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton)
Suitable tool
Grease seal
Suitable tool SFA657A
7. Press wheel hub into knuckle. Maximum load P: 29 kN (3 ton, 3.3 US ton, 3.0 Imp ton) Be careful not to damage grease seal.
Suitable tool
Wheel bearing assembly
Wheel hub Knuckle
Suitable tool SFA658A
8. Check bearing operation. (1) Add load P with press. Load P: 34.3 - 49.0 kN (3.5 - 5.0 ton, 3.9 - 5.5 US ton, 3.44 - 4.92 Imp ton)
SFA659A
FA-14
FRONT AXLE Wheel Hub and Knuckle (Cont’d) (2) Spin knuckle several turns in both directions. (3) Make sure that wheel bearings operate smoothly.
SFA182A
Drive shaft REMOVAL 1. Remove wheel bearing lock nut. 2. Remove brake caliper assembly and rotor. Brake hose need not be disconnected from brake caliper. In this case, suspend caliper assembly with wire so as not to stretch brake hose. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted. SFA897A
3. Remove tie-rod ball joint. 4. Remove upper knuckle nut. 5. Separate drive shaft from knuckle by lightly tapping it. If it is hard to remove, use a puller. When removing drive shaft, cover drive shaft boots with waste cloth to prevent damage to them. Refer to “FRONT AXLE”, “Wheel Hub and Knuckle”, FA-11.
SFA907A
6. Remove right drive shaft from transaxle. − Models without support bearing −
.
SFA499A
− Models with support bearing −
.
SFA989
FA-15
FRONT AXLE Drive shaft (Cont’d) .
7. Remove left drive shaft from transaxle. − For M/T models − ● Pry off drive shaft from transaxle as shown.
M/T model
.
SFA991
− For CVT models − ● Insert screwdriver into transaxle opening for right drive shaft and strike with a hammer. Be careful not to damage pinion mate shaft and side gear.
CVT model Screwdriver
5 mm (0.20 in)
Pinion mate shaft Side gear Drive shaft
SFA730
INSTALLATION
RH
Transaxle side 1. Install a new oil seal to transaxle. Refer to MT or AT section (“Differential Side Oil Seal Replacement”, “ON-VEHICLE SERVICE”). 2. Set Tool along the inner circumference of oil seal.
KV38106800 SFA482
LH
3. Insert drive shaft into transaxle. Be sure to correctly align the splines and then withdraw Tool. 4. Push drive shaft, then press-fit circular clip on the drive shaft into circular clip groove of side gear. 5. After its insertion, try to pull the flange out of the slide joint by hand. If it pulls out, the circular clip is not properly meshed with the side gear.
KV38106700
SFA483
FA-16
FRONT AXLE Drive shaft (Cont’d) Wheel side ● ●
Install drive shaft into knuckle. Tighten upper knuckle nut and wheel bearing lock nut. Refer to “FRONT AXLE”, “Wheel Hub and Knuckle”, FA-11.
COMPONENTS SEC. 391 Circulair clip: Make sure circular clip is properly meshed with side gear (transaxle side) and joint assembly (wheel side), and will not come out.
Wheel side (90AC type and 98AC type)
Spacer ring ABS rotor
Boot band
Be careful not to damage boots. Use suitable protector or cloth during removal and installation.
All M/T models
Joint assembly
Drive shaft Boot Circular clip B
Boot
Spider assembly
Boot band
Snap ring C Side joint housing Dust shield Circular clip
Transaxle side (GI69 type and GI82 type)
FA-17
NFA054
FRONT AXLE Drive shaft (Cont’d) Circular clip: Make sure circular clip is properly meshed with side gear (transaxle side) and joint assembly (wheel side), and will not come out.
Wheel side (B86 type)
Be careful not to damage boots. Use suitable protector or cloth during removal and installation.
All CVT models
For type with support bearing
25 - 35 (2.6 - 3.6, 19 - 26) 25 - 35 (2.6 - 3.6, 19 - 26) 43 - 58 (4.4 - 5.9, 32 - 43)
Left drive shaft 13 - 19 (1.3 - 1.9, 9 - 14)
: N·m (kg-m, ft-lb)
Transaxle side (D83/T83 type)
Right drive shaft
NFA055 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p
Joint assembly Boot band Boot Circular clip B Drive shaft Boot band Boot Snap ring A
9 p 10 p 11 p 12 p 13 p 14 p 15 p 16 p
Snap ring B Inner race Cage Ball Snap ring C Slide joint housing Dust shield Circular clip A
FA-18
17 p 18 p 19 p 20 p 21 p 22 p 23 p 24 p
Slide joint housing with extention shaft Snap ring E Dust shield Support bearing Support bearing retainer Bracket Snap ring D Dust shield
FRONT AXLE Drive shaft (Cont’d) DISASSEMBLY
Matching mark
TRANSAXLE SIDE (GI69 type and GI82 type) 1. Remove boot bands. 2. Put matching marks on slide joint housing and drive shaft before separating joint assembly. 3. Put matching marks on spider assembly and drive shaft.
SFA963
4. Pry off snap ring, then remove spider assembly. CAUTION: Do not disassemble spider assembly. 5. Draw out boot. Cover drive shaft serration with tape to prevent damage to the boot.
Snap ring SFA612
TRANSAXLE SIDE (D83/T83 type) 1. Remove boot bands. 2. Put matchmarks on slide joint housing and inner race, before separating joint assembly. 3. Remove snap ring “A” with a screwdriver, and pull out slide joint housing.
SFA476
4. Put matchmarks on inner race and drive shaft. 5. Remove snap ring “C”, then remove ball cage, inner race and balls as a unit. 6. Remove snap ring “B”. 7. Draw out boot. Cover drive shaft serrations with tape so as not to damage the boot.
SFA514A
WHEEL SIDE (90AC, 98AC and B86 type) Suitable tool (Sliding hammer)
CAUTION: The joint on the wheel side cannot be disassembled. Before separating joint assembly, put matching marks on drive shaft and joint assembly. ● Separate joint assembly with a suitable tool. Be careful not to damage threads on drive shaft. ● Remove boot bands and draw out boot. ●
Wheel bearing lock nut SFA092A
FA-19
FRONT AXLE Drive shaft (Cont’d) SUPPORT BEARING ●
Remove outer dust shield.
●
Remove inner dust shield.
●
Pry off snap ring.
●
Press support bearing assembly out of drive shaft.
●
Press support bearing out of retainer.
SFA613
SFA691
Suitable tool Snap ring
SFA692
SFA693
Suitable tool
SFA617
FA-20
FRONT AXLE Drive shaft (Cont’d) INSPECTION 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) GI69 and GI82 type ● 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. D83/T83 type ● Replace joint assembly if it is deformed or damaged.
Joint assembly (Wheel side) Replace joint assembly if it is deformed or damaged.
Support bearing Make sure bearing rolls freely, and is free from noise, cracks, pitting or wear.
Support bearing bracket Check support bearing bracket for cracks with a magnetic exploration or dyeing test.
ASSEMBLY ● ●
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.
FA-21
FRONT AXLE Drive shaft (Cont’d) Wheel side (90AC, 98AC and B86 type) 1. Install boot and new small boot band on drive shaft. Cover drive shaft serration with tape so as not to damage boot during installation.
Tape
SFA800
Wheel bearing lock nut
2. Set joint assembly onto drive shaft by lightly tapping it. Install joint assembly securely, ensuring marks which were made during disassembly are correctly aligned.
SFA942A
3. Pack drive shaft with specified amount of grease. Specified amount of grease: 90AC type 80 - 110 m (2.8 - 3.9 Imp fl oz) 98AC type 110 - 130 m (3.9 - 4.6 Imp fl oz) B86 type 95 - 115 m (3.3 - 4.0 Imp fl oz)
SFA885
4. Make sure that boot is correctly installed on the drive shaft groove. Set boot so that it does not swell and deform when its length is “L1”. Length “L1”: 90AC type 89 - 91 mm (3.50 - 3.58 in) 98AC type 96 - 98 mm (3.78 - 3.86 in) L1 SFA886
5. Lock new larger and smaller boot bands securely with a suitable tool.
Boot band
SFA395
FA-22
FRONT AXLE Drive shaft (Cont’d)
Suitable tool
.
SFA472 SFA472
Transaxle side (GI69 type and GI82 type) 1. Install boot and new small boot band on drive shaft. Cover drive shaft serration with tape to prevent damage to boot during installation.
Tape
SFA800
2. Install spider assembly securely, making sure the marks which were made during disassembly are properly aligned. 3. Install new snap ring.
Snap ring SFA023A
4. Pack drive shaft with specified amount of grease. Specified amount of grease: GI69 type 165 - 175 m (5.8 - 6.2 Imp fl. oz) GI82 type 160 - 170 m (5.6 - 6.0 Imp fl. oz) 5. Install slide joint housing. 6. Make sure that boot is properly installed on the drive shaft groove. Set boot so that it does not swell and deform.
Shaft groove SFA065A
7. Lock new larger and smaller boot bands securely with a suitable tool.
Boot band
SFA395
FA-23
FRONT AXLE Drive shaft (Cont’d) Transaxle side (D83/T83 type) 1. Install boot and new small boot band on drive shaft. Cover drive shaft serration with tape to prevent damage boot during installation.
Tape
SFA800
2. Install ball cage, inner race and balls as a unit, making sure the matching marks which were made during disassembly are properly aligned. 3. Install new snap ring “C”.
SFA514A
4. Pack drive shaft with specified amount of grease. Specified amount of grease: 115 - 135 m (4.0 - 4.8 Imp fl oz) 5. Install slide joint housing, then install new snap ring “A”. 6. Make sure that boot is properly installed on the drive shaft groove. Set boot so that it does not swell and deform.
NFA050
7. Lock new larger and smaller boot bands securely with a suitable tool.
Boot band
SFA395
Support bearing ●
Press bearing into retainer.
Suitable tool
SFA618
FA-24
FRONT AXLE Drive shaft (Cont’d) ●
Press drive shaft into bearing.
● ●
Install snap ring. Install new dust shield.
Suitable tool
SFA694
SFA695
Transaxle side
SFA621
FA-25
FRONT SUSPENSION MODELS BEFORE VIN - P11U0559000 SEC. 391⋅400⋅401 When installing stabilizer bar and transverse link, final tightening requires to be carried out under unladen condition* with tires on the ground. 42 - 54 * Fuel, radiator coolant and engine oil full. (4.3 - 5.5, Spare tire, jack, hand tools and mats in 31 - 40) designated positions.
18 - 24 (1.8 - 2.4, 13 - 17) Upper bushing A Gasket Upper mounting Upper rubber seat Upper bushing B
Dust cover
Bound bumper rubber
Coil spring
Shock absorber
16 - 22 (1.6 - 2.2, 12 - 16) Washer 88 - 123 (9.0 - 12.5, 65 - 90)
Bushing Third link Upper link 112 - 126 (11.4 - 12.8, 82 - 93)
88 - 123 (9.0 - 12.5, 65 - 90) Upper link bracket
98 - 118 (10 - 12, 72 - 87)
112 - 126 (11.4 - 12.8, 82 - 93) 88 - 123 (9.0 - 12.5, 65 - 90)
Wheel hub end steering knuckle assembly
Cotter pin
71 - 86 (7.2 - 8.8, 52 - 63) 118 - 147 (12.0 - 15.0, 87.0 - 108.4)
Cotter pin Adjusting cap
Drive shaft
.
255 - 333 (26 - 34, 188 - 246)
Gusset pin Insulator 118 - 147 (12 - 15, 87 - 108)
Transverse link
118 - 147 (12 - 15, 87 - 108)
Connecting rod
Stabilizer bar
: N·m (kg-m, ft-lb)
42 - 49 (4.3 - 5.0, 31 - 36)
FA-26
42 - 49 (4.3 - 5.0, 31 - 36) NFA057
FRONT SUSPENSION MODELS AFTER VIN - P11U0559000
YFA002
FA-27
FRONT SUSPENSION Coil Spring and Shock Absorber REMOVAL AND INSTALLATION ● ●
Strut upper mounting
Remove shock absorber fixing bolt and nut (to hoodledge). Do not remove piston rod lock nut.
NFA034
DISASSEMBLY
Suitable bar
1. Set shock absorber on vise, then loosen piston rod lock nut. WARNING: ● Do not remove piston rod lock nut.
ST35652000 SFA020A
2. Compress spring with Tool so that shock absorber mounting insulator can be turned by hand. WARNING: Make sure that the pawls of the two spring compressors are firmly hooked on the spring. The spring compressors must be tightened alternately so as not to tilt the spring.
HT71780000
SFA918A
3. Remove piston rod lock nut.
SFA919A
FA-28
FRONT SUSPENSION Coil Spring and Shock Absorber (Cont’d) INSPECTION Shock absorber assembly ● ● ●
Check for smooth operation through a full stroke, both compression and extension. Check for oil leakage occurring on welded or gland packing portions. Check piston rod for cracks, deformation or other damage. Replace if necessary.
Mounting insulator and rubber parts ● ●
Check cemented rubber-to-metal portion for separation or cracks. Check rubber parts for deterioration. Replace if necessary.
Coil spring ●
Check for cracks, deformation or other damage. Replace if necessary.
ASSEMBLY ●
When shock absorber is installed, it must be positioned so that arrow point A faces rearward on LH side, and forward on RH side.
●
Install upper spring seat with its cutout facing the inside of the vehicle.
SFA920A
Inside
Cutout SFA921A
Third Link and Upper Link REMOVAL CAUTION: Kingpin bearing usually does not require maintenance. If any of the following symptoms are noted, replace kingpin bearing assembly. ● Growling noise is emitted from kingpin bearing during operation. ● Kingpin bearing drags or turns roughly when steering knuckle is turned by hand.
FA-29
FRONT SUSPENSION Third Link and Upper Link (Cont’d) 1. 2. 3. 4.
Remove cap and kingpin nut. Remove shock absorber fixing nut and upper link fixing bolts. Remove stabilizer connecting rod. Remove third link and upper link.
SFA922A
INSTALLATION Third link ●
Pack kingpin housing and cap with multi-purpose grease. Grease capacity: Kingpin housing 4 g (0.14 oz) Cap 10 g (0.35 oz)
●
Install third link and cap.
Grease
SFA727A
SFA923A
Upper link ● Upper link has “L” or “R” stamped on it as shown. Upper link bushings cannot be disassembled. ● When installing upper link, make sure that parts are in their correct positions. ● Bushings have in-built play of between 0.5 to 1.0 mm (0.020 to 0.039 in).
R = Upper link (right) L = Upper link (left)
Stamping SFA924A
DISASSEMBLY ●
Remove upper bearing (inner race and ball).
Upper bearing SFA721A
FA-30
FRONT SUSPENSION Third Link and Upper Link (Cont’d) ●
Remove kingpin grease seal. Remove lower bearing (inner race and ball).
● ●
Remove upper and lower outer race. Be careful not to damage kingpin housing.
●
Lower bearing
Kingpin grease seal
SFA722A
Outer race Kingpin housing Outer race SFA723A
ASSEMBLY
Press
Press
Kingpin housing
Install lower bearing.
●
Install upper bearing.
●
Install lower oil seal. Apply multi-purpose grease to oil seal lip.
SFA724A
2.5 ± 0.2 mm (0.098 ± 0.008 in)
Kingpin housing
●
SFA725A
Press
● Grease
Kingpin grease seal
SFA726A
FA-31
FRONT SUSPENSION Transverse Link and Lower Ball Joint REMOVAL AND INSTALLATION ● ● ●
Remove tension rod, ball joint and transverse link assembly. During installation, final tightening must be done at curb weight with tires on ground. After installation, check wheel alignment. Refer to “Front Wheel Alignment”, “ON-VEHICLE SERVICE”, FA-6.
NFA036
INSPECTION Transverse link ● ●
Check transverse link for damage, cracks or deformation. Replace it if necessary. Check rubber bushing for damage, cracks and deformation. Replace transverse link if necessary.
Lower ball joint A
●
B
C
SFA858A
●
Check ball joint for excessive play. Replace transverse link assembly if any of the following exists: ● Ball stud is worn. ● Joint is hard to swing. ● Play in axial direction is excessive. Before checking, turn ball joint at least 10 revolutions so that ball joint is properly broken in. Swinging force “A”: (measuring point: cotter pin hole of ball stud) 7.8 - 57.9 N (0.8 - 5.9 kg, 1.8 - 13.0 lb) Turning torque “B”: 0.5 - 3.4 (5 - 35 kg-cm, 4.3 - 30.4 in-lb) Vertical end play “C”: 0 mm (0 in) Check dust cover for damage. Replace it and cover clamp if necessary.
Stabilizer Bar REMOVAL AND INSTALLATION CAUTION: — For models with xenon headlamps only ● When removing or installing stabilizer bar, take care not to damage headlamp leveling sensor. ● After installation of the stabilizer bar, the headlamp sensor has to be recalibrated. Refer to EL-section. ● Remove stabilizer bar. .
SFA925A
FA-32
FRONT SUSPENSION Stabilizer Bar (Cont’d) ●
When installing stabilizer, make sure that paint mark and clamp face in their correct directions.
●
When removing and installing stabilizer bar, hold part A as shown.
●
Install stabilizer bar with ball joint socket correctly located.
Stabilizer
Rear
Paint mark SRA198A
.
SFA926A
View from B
O.K.
N.G.
SFA002A
INSPECTION ● ● ●
Check stabilizer bar for deformation or cracks. Replace if necessary. Check rubber bushings for deterioration or cracks. Replace if necessary. Check ball joint can rotate in all directions. If movement is not smooth and free, replace stabilizer bar link.
ARA027
FA-33
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications Suspension type
Independent multi-link strut with coil spring
Strut type
Double-acting hydraulic
Stabilizer bar
Standard equipment
DRIVE SHAFT QG16DE/ QG18DE
Applied model
CD20T
SR20DE M/T
CVT
Joint type Transaxle side
GI82
D83/T83
Wheel side
98AC
B86
Transaxle side “D1”
26 (1.02)
25 (0.98)
Wheel side “D2”
28 (1.10)
27 (1.06)
Diameter (Serration)
mm (in)
Grease Quality Capacity
Nissan Genuine Grease or equivalent m (Imp fl oz)
Transaxle side
175 - 185 (6.2 - 6.5)
115 - 135 (4.0 - 4.8)
Wheel side
110 - 130 (3.9 - 4.6)
95 - 115 (3.3 - 4.0)
96 - 98 (3.78 - 3.86)
96 - 98 (3.78 - 3.86)
Boot length
mm (in)
Wheel side “L” Wheel side
Transaxle side
SFA928A
FA-34
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment WHEEL ALIGNMENT (Unladen*1) 195/60 R15 195/60 VR15 185/65 HR15
Applied model Camber
205/50 R16
Minimum
−0°45′
Degree minute Nominal
Caster
0°
Maximum
0°45′
Minimum
1°10′
Degree minute Nominal
Kingpin inclination
1°55′
Maximum
2°40′
Minimum
13°45′
Degree minute Nominal
14°30′
Maximum Total toe-in
15°15′
Minimum Distance (A - B)
0 (0)
Nominal
1 (0.04)
mm (in) Maximum Angle (left plus right)
2 (0.08)
Minimum
0°
Degree minute Nominal
0°6′
Maximum Wheel turning angle Full turn *2
0°12′
Minimum
32
31
Nominal
35
34
Inside
Degree minute Maximum
36
35
Outside
Degree minute Nominal
30
29
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.
WHEEL BEARING
LOWER BALL JOINT
Wheel bearing axial end play limit mm (in)
0.05 (0.0020) or less
Wheel bearing lock nut tightening torque N·m (kg-m, ft-lb)
235 - 314 (24 - 32, 174 - 231)
Ball stud swinging force at cotter pin hole N (kg, lb)
7.8 - 57.9 (0.8 - 5.9, 6 - 42)
Ball stud rotating torque N·m (kg-cm, in-lb)
0.5 - 3.4 (5 - 34, 5 - 30)
Ball stud axial end play limit mm (in)
0 (0)
WHEEL RUNOUT Wheel type
Aluminium
Steel
Radial runout limit
mm (in)
0.3 (0.012)
0.5 (0.020)
Lateral runout limit
mm (in)
0.3 (0.012)
0.8 (0.031)
FA-35
SERVICE DATA AND SPECIFICATIONS (SDS) NOTE
FA-36
REAR AXLE & REAR SUSPENSION SECTION
RA
CONTENTS PRECAUTIONS AND PREPARATION.......................... 2 Precautions ................................................................ 2 Special Service Tools ................................................ 2 Commercial Service Tools ......................................... 2 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................... 3 NVH Troubleshooting Chart....................................... 3 REAR SUSPENSION SYSTEM..................................... 4 ON-VEHICLE SERVICE ................................................ 5 Rear Axle and Rear Suspension Parts ..................... 5 Rear Wheel Bearing .................................................. 5
Rear Wheel Alignment............................................... 6 REAR AXLE................................................................... 7 Wheel Hub ................................................................. 7 REAR SUSPENSION..................................................... 9 Removal and Installation ......................................... 10 Coil Spring and Shock Absorber ..............................11 Torsion Beam, Lateral Link and Control Rod .......... 12 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 14 General Specifications............................................. 14 Inspection and Adjustment ...................................... 14
RA
PRECAUTIONS AND PREPARATION Precautions ●
● GG94310000
● SBR820B
● ●
When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. *: Fuel, radiator coolant and engine oil full. Spare tire, 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. Do not jack up at the trailing arm and lateral link. Always torque brake lines when installing.
Special Service Tools Tool number Tool name
Description
GG94310000 Flare nut torque wrench
Removing and installing brake piping
a: 10 mm (0.39 in)
NT406
HT71780000 Spring compressor
Removing and installing coil spring
NT144
KV40106400 Piston rod lock nut wrench
a: b: c: d: e: f :
NT369
ST35652000 Shock absorber attachment
5 mm (0.20) 16.2 mm (0.64 in) DIA 52 mm (2.05 in) 14 mm (0.55 in) 25.4 mm (1.00 in) DIA 55 mm (2.17 in)
Fixing strut assembly
NT145
Commercial Service Tools Tool name
Description
Equivalent to GG94310000 1 Flare nut crows foot p 2 p Torque wrench
Removing and installing brake piping
a: 10 mm (0.39 in)
NT360
RA-2
X
X
X
X
—
X
Suspension looseness
RA-9
Incorrect wheel alignment
RA-14
Wheel bearing damage
RA-5
X
X
Spring fatigue
X
—
X
X
X
Parts interference
X
NVH in FA section
ROAD WHEEL
NVH in FA section
BRAKES
NVH in BR section
X
X
TIRES
X
X X
X
X
NVH in FA section
X
X
X
X
FRONT AXLE AND FRONT SUSPENSION
X
X
X
X
X
X
NVH in FA section
X
X
X
X
X
X
X
X
X X
X
X
DRIVE SHAFT
STEERING
NVH in ST section
NVH Troubleshooting Chart
RA-11
Bushing or mounting deterioration
X
RA-11
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Shock absorber deformation, damage or deflection
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Noise
Shake
Vibration
Shimmy
Judder
Poor quality ride or handling
RA-9
Use the chart below to help you to find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
REAR AXLE AND REAR SUSPENSION
Possible cause and SUSPECTED PARTS
Symptom
X: Applicable
RA-3
Improper installation, looseness
REAR SUSPENSION SYSTEM SEC. 431 When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
p1
98 - 118 (10 - 12, 73 - 87)
42 - 57 (4.3 - 5.8, 31 - 42)
p2 p4 p5 p3
Front
98 - 118 (10 - 12, 73 - 87)
: Do not re-use : N·m (kg-m, ft-lb) NRA004 1 p 2 p
Coil spring Shock absorber
3 p 4 p
Torsion beam Lateral link
RA-4
5 p
Control rod
ON-VEHICLE SERVICE Rear Axle and Rear Suspension Parts Check axle and suspension parts for excessive play, wear or damage. ● Shake each rear wheel to check for excessive play.
SMA525A
●
Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to REAR SUSPENSION (RA-9).
●
Check shock absorber for oil leakage or other damage.
NRA005
SMA113
Rear Wheel Bearing ●
● ● ●
SRA690A
Check axial end play. Axial end play: 0.00 mm (0.0000 in) Check that wheel hub bearings operate smoothly. Check tightening torque of wheel bearing lock nut. : 187 - 255 N·m (19 - 26 kg-m, 138 - 188 ft-lb) Replace wheel bearing assembly if there is axial end play or wheel bearing does not turn smoothly. Refer to REAR AXLE — Wheel Hub (RA-7).
RA-5
ON-VEHICLE SERVICE Rear Wheel Alignment PRELIMINARY INSPECTION
Lateral runout
Radial runout
SFA975B
Make following checks. Adjust, repair or replace if necessary. ● Check tires for wear and for improper inflation. ● Check rear wheel bearings for excessive play. ● Check wheels for deformation, cracks and other damage. If deformed, remove tire and check wheel runout. Wheel runout: Refer to SDS in FA section. ● Check that rear shock absorber functions correctly. ● Check rear axle and rear suspension parts for excessive play. ● Check vehicle posture (Unladen*). *: Fuel, radiator and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
CAMBER Camber is preset at factory and cannot be adjusted. Camber: Refer to SDS (RA-14). ● If the camber is not within specification, inspect and replace any damaged or worn rear suspension parts.
SFA948A
TOE-IN Front
Hub center height
Base line Measuring point
SFA614B
SFA234AC
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 the tread (rear side) of both tires at the same height of hub center. This mark is a measuring point. 4. Measure distance “A” (rear side). 5. 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 side). Total toe-in: Refer to SDS, RA-14.
RA-6
REAR AXLE Wheel Hub SEC. 430
187 - 255 (19 - 26, 138 - 188)
25 - 33 (2.6 - 3.3, 19 - 24) 22 - 29 (2.3 - 2.9, 17 - 21)
Front
: Do not re-use : N·m (kg-m, ft-lb) 1 p 2 p 3 p
Spindle Baffle plate Wheel hub bearing
NRA015 4 p 5 p
Wheel bearing lock nut Cotter pin
6 p 7 p
Hub cap ABS sensor
REMOVAL CAUTION: ● Before removing the rear wheel hub assembly, disconnect the ABS wheel sensor from the assembly. Then move it away from the hub assembly. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative. ● Wheel hub bearing does not require maintenance. If any of the following symptoms are noted, replace wheel hub bearing assembly. ● Growling noise is emitted from wheel hub bearing during operation. ● Wheel hub bearing drags or turns roughly. This occurs when turning hub by hand after bearing lock nut is tightened to specified torque.
RA-7
REAR AXLE Wheel Hub (Cont’d) 1. Remove brake caliper assembly. 2. Remove brake rotor. 3. Remove wheel bearing lock nut. 4. Remove wheel hub bearing from spindle. Brake hose does not need to be disconnected from brake caliper. Suspend caliper assembly with wire so as not to stretch brake hose. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted. SRA711A
INSTALLATION ● ●
●
Install wheel hub bearing. Tighten wheel bearing lock nut. Before tightening, apply oil to threaded portion of rear spindle and both sides of plain washer. : 187 - 255 N·m (19 - 26 kg-m, 138 - 188 ft-lb) Check that wheel bearings operate smoothly.
SRA712A
●
Check wheel hub bearing axial end play. Axial end play: 0.00 mm (0.0000 in)
SRA690A
RA-8
REAR SUSPENSION SEC. 431 When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. 36 - 47 (3.7 - 4.7, 27 - 34)
p6
p1 p2
p3 42 - 57 (4.3 - 5.8, 31 - 42)
p7
p 4
25 - 33 (2.6 - 3.3, 19 - 24)
p5
11 p
p8
98 - 118 (10 - 12, 73 - 87)
p9
98 - 118 (10 - 12, 73 - 87)
59 - 78 (6.1 - 7.9, 44 - 57) 98 - 118 (10 - 12, 73 - 87) 10 p
98 - 118 (10 - 12, 73 - 87) 98 - 118 (10 - 12, 73 - 87) : N·m (kg-m, ft-lb)
Front
: Do not re-use
1 p 2 p 3 p 4 p
Washer Bushing Shock absorber mounting bracket Bound bumper cover
5 p 6 p 7 p 8 p
Bound bumper Coil spring Shock absorber Torsion beam
RA-9
9 p 10 p 11 p
Lateral link Control rod ABS sensor
NRA018
REAR SUSPENSION Removal and Installation
SRA695A
CAUTION: ● Before removing the rear suspension assembly, disconnect the ABS wheel sensor and headlamp leveling sensor from the assembly. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative. ● Remove suspension assembly. 1. Disconnect parking brake cable from caliper and remove brake caliper and rotor. Suspend caliper assembly with wire so as not to stretch brake hose.
Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted. 2. Using a transmission jack, raise torsion beam a little, and remove nuts and bolts from the trailing arm, shock absorber assembly (lower side) and lateral link. 3. Lower transmission jack, and remove suspension. 4. Remove shock absorber assembly.
NRA016
● Install suspension assembly. CAUTION: Refill with new brake fluid “DOT 4”. Never reuse drained brake fluid. ● After installation of the suspension assembly the headlamp leveling sensor has to be recalibrated. Refer to EL section (models equipped with xenon headlamps only). 1. Attach torsion beam, at trailing arm and lateral link, to vehicle. Do not tighten bolts at this time. SRA697A
2. Using a transmission jack, place lateral link and control rod horizontally against torsion beam. Tighten lateral link on vehicle. 3. Attach shock absorber assembly to vehicle. Then tighten the lower side of shock absorber assembly. 4. Lower torsion beam to fully extended position. Remove transmission jack and tighten torsion beam, at trailing arm, to specified torque. Refer to RA-9. 5. Install ABS-wheel sensor. SRA698A
RA-10
REAR SUSPENSION Coil Spring and Shock Absorber REMOVAL Remove shock absorber upper and lower fixing nuts. Do not remove piston rod lock nut on vehicle.
DISASSEMBLY 1. Set shock absorber in vise with attachment, then loosen piston rod lock nut. WARNING: Do not remove piston rod lock nut at this time. 2. Compress spring with Tool so that the shock absorber upper spring seat can be turned by hand.
Suitable bar
NRA008
3. Remove piston rod lock nut.
NRA009
INSPECTION Shock absorber assembly ● ● ●
Check for smooth operation through a full stroke, both compression and extension. Check for oil leakage on welded or gland packing portions. Check piston rod for cracks, deformation or other damage. Replace if necessary.
Upper rubber seat and bushing Check rubber parts for deterioration or cracks. Replace if necessary.
Coil spring Check for cracks, deformation or other damage. Replace if necessary.
RA-11
REAR SUSPENSION Coil Spring and Shock Absorber (Cont’d) Shock absorber lower bushing center
LH
Front 12.8°
12.8°
Spring lower end position
Spring lower end position
ASSEMBLY ●
Locate upper spring seat as shown.
●
When installing coil spring, be careful not to reverse top and bottom direction. (Top end is flat.) When installing coil spring on shock absorber, it must be positioned as shown in figure at left.
RH NRA010
●
SFA436B
Torsion Beam, Lateral Link and Control Rod DISASSEMBLY ● ●
Remove torsion beam assembly. Refer to Removal and Installation in REAR SUSPENSION (RA-10). Remove lateral link and control rod from torsion beam.
INSPECTION ● SRA703A
●
Check for cracks, distortion or other damage. Replace if necessary. Standard length: A 207 - 208 mm (8.15 - 8.19 in) B 394 - 395 mm (15.51 - 15.55 in) C 601 - 603 mm (23.66 - 23.74 in) D 106 - 108 mm (4.17 - 4.25 in) Check all rubber parts for wear, cracks or deformation. Replace if necessary.
ASSEMBLY 1. Temporarily assemble lateral link and control rod. ● When installing the control rod, connect the bush with the smaller inner diameter to the lateral link.
SRA700A
RA-12
REAR SUSPENSION Torsion Beam, Lateral Link and Control Rod (Cont’d) 2. Temporarily install lateral link and control rod on torsion beam. ● When installing, place lateral link with the arrow topside.
SRA701A
3. Place lateral link and control rod horizontally against torsion beam, and tighten to the specified torque. 4. Install torsion beam assembly. Refer to Removal and Installation in REAR SUSPENSION (RA-10).
SRA702A
RA-13
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications Suspension type
Multi-link beam suspension
Shock absorber type
Double-acting hydraulic
Stabilizer
Standard equipment
Inspection and Adjustment WHEEL ALIGNMENT (Unladen*) Camber
Minimum
−2°9′ (−2.15°)
Nominal
−1°24′ (−1.4°)
Degree minute (Decimal degree) Maximum Total toe-in
WHEEL BEARING
−0°39′ (−0.65°)
Minimum
−1.8 (−0.07)
Nominal
2.2 (0.09)
Distance (A−B) mm (in) Maximum Angle (left plus right) Minimum Nominal Degree minute (Decimal degree) Maximum
Wheel bearing axial end play mm (in)
0.0 (0.00)
Wheel bearing lock nut tightening torque N·m (kg-m, ft-lb)
187 - 255 (19 - 26, 138 - 188)
6.2 (0.24) −0°11′24″ (−0.19°) 0°12′36″ (0.21°) 0°36′36″ (0.61°)
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
RA-14
BRAKE SYSTEM SECTION
BR
CONTENTS PRECAUTIONS ............................................................. 3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 3 Precautions for Brake System................................... 3 Precautions When Working On ABS......................... 4 Wiring Diagrams and Trouble Diagnosis................... 4 PRECAUTIONS AND PREPARATION.......................... 5 Commercial Service Tools ......................................... 5 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLE SHOOTING.................................................. 6 NVH Troubleshooting Chart....................................... 6 CHECK AND ADJUSTMENT ........................................ 7 Checking Brake Fluid Level....................................... 7 Checking Brake Line ................................................. 7 Changing Brake Fluid ................................................ 7 Brake Burnishing Procedure...................................... 7 Bleeding Brake System ............................................. 8 BRAKE HYDRAULIC LINE ........................................... 9 Removal................................................................... 10 Inspection................................................................. 10 Installation................................................................ 10 CONTROL VALVE ........................................................11 Dual Proportioning Valve ..........................................11 BRAKE PEDAL AND BRACKET................................ 13 Removal and Installation ......................................... 13 Inspection................................................................. 13 Adjustment ............................................................... 13 MASTER CYLINDER................................................... 15 Removal................................................................... 15 Disassembly............................................................. 15 Inspection................................................................. 16 Assembly ................................................................. 16 Installation................................................................ 17
BRAKE BOOSTER...................................................... 18 On-vehicle Service................................................... 18 Removal................................................................... 18 Inspection................................................................. 19 Installation................................................................ 19 VACUUM HOSE........................................................... 20 Removal and Installation ......................................... 21 Inspection................................................................. 21 FRONT DISC BRAKE ................................................. 23 Pad Replacement .................................................... 23 Removal................................................................... 24 Disassembly............................................................. 25 Inspection - Caliper.................................................. 25
SR20DE - M/T FRONT DISC BRAKE ................................................. 26 Pad Replacement .................................................... 26 Installation................................................................ 28 Removal................................................................... 29 Disassembly............................................................. 29 Inspection - Caliper.................................................. 29
FRONT DISC BRAKE ................................................. 31 Inspection - Rotor .................................................... 31 Assembly ................................................................. 31 Installation................................................................ 32 REAR DISC BRAKE TYPE 1...................................... 33 Component .............................................................. 33 Pad Replacement .................................................... 33 Removal................................................................... 35 Disassembly............................................................. 35
BR
Inspection................................................................. 36 Assembly ................................................................. 37 Installation................................................................ 39 REAR DISC BRAKE TYPE 2...................................... 40 Component .............................................................. 40 Pad Replacement .................................................... 40 Removal................................................................... 42 Disassembly............................................................. 42 Inspection................................................................. 42 Installation................................................................ 43 REAR DRUM BRAKE ................................................. 44 Components............................................................. 44 Removal................................................................... 44 Inspection - Wheel Cylinder .................................... 45 Wheel Cylinder Overhaul......................................... 46 Inspection - Drum .................................................... 46 Inspection - Lining ................................................... 46 Installation................................................................ 46 PARKING BRAKE CONTROL .................................... 48 Removal and Installation ......................................... 48 Inspection................................................................. 49 Adjustment ............................................................... 49 ANTI-LOCK BRAKE SYSTEM.................................... 50 Purpose.................................................................... 50 Operation ................................................................. 50 ABS Hydraulic Circuit .............................................. 50 System Components ............................................... 51 System Description.................................................. 51 Removal and Installation ......................................... 53 TROUBLE DIAGNOSES ............................................. 57 How to Perform Trouble Diagnoses for Quick and Accurate Repair ................................................ 57 Preliminary Check.................................................... 59 Component Parts and Harness Connector Location ................................................................... 60 Circuit Diagram for Quick Pinpoint Check............... 61
Wiring Diagram - ABS - ........................................... 62 Self-diagnosis (Only models with data link connector terminal No. 8) ........................................ 67 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ............................................................. 69 CONSULT-II ............................................................. 69 CONSULT-II Inspection Procedure.......................... 70 Ground Circuit Check .............................................. 75 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ............................................................. 76 Malfunction Code/Symptom Chart........................... 76 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS........................................................................... 77 Diagnostic Procedure 1 (Wheel sensor or rotor) .... 77 Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay) ............................... 79 Diagnostic Procedure 3 (Motor Relay or motor) ..... 81 Diagnostic Procedure 4 (Low voltage) .................... 83 Diagnostic Procedure 5 (Control unit) ..................... 84 TROUBLE DIAGNOSES FOR SYMPTOMS............... 85 Diagnostic Procedure 6 (ABS works frequently)..... 85 Diagnostic Procedure 7 (Unexpected pedal action) ...................................................................... 86 Diagnostic Procedure 8 (Long stopping distance) .. 86 Diagnostic Procedure 9 (ABS does not work.) ....... 87 Diagnostic Procedure 10 (Pedal vibration and noise) ....................................................................... 87 Diagnostic Procedure 11 (ABS Warning lamp does not come on when ignition switch is turned ON) .......................................................................... 88 Diagnostic Procedure 12 (Warning lamp stays on when ignition switch is turned ON).......................... 90 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 91 General Specifications............................................. 91 Inspection and Adjustment ...................................... 92
When you read wiring diagrams: ● Read GI section, “HOW TO READ WIRING DIAGRAMS”. ● See EL section, “POWER SUPPLY ROUTING” for power distribution circuit. ● See EL section for NATS information and wiring diagram. When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.
BR-2
PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL P11 is as follows (The composition varies according to the destination and optional equipment.): ● For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. ● For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS 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 should be performed by an authorized NISSAN 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 RS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just before the harness connectors or for the complete harness are related to the SRS.
Precautions for Brake System Recommended fluid is brake fluid “DOT 4”. Never reuse drained brake fluid. ● Be careful not to splash brake fluid on painted areas. ● To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid. ● Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system. ● Use flare nut wrench when removing and installing brake tube. ● Always torque brake lines when installing. ● Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “Check and Adjustment”, BR-7. WARNING: ● Clean brake pads with a waste cloth, then wipe with a dust collector. ● ●
Commercial service tool SBR686C
BR-3
PRECAUTIONS Precautions When Working On ABS ● ● ●
● ●
● ●
Use recommended tyres in combination with ABS. Install tyres or studded tyres, etc. with the same size. If different sizes of tyres, or tyres other than the ones recommended for use with the ABS, are fitted, stopping distance will increase and control and stability could deteriorate. When changing brake pads, use Nissan genuine parts. When fitting radios etc, do not position the radio unit, antenna, or antenna cables within an area of about 100 mm (3.94 in) of the control unit. When doing any work that requires electro-welding, first remove the control unit. Make sure when taking a power supply for the audio, lamps etc., not to take this from any ABS-related harness. (Refer to the electrical wiring diagrams for ABSrelated harnesses)
Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the following: ● GI-11, “HOW TO READ WIRING DIAGRAMS” ● EL-10, “POWER SUPPLY ROUTING” When you perform trouble diagnosis, refer to the following: ● GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSIS” ● GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT”
BR-4
PRECAUTIONS AND PREPARATION Commercial Service Tools Tool name 1 p 2 p
Description
Flare nut crows foot Torque wrench
Removing and installing each brake piping
a: 10 mm (0.39 in)
NT360
Brake fluid pressure gauge
Measuring brake fluid pressure
NT151
BR-5
x x
Shims damaged
BR-23, 33
x x
Rotor imbalance
—
x
Rotor damaged
BR-31, 37, 43
x
Rotor runout
BR-31, 37, 43
x
Rotor deformation
—
x
Rotor deflection
—
x
Rotor rust
—
x
Rotor thickness variation
BR-31, 37
PROPELLER SHAFT
NHV in PD section
DIFFERENTIAL
NHV in PD section
x x x
AXLE AND SUSPENSION
NHV in FA, RA section
x x x
TIRES
NHV in FA section
x x x
ROAD WHEEL
NHV in FA section
AXLE SHAFT
NHV in FA section
STEERING
NHV in ST section
NVH Troubleshooting Chart
x
BR-23 26, 33
x x
Pads - uneven wear
x x x
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLE SHOOTING
Noise Shake Shimmy, Judder BR-23, 26, 33
Use the chart to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
BRAKE
Possible cause and SUSPECTED PARTS
Symptom
X : Applicable
BR-6
Pads - damaged
x x x
CHECK AND ADJUSTMENT Checking Brake Fluid Level ● ●
MAX.
●
MIN.
Check fluid level in reservoir tank. It should be between Max. and Min. lines on reservoir tank. If fluid level is extremely low, check brake system for leaks. If brake warning lamp comes on and fluid level is above “MIN” mark, check brake fluid level switch and parking brake switch.
NBR141
Checking Brake Line CAUTION: If leakage occurs around joints, retighten or, if necessary, replace damaged parts. 1. Check brake lines (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. ABR159
Changing Brake Fluid
SBR419C
CAUTION: ● Refill with new brake fluid “DOT 4”. ● Always keep fluid level higher than minimum line on reservoir tank. ● 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. Clean inside of reservoir tank, and refill with new brake fluid. 2. Connect a vinyl tube to each air bleeder valve. 3. Drain brake fluid from each air bleeder valve by depressing brake pedal while keeping reservoir level higher than minimum line by adding new brake fluid. 4. Repeat until new brake fluid comes out of each air bleeder valve. Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to “Bleeding Brake System”, BR-8.
Brake Burnishing Procedure Burnish the brake contact surfaces according to the following procedure after refinishing or replacing rotors, after replacing pads, 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 (31 MPH).
BR-7
CHECK AND ADJUSTMENT Brake Burnishing Procedure (Cont’d) 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.
Bleeding Brake System
SBR995
SBR419C
CAUTION: ● Carefully monitor brake fluid level at master cylinder during bleeding operation. ● If master cylinder is suspected to have air inside, bleed air from master cylinder first. Refer to “Installation”, “MASTER CYLINDER”, BR-17. ● Fill reservoir with new brake fluid “DOT 4”. Make sure it is full at all times while bleeding air out of system. ● Place a container under master cylinder to avoid spillage of brake fluid. ● For models with ABS, turn ignition switch to the OFF position and disconnect ABS fuse or battery cable. ● Bleed air in the following order:
1. 2. 3. 4. 5. 6. 7.
RHD models Left rear brake,Right front brake,Right rear brake,Left front brake LHD models Right rear brake,Left front brake,Left rear brake,Right front brake. Connect a transparent vinyl tube to air bleeder valve. Fully depress brake pedal several times. With brake pedal depressed, open air bleeder valve to release air. Close air bleeder valve. Release brake pedal slowly. Repeat steps 2. through 5. until clear brake fluid comes out of air bleeder valve. Tighten air bleeder valve. : 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb)
BR-8
BRAKE HYDRAULIC LINE
NBR434
BR-9
BRAKE HYDRAULIC LINE Removal
SBR419C
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 hoses and tubes must be free from excessive bending, twisting and pulling. ● For rear disc caliper, care should be taken as not to let air enter the body. 1. Connect a vinyl tube to air bleeder valve. 2. Drain brake fluid from each air bleeder valve by depressing brake pedal. 3. Remove flare nut securing brake tube to hose, then withdraw lock spring. 4. Cover openings to prevent entrance of dirt whenever disconnecting hydraulic line.
Inspection Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.
Installation
Commercial service tool SBR686C
CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. 1. Tighten all flare nuts and connecting bolts. Flare nut: : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) Connecting bolt: : 17 - 20 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb) 2. Refill until new brake fluid comes out of each air bleeder valve. 3. Bleed air. Refer to “Bleeding Brake System”, BR-8.
BR-10
CONTROL VALVE Dual Proportioning Valve Brake fluid pressure gauge
SBR822BA
Brake fluid pressure gauge
INSPECTION CAUTION: ● Carefully monitor brake fluid level at master cylinder. ● Use new brake fluid “DOT 4”. ● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on paint areas, wash it away with water immediately. ● Depress pedal slowly when raising front brake pressure. ● Check rear brake pressure at least 2 seconds after front brake pressure reaches specified value. 1. Connect brake fluid pressure gauge to air bleeders of front and rear brakes on either LH or RH side. 2. Bleed air from the tool. 3. Check fluid pressure by depressing brake pedal. Unit: kPa (bar, kg/cm2, psi) Applied pressure (Front brake)
5.39 (53.9, 55, 781.6)
Output pressure (Rear brake)
3.132 - 3.532 (31.32 - 35.32, 31.94 - 36.02, 454.3 - 512.3)
SBR823BA
If output pressure is out of specifications, replace dual proportioning valve. 4. Bleed air after disconnecting the Tool. Refer to “Bleeding Brake System”, BR-8.
REMOVAL
NBR145
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 tubes must be free from excessive bending, twisting and pulling. 1. Connect a vinyl tube to air bleeder valve. 2. Drain brake fluid from each air bleeder valve by depressing brake pedal. 3. Loosen flare nut. 4. Remove proportioning valve mounting bolt, then remove flare nut.
BR-11
CONTROL VALVE Dual Proportioning Valve (Cont’d) INSTALLATION CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. 1. Temporarily fit flare nut to proportioning valve. 2. Tighten proportioning valve mounting bolt, then tighten flare nut with wooden block placed between proportioning valve and dash panel. Flare nut: : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) Mounting bolt: : 5.1 - 8.8 N·m (0.52 - 0.9 kg-m, 45 - 78 in-lb) 3. Refill until new brake fluid comes out of each air bleeder valve. 4. Bleed air. Refer to “Bleeding Brake System”, BR-8.
BR-12
BRAKE PEDAL AND BRACKET Removal and Installation
NBR435
Inspection Stopper
Check brake pedal for following items: ● Brake pedal bend ● Clevis pin deformation ● Crack of any welded portion ● Crack or deformation of clevis pin stopper.
SBR997
Adjustment
Clevis lock nut 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb) Input rod Brake lamp switch and redundant brake switch
C1 or C2
Check brake pedal free height from dash reinforcement panel. H: Free height Refer to SDS, BR-92. D: Depressed height Refer to SDS, BR-92. C1, C2: Clearance between pedal stopper rubber and threaded end of brake lamp switch (or redundant brake switch). 0.75 - 2.0 mm (0.03 - 0.08 in) A: Pedal free play 1 - 3 mm (0.039 - 0.118 in)
A
Floor carpet Dash insulator
90°
D
Floor carpet H
Dash insulator
Floor panel Melt sheet SBR110B
BR-13
BRAKE PEDAL AND BRACKET Adjustment (Cont’d) Stays inside
Lock nut Input rod
Clevis
1. Loosen lock nut and adjust pedal free height by turning brake booster input rod. Then tighten lock nut. 2. Check pedal free play. Make sure that brake lamps go off when pedal is released. 3. Check brake pedal’s depressed height while engine is running. If depressed height is below specified value, check brake system for leaks, accumulation of air or any damage to components (master cylinder, wheel cylinder, etc.); then make necessary repairs.
SBR229E
BR-14
MASTER CYLINDER Removal
NBR436
1. 2. 3. 4.
Reservoir cap Oil filter Reservoir tank Seal
5. 6. 7.
Cylinder body Elastic pin Piston stopper pin
8. Secondary piston assembly 9. Primary piston assembly 10. Circlip
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. 1. Disconnect fluid level connector. 2. Connect a vinyl tube to air bleeder valve. 3. Drain brake fluid from each air bleeder valve, depressing brake pedal to empty fluid from master cylinder. 4. Remove brake pipe flare nuts. 5. Remove master cylinder mounting nuts.
Disassembly 1. Drive out elastic pin from cylinder body. 2. Remove reservoir tank and seals.
SBR231E
BR-15
MASTER CYLINDER Disassembly (Cont’d) 3. Remove the circlip with suitable pliers while piston is pushed into cylinder.
NBR353
4. Remove piston stopper pin while piston is pushed into cylinder. 5. Remove piston assemblies. If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet.
Push
Piston stopper pin SBR232E
Inspection Check for the following items. Replace any part if damaged. Master cylinder: ● Pin holes or scratches on inner wall. Piston: ● Deformation of or scratches on piston cups.
Assembly
Secondary piston
1. Insert secondary piston assembly. Then insert primary piston assembly. ● Pay attention to alignment of secondary piston slit with valve stopper mounting hole of cylinder body. Primary piston
SBR233E
2. Install piston stopper pin while piston is pushed into cylinder. Then secure the primary and secondary piston assemblies with new circlip. 3. Push reservoir tank seals and reservoir tank into cylinder body. 4. Install elastic pin.
Push
Piston stopper pin SBR232E
BR-16
MASTER CYLINDER Installation
SBR236E
CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. 1. Place master cylinder onto brake booster and secure mounting nuts lightly. 2. Torque mounting nuts. : 14 - 17 N·m (1.5 - 1.7 kg-m, 11 - 12 ft-lb) 3. Fill up reservoir tank with new brake fluid. 4. Plug all ports on master cylinder with fingers to prevent air suction while releasing brake pedal. 5. Have driver depress brake pedal slowly several times until no air comes out of master cylinder. 6. Fit brake lines to master cylinder. 7. Tighten flare nuts. : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) 8. Connect fluid level connector. 9. Bleed air from brake system. Refer to “Bleeding Brake System”, BR-8.
BR-17
BRAKE BOOSTER On-vehicle Service OPERATING CHECK 1. Depress brake pedal several times with engine off. After exhausting vacuum, make sure there is no change in pedal stroke. 2. Depress brake pedal, then start engine. If pedal goes down slightly, operation is normal.
SBR002A
AIRTIGHT CHECK OK
NG
Third
1. Start engine, and stop it after one or two minutes. Depress brake pedal several times slowly. Booster is airtight if pedal stroke is less each time. 2. Depress brake pedal while engine is running, and stop engine with pedal depressed. The pedal stroke should not change after holding pedal down for 30 seconds.
Second First SBR365AA
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. ● Be careful not to deform or bend brake pipes, during removal of booster.
NBR437
BR-18
BRAKE BOOSTER Inspection Output rod length
OUTPUT ROD LENGTH CHECK 1. Supply brake booster with vacuum of −66.7 kPa (−667 mbar, −500 mmHg, −19.69 inHg) using a hand vacuum pump. 2. Add preload of 19.6N (2.0 kg, 4.4lb) to output rod. 3. Check output rod length. Specified length: 10.275 - 10.525 mm (0.4045 - 0.4144 in) SBR281A
Installation Approx. 125 - 127.5 (4.92 - 5.02)
Clevis locknut
mm (in)
Clevis NBR191
CAUTION: ● Be careful not to deform or bend brake pipes during installation of booster. ● Replace clevis pin if damaged. ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. ● Take care not to damage brake booster mounting bolt thread when installing. Due to the acute angle of installation, the threads can be damaged on the metal surrounding the dash panel holes. 1. Before fitting booster, temporarily adjust clevis to dimension shown in the table. Adjustment mm (in) LHD
127.5 (5.02)
RHD
125 (4.92)
2. Fit booster, then secure mounting nuts (brake pedal bracket to booster) lightly. 3. Connect brake pedal and booster input rod with clevis pin. 4. Secure mounting nuts. Specification: : 11 - 17 N·m (1.2 - 1.7 kg-m, 9 - 12 ft-lb) 5. Install master cylinder. Refer to BR-14. 6. Bleed air. Refer to “Bleeding Brake System”, BR-8. 7. Adjust pedal height to specification. Refer to SDS (BR-92). Retighten clevis locknut. Specification: : 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)
BR-19
VACUUM HOSE LHD Petrol models
Tube
To intake manifold
Check valve
Vacuum hose
To Brake booster
RHD Petrol models
To brake booster
Check valve .
To Intake manifold
Vacuum hose
Diesel models Check valve Vacuum reservoir
NBR421
BR-20
VACUUM HOSE Removal and Installation
More than 24 mm (0.94 in)
Connect hose until it contacts protrusion on vacuum tube.
CAUTION: When installing vacuum hoses, pay attention to the following points. ● Do not apply any oil or lubricants to vacuum hose and check valve. ● Insert vacuum tube into vacuum hose as shown.
SBR225B
●
Intake manifold side
Install check valve, paying attention to its direction.
Brake booster side
SBR498A
CAUTION
Caution label ENG.
NBR385
Inspection HOSES AND CONNECTORS Check vacuum lines, connections and check valve for air tightness, improper attachment, chafing and deterioration.
CHECK VALVE Check vacuum with a vacuum pump. Booster side
Engine side
Connect to booster side
Vacuum should exist.
Connect to engine side
Vacuum should not exist.
SBR943A
BR-21
VACUUM HOSE Inspection (Cont’d)
Booster side Engine side Arrow indicates engine side
SBR844B
VACUUM PUMP Vacuum gauge
1. Install vacuum gauge. 2. Run engine at 1,000 rpm or more. 3. Check vacuum. Specified vacuum: 86.6 kPa (866 mbar, 650 mmHg, 25.59 inHg) or more
SBR209DA
BR-22
FRONT DISC BRAKE
NBR438
Pad Replacement WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ● When cylinder body is open, do not depress brake pedal because piston will pop out. ● Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads. ● If shims are rusted or show peeling of the rubber coat, replace them with new shims. ● It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. ● Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “CHECK AND ADJUSTMENT”, BR-7.
BR-23
FRONT DISC BRAKE Pad Replacement (Cont’d) 1. Remove master cylinder reservoir cap. 2. Remove lower pin bolt.
NBR156
3. Open cylinder body upward. Then remove pad retainers, and inner and outer shims. Standard pad thickness: 11 mm (0.43 in) Pad wear limit: 2.0 mm (0.079 in) Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.
Wire
SBR079B
Removal WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne materials.
CAUTION:
NBR159
Suspend caliper assembly with wire so as not to stretch brake hose. Remove torque member fixing bolts and connecting bolt. It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly.
BR-24
FRONT DISC BRAKE Disassembly WARNING: Do not place your fingers in front of piston. CAUTION: Do not scratch or score cylinder wall. 1. Push out piston with dust seal with compressed air. 2. Remove piston seal with suitable tool.
SBR772
Inspection — Caliper CYLINDER BODY Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. ● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary. CAUTION: Use brake fluid to clean. Never use mineral oil. ●
PISTON CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface. Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.
SLIDE PIN, PIN BOLT AND PIN BOOT Check for wear, cracks or other damage. Replace if any of the above conditions are observed.
BR-25
FRONT DISC BRAKE
SR20DE - M/T
NBR439
Pad Replacement WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ● When cylinder body is open, do not depress brake pedal because piston will pop out. ● Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads. ● If shims are rusted or show peeling of the rubber coat, replace them with new shims. ● It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. ● Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “CHECK AND ADJUSTMENT”, BR-7.
BR-26
FRONT DISC BRAKE Pad Replacement (Cont’d) Torque member lug Cylinder body
Spring
SR20DE - M/T
REMOVAL 1. Remove the housing retaining spring. 2. Wipe away any dirt from the guide pins between the torque member and the cylinder body.
Locating holes .
Torque member lug
NBR292
Protective caps
3. Pull out the protective caps from the guide sleeves. 4. Use a 7 - mm ALLEN key to unscrew the guide pins from the torque member. 5. Partially remove the guide pins from the guide sleeve.
NBR300
6. Pull the cylinder body manually towards the outer side of the vehicle so that the piston is slightly pressed back. 7. Remove the cylinder body and hang it on a wire in the wheel arch in a suitable position. Make sure there is no strain on the brake hose piping. 8. Remove the brake pad on the piston side from the piston. 9. Remove the second brake pad from the torque member.
Wire
Spring
NBR290
BR-27
FRONT DISC BRAKE Pad Replacement (Cont’d)
SR20DE - M/T
CAUTION: Do not use any sharp tools or cleaning agents which contains mineral oil. Damage to the installation can occur. 10. Clean the cylinder body and guide grooves in the torque member. 11. Check the dust cover and guide sleeves for damage. 12. Measure the amount of wear on the brake pad Standard pad thickness: 11 mm (0.43 in) Pad wear limit: 2.0 mm (0.079 in) 14. Press the piston fully back with a suitable tool. CAUTION: Carefully monitor brake fluid level to avoid brake fluid from returning to the reservoir when pushing back the piston.
Installation
Wire Piston
Cylinder body Torque member
1. Install the brake pad with a three-pronged retaining spring into the piston. 2. Place the second brake pad into the guide groove of the torque member on the outer side of the brake disc. 3. Place the cylinder body with the installed brake pad over the brake disc and the second brake pad.
Guide groove
Second brake pad Three-pronged brake pad
NBR303
Protective caps Guide pins
4. Tighten the guide pins with a 7 - mm Allen key. 5. Press back the protective caps into the guides sleeve.
25 - 30 (2.5 - 3.1, 18 - 22)
.
N·m (kg-m, ft-lb)
NBR299
BR-28
FRONT DISC BRAKE Installation (Cont’d) Torque member lug Cylinder body
Spring
SR20DE - M/T
6. Check the cylinder body retaining spring for damage if the spring is defective, replace the spring. 7. Click the cylinder body retaining spring in position and make sure that: ● The two ends of spring click correctly into the locating holes of the cylinder body. ● The spring is in the correct position against the lugs of the torque member.
Locating holes Torque member lug
NBR292
Removal WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne materials. CAUTION: Suspend caliper assembly with wire to avoid stretching the brake hose.
Remove torque member fixing bolts and connecting bolt. It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly.
NBR289
Disassembly WARNING: Do not place your fingers in front of piston. CAUTION: Do not scratch or score cylinder wall. 1. Push out piston with dust seal with compressed air. 2. Remove piston seal with a suitable tool.
NBR294
Inspection — Caliper CYLINDER BODY Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. ● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary. CAUTION: Use brake fluid to clean. Never use mineral oil. ●
BR-29
FRONT DISC BRAKE Inspection — Caliper (Cont’d)
SR20DE - M/T
PISTON CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface. Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.
GUIDE PIN, BOLT, AND RETAINING SPRING Check for wear, cracks or other damage. Replace if any of the above conditions are observed.
BR-30
FRONT DISC BRAKE Inspection — Rotor RUBBING SURFACE Check rotor for roughness, cracks or chips.
RUNOUT
SBR936A
1. Secure rotor to wheel hub with at least two nuts (M12 × 1.25). 2. Check runout using a dial indicator. Make sure that wheel bearing axial end play is within the specifications before measuring. Refer to section FA. Maximum runout: 0.07 mm (0.0028 in) 3. If the runout is out of specification, find minimum runout position as follows: a. Remove nuts and rotor from wheel hub. b. Shift the rotor one hole and secure rotor tho wheel hub with nuts. c. Measure runout. d. Repeat steps a. to c. so minimum runout position can be found. 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 Rotor repair limit: Standard thickness 22 mm (0.87 in) Minimum thickness 20.0 mm (0.787 in) Thickness variation (At least 8 positions) Maximum 0.02 mm (0.0008 in)
SBR944A
Assembly Dust seal
Piston seal Piston
Cylinder body
CAUTION: Always use new piston seal. 1. Insert new piston seal into groove in cylinder body 2. With dust seal fitted to piston, insert dust seal into groove on cylinder body and install piston. 3. Properly secure dust seal.
SBR574
BR-31
FRONT DISC BRAKE Installation
.
Protrusions
CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. 1. Install brake hose to caliper securely. 2. Install all parts and secure all bolts. 3. Bleed air. Refer to “Bleeding Brake System” BR-8.
NBR160
Protrusions
NBR298
BR-32
REAR DISC BRAKE TYPE 1 Component SEC. 440 29 p
p2 19 p
p3 p 11
31 - 38 (3.2 - 3.8, 23 - 28)
21 p 22 p
p R
23 p 24 p
Stopper bolt
B p 25 26 p p
12 p
p 4
p p P
p 27
10 - 12 (1.0 - 1.2, 7 - 9)
p1 22 - 32 (2.3 - 3.2, 17 - 23)
R p
20 p
13 p
R p
to sliding portion
R p
14 p
5
p6
15 p
16 p
17 p 18 p
28 p
R p p B
R p
p7 p8 38 - 52 (3.9 - 5.3, 28 - 38)
p9
P p 10 p
: Do not re-use P p
: N·m (kg-m, ft-lb)
p B p P p R
: Rubber grease point : Brake fluid point : PBC (Poly Butyl Cuprysil) grease or silicone-based grease point
NBR366
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Cable guide Cylinder Toggle lever Pin Pin boot Torque member Inner shim Inner pad Outer pad Outer shim
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Strut O-ring Push rod Key plate Retaining washer Spring Spring cover Snap ring B Piston seal Snap ring A
21. 22. 23. 24. 25. 26. 27. 28. 29.
Washer Wave washer Washer Bearing Adjuster Cup Piston Piston boot Sleeve
Pad Replacement WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ● When cylinder body is open, do not depress brake pedal because piston will pop out. ● Be careful not to damage piston boot or get oil on rotor. Always replace shims in replacing pads. ● If shims are rusted or show peeling of rubber coat, replace them with new shims.
BR-33
REAR DISC BRAKE TYPE 1 Pad Replacement (Cont’d) ●
●
NBR192
It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “CHECK AND ADJUSTMENT”, BR-7.
1. Remove master cylinder reservoir cap. 2. Remove brake cable mounting bolt and lock spring. 3. Release parking brake control lever, then disconnect cable from the caliper. 4. Remove upper pin bolt. 5. Open cylinder body downward. Then remove pads inner and outer shims. Standard pad thickness: 9.3 mm (0.366 in) Pad wear limit: 2.0 mm (0.079 in)
Wire
SBR916C
6. When installing new pads, push piston into cylinder body by gently turning piston clockwise, as shown. Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.
SBR641
7. Adjust the piston to the right angle as shown in the figure. Assembly to the right angle
Piston
Alignment position of disc pad’s concave
Concave portion NBR374
BR-34
REAR DISC BRAKE TYPE 1 Pad Replacement (Cont’d) 8. As shown in the figure, align the piston’s concave to the pad’s convex, then install the cylinder body to the torque member. 9. Install brake cable, brake cable mounting bolt, lock spring and master cylinder reservoir cap.
Concave portion
Convex portion
NBR375
Removal
NBR167
WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. 1. Remove brake cable mounting bolt and lock spring. 2. Release parking brake control lever, then disconnect cable from the caliper. 3. Remove torque member fixing bolts and connecting bolt. It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.
Disassembly 1. Remove piston by turning it counterclockwise with long nose pliers or suitable tool.
SBR646
2. Pry off snap ring A from piston with suitable pliers and remove adjusting nut.
Ring “A”
SBR889
BR-35
REAR DISC BRAKE TYPE 1 Disassembly (Cont’d) 3. Disassemble cylinder body. a. Pry off snap ring B with suitable pliers, then remove spring cover, spring and retaining washer. b. Remove key plate, push rod, O-ring and strut.
SBR088B
c. Remove piston seal. Be careful not to damage cylinder body.
SBR656
4. Remove return spring, toggle lever and cable guide. Return spring Stopper bolt
Lever SBR767E
Inspection Caliper CAUTION: Use brake fluid to clean cylinder. Never use mineral oil.
Cylinder Body ●
●
Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.
Torque Member Check for wear, cracks or other damage. Replace if necessary.
Piston CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign matter is stuck to sliding surface. Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.
BR-36
REAR DISC BRAKE TYPE 1 Inspection (Cont’d) Pin and Pin Boot Check for wear, cracks or other damage. Replace if any of the above conditions are observed.
Rotor Rubbing Surface Check rotor for roughness, cracks or chips.
Runout
SBR219C
1. Secure rotor to wheel hub with two nuts (M12 x 1.25). 2. Check runout using a dial indicator. Make sure that axial end play is within the specifications before measuring. Refer to RA section (“REAR WHEEL BEARING”, “On-vehicle Service”). 3. Change relative positions of rotor and wheel hub so that runout is minimized. Maximum runout: 0.07 mm (0.0028 in)
Thickness Rotor repair limit: Standard thickness 10 mm (0.39 in) Minimum thickness 9 mm (0.35 in) Thickness variation (At least 8 portions) Maximum 0.02 mm (0.0008 in)
Assembly 1. Insert cam with depression facing towards open end of cylinder. Cam Seal Sleeve
NBR367
2. Generously apply rubber grease to strut and push rod to make insertion easy.
O-ring Strut
R p
Push rod Rubber grease
SBR248B
BR-37
REAR DISC BRAKE TYPE 1 Assembly (Cont’d) 3. Install rod, push rod and key plate. Key plate
Push rod
Rod
SBR754E
4. Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder.
Concave portion Convex portion
SBR893
5. Install retaining washer, spring, spring cover and snap ring B with suitable press and drift. Ring B Spring cover
Spring
Commercial service tool
Retaining washer SBR869CB Push Ring B Spring cover Tool Spring
Retaining washer SBR879-B
6. Install cup in the specified direction.
Adjusting nut SBR892
BR-38
REAR DISC BRAKE TYPE 1 Assembly (Cont’d) 7. Install cup adjuster, bearing, washers and snap ring A with a suitable tool.
Ring A Washer Wave washer Washer Ball bearing Adjuster Cup Piston SBR755E
8. Insert piston seal into groove on cylinder body. 9. With piston boot fitted to piston, insert piston boot into groove on cylinder body and fit piston by turning it clockwise with long nose pliers, or suitable tool.
SBR646
10. Fit toggle lever, return spring and cable guide. Return spring Stopper bolt
Lever SBR767E
11. Adjust the piston to the right angle as shown in the figure. Assembly to the right angle
Piston
Alignment position of disc pad’s concave
Concave portion NBR374
Installation
Concave portion
Convex portion
NBR375
CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. 1. Install caliper assembly. ● As shown in the figure, align the piston’s concave to the pad’s convex, then install the cylinder body to the torque member. 2. Install brake hose to caliper securely. 3. Install all parts and secure all bolts. 4. Bleed air. Refer to “Bleeding Brake System”, BR-8
BR-39
REAR DISC BRAKE TYPE 2 Component
NBR440
1. 2. 3. 4.
Cylinder body Pin Pin boot Torque member
5. 6. 7.
Inner shim Inner pad OUter pad
8. Outer shim 9. Bleed valve 10. Connecting bolt
NOTE: The cylinder body cannot be disassembled.
Pad Replacement WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ● When cylinder body is open, do not depress brake pedal because piston will pop out. ● Be careful not to damage piston boot or get oil on rotor. Always replace shims in replacing pads. ● If shims are rusted or show peeling of rubber coat, replace them with new shims. ● It is not necessary to remove connecting bolt except for replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. ● Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”, BR-7.
BR-40
REAR DISC BRAKE TYPE 2 Pad Replacement (Cont’d) 1. Remove master cylinder reservoir cap. 2. Remove brake cable lock spring. 3. Release parking brake control lever, then disconnect cable from the caliper. 4. Remove upper pin bolt.
NBR423
5. Open cylinder body downward. Then remove pad inner and outer shims. Standard pad thickness: 9.3 mm (0.366 in) Pad wear limit: 2.0 mm (0.079 in)
NBR426
6. When installing new pads, push piston into cylinder body by gently turning piston clockwise, as shown. Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.
SBR641
7. Adjust the piston to the right angle as shown in the figure.
NBR374
8. As shown in the figure, align the piston’s concave to the pad’s convex, then install the cylinder body to the torque member. 9. Install brake cable, brake cable mounting bolt, lock spring and master cylinder reservoir cap.
NBR375
BR-41
REAR DISC BRAKE TYPE 2 Removal
NBR427
WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. 1. Remove brake cable lock spring. 2. Release parking brake control lever, then disconnect cable from the caliper. 3. Remove torque member fixing bolts and connecting bolt. 4. Remove brake hose connecting bolt. 5. Plug off the brake hose and cylinder body to prevent air entering the system. CAUTION: Care should be taken as not to let: ● Air enter the cylinder body and brake hose. ● Brake fluid spill from the cylinder body and brake hose.
Disassembly Remove pin bolts and pins. NOTE: Cylinder body can not be disassembled.
Inspection CALIPER CAUTION: Do not drain any brake fluid from cylinder body. Cylinder body can not be disassembled.
Cylinder Body Check cylinder body for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body.
Torque Member Check for wear, cracks or other damage. Replace if necessary.
Pin and Pin Boot Check for wear, cracks or other damage. Replace if any of the above conditions are observed.
BR-42
REAR DISC BRAKE TYPE 2 Inspection (Cont’d) ROTOR Rubbing Surface Check rotor for roughness, cracks or chips.
Runout
SBR219C
1. Secure rotor to wheel hub with two nuts (M12 x 1.25). 2. Check runout using a dial indicator. Make sure that axial end play is within the specifications before measuring. Refer to AX section (“REAR WHEEL BEARING”, “On-vehicle Service”). 3. Change relative positions of rotor and wheel hub so that runout is minimized. Maximum runout: 0.07 mm (0.0028 in)
Thickness Rotor repair limit: Standard thickness 10 mm (0.39 in) Minimum thickness 9 mm (0.35 in) Thickness variation (At least 8 portions) Maximum 0.02 mm (0.0008 in)
Installation
NBR374
CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. ● Do not drain (factory) filled brake fluid from (new) caliper assemblies. 1. Install caliper assembly. ● As shown in the figure, align the piston’s concave to the pad’s convex, then install the cylinder body to the torque member. 2. Remove the plug from the cylinder body and brake hose. CAUTION: Care should be taken as not to let: ● Air enter the cylinder body and brake hose. ● Brake fluid spill from the cylinder body and brake hose. 3. Install brake hose to caliper securely. 4. Install all parts and secure all bolts. 5. Bleed air. Refer to “Bleeding Brake System”, BR-8.
NBR375
BR-43
REAR DRUM BRAKE Components
SBR616E
1. 2. 3. 4. 5.
Boot Piston Piston cap Spring Wheel cylinder
6. 7. 8. 9. 10.
Shoe hold-down pin Plug Brake drum Shoe hold-down spring Adjuster
11. 12. 13. 14. 15.
Retainer ring Return spring (Upper) Return spring (Lower) Spring Toggle lever
Removal WARNING: Clean brake lining with a vacuum dust collector to minimize the hazard of airborne materials. CAUTION: Make sure parking brake lever is completely released.
BR-44
REAR DRUM BRAKE Removal (Cont’d) 1. Release parking brake lever fully, then remove drum. If drum is hard to remove, the following procedures should be carried out. a. Remove plug. To make shoe clearance, push shoe holddown spring to free toggle lever.
SBR617E
b. Install two bolts as shown. Tighten the two bolts gradually.
SBR020A
2. After removing retainer, remove spring by rotating shoes. ● Be careful not to damage wheel cylinder piston boots. ● Be careful not to damage parking brake cable when separating it. 3. Remove adjuster. 4. Disconnect parking brake cable from toggle lever.
SBR214B
5. Remove retainer ring with a suitable tool. Then separate toggle lever and brake shoe.
SBR329C
Inspection — Wheel Cylinder ● ●
Check wheel cylinder for leakage. Check for wear, damage and loose conditions. Replace if any such condition exists.
SBR330C
BR-45
REAR DRUM BRAKE Wheel Cylinder Overhaul ● ●
Check all internal parts for wear, rust and damage. Replace if necessary. Pay attention so as not to scratch cylinder when installing pistons.
SBR215B
Inspection — Drum
● ● ● SBR022A
Maximum inner diameter: 204.5 mm (8.05 in) Maximum out-of-round: 0.03 mm (0.0012 in) Contact surface should be fine finished with No. 120 to 150 emery paper. Using a drum lathe, resurface brake drum if it shows scoring, partial wear or stepped wear. After brake drum has been completely reconditioned or replaced, check drum and shoes for proper contact pattern.
Inspection — Lining Check lining thickness. Standard lining thickness: 4.5 mm (0.177 in) Lining wear limit: 1.5 mm (0.059 in)
SMA849B
Installation Always perform shoe clearance adjustment. Refer to BR-49. ● 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. Refer to “Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”, BR-7. 1. Fit toggle lever to brake shoe with retainer ring. 2. Apply brake grease to the contact areas shown at left. ●
SBR618E
BR-46
REAR DRUM BRAKE Installation (Cont’d)
SBR619E
3. Shorten adjuster by rotating it. ● To tighten loosened brake shoes, first, insert a screw driver in the direction shown in the left. Then, move the adjuster in the direction shown by the arrow while disengaging the tooth contact. Never tap the area E. 4. Connect parking brake cable to toggle lever. 5. Install all parts. Be careful not to damage wheel cylinder piston boots. 6. Check all parts are installed properly. Pay attention to direction of adjuster assembly. 7. Install brake drum. 8. When installing new wheel cylinder or overhauling wheel cylinder, bleed air. Refer to “Bleeding Brake System”, BR-8. 9. Adjust parking brake. Refer to BR-49.
BR-47
PARKING BRAKE CONTROL
NBR441
Removal and Installation 1. 2. 3. 4. 5.
To remove parking brake cable, first remove center console. Disconnect warning lamp connector. Remove adjusting nut. Remove bolts and nuts securing parking brake cable. Remove parking brake device.
Adjusting nut Warning lamp connector NBR171
6. Remove cable mounting bracket and lock plate (disc brake only). For drum brake models, refer to “Removal”, “REAR DRUM BRAKE”, BR-44.
NBR163
BR-48
PARKING BRAKE CONTROL Inspection 1. Check control lever for wear or other damage. Replace if necessary. 2. Check wires for discontinuity or deterioration. Replace if necessary. 3. Check warning lamp and switch. Replace if necessary. 4. Check parts at each connecting portion and, if found deformed or damaged, replace the parts.
Adjustment
Stopper bolt
Lever
Before or after adjustment, pay attention to the following points. ● Make sure the toggle lever of the rear disc brakes returns to stopper, when the parking lever is released. ● There is no drag when parking brake lever is released. ● Vehicle is unladen.
SBR768E
1. Adjust clearance between shoe and drum or pad and rotor as follows: a. Release parking brake lever and loosen adjusting nut. b. Depress brake pedal fully at least 10 times with engine running.
2. Pull control lever 10 times or more to make a lever stroke of 203.5 mm (8.01 in). At 6 - 8 notches, adjust the parking brake cable by turning the adjusting nut.
Adjusting nut
SBR756E
3. Pull control lever with the specified amount of force. Check lever stroke and ensure smooth operation. Number of notches 6-8 4. Bend warning lamp switch plate to ensure: ● Warning lamp comes on when lever is lifted “A” notches. ● Warning lamp goes out when lever is fully released. Number of “A” notches: 1
196 N (20 kg, 44 lb)
SBR033A
BR-49
ANTI-LOCK BRAKE SYSTEM Purpose The Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for control of braking force so that locking of the wheels can be avoided. The ABS: 1) Provides improved steering control during braking (by preventing front wheel lock). 2) Provides improved vehicle stability and skid prevention during braking (by avoiding rear wheel lock).
Operation ● ●
●
When the vehicle speed is less than 10 km/h (6 mph) this system does not work. The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning light for 1 second after turning the ignition switch to the “ON” position. The system performs another test the first time the vehicle reaches 6 km/h (4 mph). A mechanical noise may be heard as the ABS performs a self-test. This is a normal part of the self-test feature. If a malfunction is found during this check, the ABS warning light will come on. During ABS operation, a mechanical noise may be heard. This is a normal operating condition.
ABS Hydraulic Circuit
Rear LH wheel
Front RH wheel
Front LH wheel
Rear RH wheel
NBR259 1 p 2 p 3 p
Inlet solenoid valve Outlet solenoid valve Reservoir
4 p 5 p
6 p 7 p
Pump Motor
BR-50
Bypass check valve Damper
ANTI-LOCK BRAKE SYSTEM System Components
Warning light Brake tube connector
Actuator
Rear wheel sensors
Control unit
Front wheel sensors
NBR260
System Description
Control unit Magnet . Sensor (proximity detector) Magnetic flux
SENSOR
Low carbon steel Coil Sensor rotor
Tooth
Moving time of one tooth
V: Induced electromotive force
SBR124B
The sensor unit consists of a gear-shaped sensor rotor and an electro-magnetic proximity detector. The proximity detector (“pick-up”) contains a bar magnet around which a coil is wound. The detector is installed on the back side of the brake rotor. An alternating voltage is generated in the coil of the proximity detector as each tooth of the rotor cuts the magnetic field of the detector core. The frequency and amplitude of the voltage increases in proportion to the rotational speed of the rotor.
CONTROL UNIT
ABS warning light NBR284
The control unit determines the wheel rotating speed from the signal sent from the sensor, a corresponding control signal is then output from the control unit in the form of a DC current to the actuator solenoid valve. The ABS control unit also controls ON-OFF operation of the valve relay and motor relay. If any electrical malfunction should be detected in the system, the control unit causes the warning lamp to light up. In this condition, the ABS will be deactivated by the control unit, and the vehicle’s brake system reverts to normal operation.
BR-51
ANTI-LOCK BRAKE SYSTEM System Description (Cont’d) ABS ACTUATOR AND ELECTRIC UNIT ABS control unit ABS control unit harness connector
.
ABS actuator
NBR297
The ABS actuator and electric unit contains: ● An electric motor and pump ● Two relays ● Eight solenoid valves, each inlet and outlet for — LH front — RH front — Rear LH/RH ● ABS control unit This component controls the hydraulic circuit and increases, holds or decreases hydraulic pressure to all or individual wheels. The ABS actuator and electric unit can not be disassembled and has to be serviced as an assembly.
ABS actuator operation Inlet solenoid valve
Outlet solenoid valve
OFF (Open)
OFF (Closed)
Master cylinder brake fluid pressure is directly transmitted to wheel cylinder via the inlet solenoid valve.
Pressure hold
ON (Closed)
OFF (Closed)
Hydraulic circuit is shut off to hold the wheel cylinder brake fluid pressure.
Pressure decrease
ON (Closed)
ON (Open)
Wheel cylinder brake fluid is sent to reservoir via the outlet solenoid valve. Then it is pushed up to the master cylinder by pump.
Pressure increase
OFF (Open)
OFF (Closed)
Master cylinder brake fluid pressure is transmitted to wheel cylinder.
Normal brake operation
ABS operation
BR-52
ANTI-LOCK BRAKE SYSTEM Removal and Installation CAUTION: Be careful not to damage sensor edge and sensor rotor teeth. When removing the front or rear wheel hub assembly, disconnect the ABS wheel sensor from the assembly and move it away. Failure to do so may result in damage to the sensor or wiring making it inoperative.
FRONT WHEEL SENSOR
18 - 24 (1.8 - 2.4, 13 - 18)
: N·m (kg-m, ft-lb)
NBR176
REAR WHEEL SENSOR
25 - 33 (2.6 - 3.4, 18 - 24)
: N·m (kg-m, ft-lb) NBR296
BR-53
ANTI-LOCK BRAKE SYSTEM Removal and Installation (Cont’d) SENSOR ROTOR
Front sensor rotor
Removal 1. Remove the drive shaft and rear wheel hub. Refer to FA, RA section (“Drive Shaft”, FRONT AXLE” and “Wheel Hub”, REAR AXLE”). 2. Remove the sensor rotor using suitable puller, drift and bearing replacer.
Drive shaft
SBR984C
Rear sensor rotor
Suitable drift
SBR873CA
Installation
Front sensor rotor
Install the sensor rotor. For front sensor rotor, use hammer and wooden block. For rear sensor rotor, use suitable drift and press. ● Always replace sensor rotor with new one. ● Ensure sensor rotor is completely flush with surface indicated on drive shaft.
Flush
Wooden block NBR196
●
Press
Rear sensor rotor
Pay attention to the flush position of rear sensor rotor as shown in figure. h: −0.3 to +0.3 mm (−0.012 to +0.012 in)
Suitable drift
h
Sensor rotor Wheel hub
.
NBR197
ABS control unit harness connector ABS actuator
CONTROL UNIT Location: Built-in ABS actuator. When disconnecting the harness connector, pull the lever as shown figure.
PULL
X 1 ABS control unit
X NBR261
BR-54
ANTI-LOCK BRAKE SYSTEM Removal and Installation (Cont’d) ABS ACTUATOR
Front master cylinder secondary
To front wheel cylinder (RH)
To front wheel cylinder (LH)
To rear wheel cylinder (LH)
From master cylinder primary To rear wheel cylinder (RH)
10 - 14 (1.0 - 1.4, 7.2 - 10.1)
ABS actuator & electric control unit
Actuator/ground cable
Unlock
Lock
10.8 - 14.7 (1.1 - 1.5,8.0 - 10.8)
7-9 (0.7 - 0.9, 5.1 - 6.5)
FRONT
11 - 15 (1.1 - 1.5, 8.0 -10.8)
Actuator bracket
: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) NBR262
BR-55
ANTI-LOCK BRAKE SYSTEM Removal and Installation (Cont’d) 1. Disconnect battery cable. 2. Drain brake fluid. Refer to BR-7
ABS control unit harness connector ABS actuator
3. Unlock the slider then disconnect the electrical harness connectors from ABS control unit. 4. Identify each brake pipe with corresponding actuator port hole and mark them accordingly.
PULL
ABS control unit NBR261
5. Disconnect brake pipes and move them away from actuator. Do not force brake pipes so as to kink them or bend them excessively. Ensure that brake fluid does not come into contact with any parts. 6. Loosen/remove mounting nuts between actuator and bracket.
NBR249
CAUTION: After installation, pay attention to the following points: ● Refill brake fluid and bleed air. Refer to “CHECK AND ADJUSTMENT”, BR-7 and “BLEEDING BRAKE SYSTEM”, BR-8, respectively.
ABS actuator
.
10.8 - 14.7 N·m (1.1 - 1.5 Kg-m, 8.0 - 10.8 ft-lb)
● The installation procedure is as follows: 1. Install actuator on bracket without tightening fixings. 2. Assemble brake tubes to actuator without tightening tube nuts. Ensure that correct tubes are connected to each port. 3. Fully tighten actuator and bracket fixings to specified torque. 4. Fully tighten flare nuts to specified torque, BR-10. 5. Secure ABS control unit harness connector and battery cable.
NBR171
BR-56
TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair INTRODUCTION
SEF233G
SEF234G
The ABS system has an electronic control unit to control major braking functions. The control unit accepts input signals from sensors and utilises the data to instantly drive the actuators. It is essential that both input and output signals are correct and stable. It is also important to check for conventional problems: such as air leaks in booster lines, lack of brake fluid, or other problems with the brake system. It is much more difficult to diagnose a problem that occurs intermittently rather than catastrophically. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the unnecessary replacement of good parts. A visual check may not be sufficient to find the cause of the problems, so a road test should also be performed. Before undertaking actual checks, take just a few minutes to talk with a customer who approaches with a ABS complaint. The customer is a very good source of information on such problems; especially intermittent ones. Through the talks with the customer, find out what symptoms are present and under what conditions they occur. Start your diagnosis by looking for “conventional” problems first. This is one of the best ways to troubleshoot brake problems on an ABS controlled vehicle.
BR-57
TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont’d) WORK FLOW CHECK IN
F
Reference item
H
LISTEN TO CUSTOMER COMPLAINTS
H
INVESTIGATE ITEMS YOU SHOULD CARRY OUT RELARED TO EACH SYMPTOM AND NOTE
F
Go to MALFUNCTION CODE/SYMPTOM CHART, BR-76.
F
Go to Preliminary Check, BR-59.
F
Go to Self-diagnosis, BR-67.
H
CHECK FOR ANY SERVICE BULLETINS.
H
E ELIMINATE GOOD SYSTEMS AND GOOD PARTS
Not self-diagnostic item
Self-diagnostic item H DETERMINE MALFUNCTIONING CIRCUIT(S) OR PART(S).
Self-diagnosis ●
H H ELIMINATE GOOD PART(S), HARNESS(ES) OR CONNECTOR(S) THROUGH ELECTRICALLY TESTING
Malfunctioning harness(es) and connector(s)
F
Malfunctioning parts
H INSPECTION OF EACH COMPONENT
H
H REPAIR
REPAIR OR REPLACE
H NG
●
Go to Diagnostic Procedure(s) 6 - 12, BR-85. Go to Component Parts and Harness Connector Location, BR-60.
H FINAL CHECK OK H
CHECK OUT
BR-58
F
Go to Diagnostic Procedure(s) 1 - 5, BR-77.
TROUBLE DIAGNOSES Preliminary Check Check brake fluid level in reservoir tank. -----------------------------------------------------------------------------------------------------------------------------------------------------Low fluid level may indicate brake pad wear or leakage from brake line.
MAX.
MIN.
NBR141
H
Check brake line for leakage.
NG
E
Repair.
OK F H
Check brake booster for operation and air tightness. Refer to BR-18.
NG
E
Replace.
OK F H
Check brake pads and rotor. Refer to BR-23, 26, 33. SBR389C
NG
E
Replace.
OK H
Check brake fluid level in reservoir tank. NG
E
Fill up brake fluid.
OK H
Check warning lamp activation. When ignition switch is turned on, warning lamp turns on.
NG
E
Check fuse, warning lamp bulb and warning lamp circuit.
OK SBR058C
H
Check warning lamp for deactivation. When ignition switch is turned on, warning lamp turns on, then deactivates after 1 second.
.
NG
E
Go to Self-diagnosis, BR-67 and BR-70.
E
Go to Self-diagnosis, BR-67 and BR-70.
OK H
Drive vehicle at 30 km/h (19 mph) for at least one minute. H SBR059C
Ensure warning lamp remains off while driving. OK H
END
ABS warning light NBR284
BR-59
NG
TROUBLE DIAGNOSES Component Parts and Harness Connector Location
Warning light Brake tube connector
ABS actuator and electric unit
Rear wheel sensors Rear left wheel sensor connector Rear right wheel sensor connector Front wheel sensors Front left wheel sensor connector Front right wheel sensor connector
E17
Sensor
.
E78
Sensor
E57
B33 B32
Rear left wheel sensor connector . Rear right wheel Rear tire sensor connector
NBR285
BR-60
TROUBLE DIAGNOSES Circuit Diagram for Quick Pinpoint Check
YBR228
BR-61
TROUBLE DIAGNOSES Wiring Diagram — ABS — MODELS WITH SELF-DIAGNOSIS FUNCTION IGNITION SWITCH ON or START
BATTERY
FUSE BLOCK (J/B)
Refer to EL-POWER.
: LHD models
: CVT models
: RHD models
: M/T models
STOP LAMP SWITCH DEPRESSED RELEASED COMBINATION METER (ABS WARNING LAMP)
FUSE BLOCK (J/B)
ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
TCM (TRANSMISSION CONTROL MODULE)
DATA LINK CONNECTOR
Refer to las page (Foldout page).
YBR208
BR-62
TROUBLE DIAGNOSES Wiring Diagram — ABS — (Cont’d) MODELS WITHOUT SELF-DIAGNOSIS FUNCTION
YBR229
BR-63
TROUBLE DIAGNOSES Wiring Diagram — ABS — (Cont’d)
YBR230
BR-64
TROUBLE DIAGNOSES Wiring Diagram — ABS — (Cont’d)
YBR231
BR-65
TROUBLE DIAGNOSES Wiring Diagram — ABS — (Cont’d)
YBR232
BR-66
TROUBLE DIAGNOSES Self-diagnosis (Only models with data link connector terminal No. 8) FUNCTION ●
When a problem occurs in the ABS, the warning lamp on the instrument panel comes on. To start the self-diagnostic results mode, ground the self-diagnostic (check) terminal located on “Data Link Connector for CONSULT-II”. The location of the malfunction is indicated by the warning lamp flashing.
SELF-DIAGNOSIS PROCEDURE .
DATA link connector for CONSULT-II
Drive vehicle over 30 km/h (19 mph) for at least one minute. (Ground terminal 8 with a suitable harness.)
H
Turn ignition switch to the “LOCK” position. H
NBR295
Ground terminal “8” of “DATA LINK CONNECTOR for CONSULT-II” with a suitable harness. H
Turn ignition switch to “ON” position while grounding terminal “8”. Do not depress brake pedal. H
After 3.0 seconds, the warning lamp starts flashing to indicate the malfunction code No. (See NOTE.) ABS warning light NBR284 .
DATA link connector for CONSULT-II (Disconnect the harness)
H
Verify the location of the malfunction with the malfunction code chart. Refer to BR-69. Then make the necessary repairs following the diagnostic procedures. H
After the malfunctions are repaired, erase the malfunction codes stored in the control unit. Refer to BR-68. H NBR305
Rerun the self-diagnostic results mode to verify that the malfunction codes have been erased.
H
Disconnect the check terminal from the ground. The self-diagnostic results mode is now complete. H
A p
BR-67
NOTE: The indication terminates after five minutes. However, when the ignition switch is turned from off to on, the indication starts flashing again.
TROUBLE DIAGNOSES Self-diagnosis (Only models with data link connector terminal No. 8) (Cont’d) A p
H
Check warning lamp for deactivation after driving vehicle over 30 km/h (19 mph) for at least one minute. H
After making certain that warning lamp does not come on, test the ABS in a safe area to verify that it functions properly.
HOW TO READ SELF-DIAGNOSTIC RESULTS (Malfunction codes) ● ● ●
●
üüüDetermine the code No. by counting the number of times the warning lamp flashes on and off. When several malfunctions occur at one time, up to three code numbers can be stored; the latest malfunction will be indicated first. The indication begins with the start code 12. After that a maximum of three code numbers appear in the order of the latest one first. The indication then returns to the start code 12 to repeat (the indication will stay on for five minutes at the most). The malfunction code chart is given on the next page.
Example: Code No. 32 REAR SENSOR SHORT-CIRCUIT Start code: 12 Tens digits Units digits ON Warning lamp OFF 3.0
0.6
0.9
0.3
0.3
CODE No. 32 Tens digits
3.3
0.3
ON
0.6 0.6
0.6
0.6
0.6
Units digits
0.9
0.3 0.3 0.3 Unit: Second
IGN OFF
SBR457C
Self-diagnosis completed ABS warning lamp
ON OFF Check terminal
Open (disconnect) Ground More than 1 sec 12.5 sec Malfunction code memory erased ABR256
HOW TO ERASE SELF-DIAGNOSTIC RESULTS (Malfunction codes) 1. Disconnect the check terminal from ground (ABS warning lamp will stay lit). 2. Within 12.5 seconds, ground the check terminal 3 times. Each terminal ground must last more than 1 second. The ABS warning lamp goes out after the erase operation has been completed. 3. Perform self-diagnosis again. Refer to BR-67. Only the startcode should appear, no malfunction codes.
BR-68
Trouble Diagnosis — General Description CONSULT-II CONSULT-II APPLICATION TO ABS SELF-DIAGNOSTIC RESULTS
DATA MONITOR
ACTIVE TEST
Front right wheel sensor
X
X
—
Front left wheel sensor
X
X
—
Rear right wheel sensor
X
X
—
Rear left wheel sensor
X
X
—
Stop lamp switch
—
X
—
Front right inlet solenoid valve
X
X
X
Front right outlet solenoid valve
X
X
X
Front left inlet solenoid valve
X
X
X
Front left outlet solenoid valve
X
X
X
Rear right inlet solenoid valve
X
X
X
Rear left inlet solenoid valve
X
X
X
Rear right outlet solenoid valve
X
X
X
Rear left outlet solenoid valve
X
X
X
Actuator solenoid valve relay
X
X
—
Actuator motor relay (ABS MOTOR is shown on the Data Monitor screen.)
X
X
X
ABS warning lamp
—
X
—
Battery voltage
X
X
—
Control unit
X
—
—
ITEM
X: Applicable —: Not applicable
ECU part number mode Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order the ECU.
BR-69
Trouble Diagnosis — General Description CONSULT-II Inspection Procedure SELF-DIAGNOSIS PROCEDURE Fuses
Data link connector
1) Turn ignition switch to the “LOCK” position. 2) Connect CONSULT-II to Data Link Connector.
.
H
NEF125A
1) Start engine. 2) Drive vehicle over 30 km/h (19 mph) for at least one minute. H
C2NCS01
●
1) Stop vehicle with engine running and touch “START” on CONSULT-II screen. 2) Touch “ABS”. 3) Touch “SELF-DIAG RESULTS”. The screen shows the detected malfunction and how many times the ignition switch has been turned since the malfunction. H
.
MALFUNCTION REPAIR ----------------------------------------------------------------------------------------------------------------------------------------------------Make the necessary repairs following the diagnostic procedures.
CVT
C2SSE01 H
After repairing the malfunctions, erase the self-diagnostic results stored in the control unit by touching “ERASE”. H
Check warning lamp for deactivation after driving vehicle over 30 km/h (19 mph) for at least one minute. C2SDM01
H
End
Note: “SELF-DIAG RESULTS” screen shows the detected malfunction and the times of ignition switch on and off after it occurred.
C2SDR01
BR-70
Trouble Diagnosis — General Description CONSULT-II Inspection Procedure (Cont’d) SELF-DIAGNOSTIC RESULTS MODE Diagnostic item FR RH SENSOR★ [OPEN] FR LH SENSOR★ [OPEN] RR RH SENSOR★ [OPEN] RR LH SENSOR★ [OPEN] FR RH SENSOR★ [SHORT] FR LH SENSOR★ [SHORT] RR RH SENSOR★ [SHORT] RR LH SENSOR [SHORT] ABS SENSOR★ [ABNORMAL SIGNAL] FR RH IN ABS SOL [OPEN] FR LH IN ABS SOL [OPEN] RR RH IN ABS SOL [OPEN] RR LH IN ABS SOL [OPEN] FR RH IN ABS SOL [SHORT] FR LH IN ABS SOL [SHORT] RR RH IN ABS SOL [SHORT] RR LH IN ABS SOL [SHORT] FR RH OUT ABS SOL [OPEN] FR LH OUT ABS SOL [OPEN] RR RH OUT ABS SOL [OPEN] RR LH OUT ABS SOL [OPEN] FR RH OUT ABS SOL [SHORT] FR LH OUT ABS SOL [SHORT] RR RH OUT ABS SOL [SHORT] RR LH OUT ABS SOL [SHORT] ABS ACTUATOR RELAY [ABNORMAL] ABS MOTOR RELAY [ABNORMAL] BATTERY VOLT [VB-LOW] CONTROL UNIT
Diagnostic item is detected when . . .
Diagnostic procedure
● ● ●
Circuit for front right wheel sensor is open. (An abnormally high input voltage is entered.) Circuit for front left wheel sensor is open. (An abnormally high input voltage is entered.) Circuit for rear right sensor is open. (An abnormally high input voltage is entered.) Circuit for rear left sensor is open. (An abnormally high input voltage is entered.) Circuit for front right wheel sensor is shorted. (An abnormally low input voltage is entered.) Circuit for front left wheel sensor is shorted. (An abnormally low input voltage is entered.) Circuit for rear right sensor is shorted. (An abnormally low input voltage is entered.) Circuit for rear left sensor is shorted. (An abnormally low input voltage is entered.) Teeth damage on sensor rotor or improper installation of wheel sensor. (Abnormal wheel sensor signal is entered.) Circuit for front right inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for front left inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for rear right inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for rear left inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for front right inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for front left inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for rear right inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for rear left inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for front right outlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for front left outlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for rear right outlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for rear left outlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for front right outlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for front left outlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for rear right outlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for rear left outlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Actuator solenoid valve relay is ON, even control unit sends off signal. Actuator solenoid valve relay is OFF, even control unit sends on signal. Circuit for actuator motor is open or shorted. Actuator motor relay is stuck. Circuit for actuator is open or shorted.
●
Power source voltage supplied to ABS control unit is abnormally low.
4
●
Function of calculation in ABS control unit has failed.
5
● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3
★: If one or more wheels spin on a rough or slippery road for 40 seconds or more, the ABS warning lamp will illuminate. This does not indicate a malfunction. Only in the case of the short-circuit after repair the ABS warning lamp also illuminates when the ignition switch is turned “ON”. In this case, drive the vehicle at speeds greater than 30 km/h (19 MPH) for approximately 1 minute as specified in “SELF-DIAGNOSIS PROCEDURE”, BR-70. Check to ensure that the ABS warning lamp goes out while the vehicle is being driven.
BR-71
Trouble Diagnosis — General Description CONSULT-II Inspection Procedure (Cont’d) DATA MONITOR PROCEDURE 1) Turn ignition switch to the off position. 2) Connect CONSULT-II to Data Link Connector. 3) Turn ignition switch to the ON position. H
1) Touch “START” on CONSULT-II screen. 2) Touch “ABS”. 3) Touch “DATA MONITOR”. C2NCS01 H
1) Select “SELECT MONITOR ITEM”. H
Carry out the monitor test under the condition as described in page BR-73.
C2SSE01
C2SDM01
C2SMI01
BR-72
Trouble Diagnosis — General Description CONSULT-II Inspection Procedure (Cont’d) DATA MONITOR MODE MONITOR ITEM
CONDITION
SPECIFICATION
FR RH SENSOR FR LH SENSOR REAR RH SENSOR REAR LH SENSOR
Drive vehicle. (Each wheel is rotating.)
Wheel speed signal Almost the same speed as speedometer.
STOP LAMP SW
Brake is depressed.
Depress the pedal: ON Release the pedal: OFF
FR RH IN SOL FR RH OUT SOL FR LH IN SOL FR LH OUT SOL RR RH IN SOL RR RH OUT SOL RR LH IN SOL RR LH OUT SOL
1. Drive vehicle at speeds over 30 km/h (19 mph) for at least one minute. 2. Engine is running.
Operating conditions for each solenoid valve are indicated. ABS is not operating: OFF
MOTOR RELAY
ABS is not operating: OFF ABS is operating: ON
ACTUATOR RELAY
Ignition switch in the “ON” position (Engine stops): OFF Engine running: ON
WARNING LAMP BATTERY VOLT
Ignition switch is set to the “ON” position or engine is running.
Warning lamp is turned on: ON Warning lamp is turned off: OFF Power supply voltage for control unit
BR-73
Trouble Diagnosis — General Description CONSULT-II Inspection Procedure (Cont’d) ACTIVE TEST PROCEDURE ● ●
When conducting Active test, vehicle must be stationary. When ABS warning lamp stays on, never conduct Active test.
1) Turn ignition switch to the “LOCK” position. 2) Connect CONSULT-II to Data Link Connector. 3) Start engine.
C2NCS01
H
1) Touch “START” on CONSULT-II screen. 2) Touch “ABS”. 3) Touch “ACTIVE TEST”. H
.
1) Select active test item by touching screen. 2) Touch “START”.
CVT
H
Carry out the active test by touching screen key. C2SSE01
C2SDM01
C2STI01
C2FRS01
BR-74
Trouble Diagnosis — General Description CONSULT-II Inspection Procedure (Cont’d) ACTIVE TEST MODE TEST ITEM
CONDITION
JUDGEMENT Brake fluid pressure control operation
FR RH SOLENOID FR LH SOLENOID RR RH SOLENOID RR LH SOLENOID
Engine is running.
UP (Increase): KEEP (Hold): DOWN (Decrease):
IN SOL
OUT SOL
OFF ON ON
OFF OFF ON
ABS actuator motor ON: Motor runs (ABS motor relay ON) OFF: Motor stops (ABS motor relay OFF)
ABS MOTOR
Note: Active test will automatically stop ten seconds after the test starts. (LIMIT SIGNAL monitor shows ON.)
Ground Circuit Check ABS ACTUATOR AND ELECTRIC UNIT GROUND ● ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR
Check resistance between ABS actuator and electric unit connector terminals and ground. Resistance: approximately 0Ω
YBR170
BR-75
Trouble Diagnosis — General Description Malfunction Code/Symptom Chart MODELS WITH SELF-DIAGNOSIS FUNCTION Code No. (No. of LED flashes)
Malfunctioning part
Reference page
12
Self-diagnosis could not detect any malfunctions.
—
18
Sensor rotor
BR-77
21
Front right sensor (open-circuit)
BR-77
22
Front right sensor (short-circuit)
BR-77
25
Front left sensor (open-circuit)
BR-77
26
Front left sensor (short-circuit)
BR-77
31
Rear right sensor (open-circuit)
BR-77
32
Rear right sensor (short-circuit)
BR-77
35
Rear left sensor (open-circuit)
BR-77
36
Rear left sensor (short-circuit)
BR-77
41
Actuator front right outlet solenoid valve
BR-79
42
Actuator front right inlet solenoid valve
BR-79
45
Actuator front left outlet solenoid valve
BR-79
46
Actuator front left inlet solenoid valve
BR-79
51
Actuator rear right outlet solenoid valve
BR-79
52
Actuator rear right inlet solenoid valve
BR-79
55
Actuator rear left outlet solenoid valve
BR-79
56
Actuator rear left inlet solenoid valve
BR-79
57*
Power supply (Low voltage)
BR-83
61
Actuator motor or motor relay
BR-81
63
Solenoid valve relay
BR-79
71
Control unit
BR-84
ABS warning lamp stays on when ignition switch is turned on.
Control unit power supply circuit Warning lamp bulb circuit Control unit or control unit connector Solenoid valve relay stuck Power supply for solenoid valve relay coil
BR-90
ABS warning lamp stays on, during self-diagnosis.
Control unit
ABS warning lamp does not come on when ignition switch is turned on.
Fuse, warning lamp bulb or warning lamp circuit Control unit
ABS warning lamp does not come on during self-diagnosis.
Control unit
—
BR-88
—
Pedal vibration and noise
—
BR-87
Long stopping distance
—
BR-86
Unexpected pedal action
—
BR-86
ABS does not work.
—
BR-87
ABS works frequently.
—
BR-85
*: Under voltage that is too low, the control unit disable the ABS. It does not set the ABS in fail-safe condition. Instead, the ABS becomes a conventional brake system. After the power supply has resumed, the warning lamp goes off, making it possible for the ABS to be re-engaged.
BR-76
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Front RH
Front LH
Rear RH
Rear LH
Diagnostic Procedure 1 (Wheel sensor or rotor) (Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18 for models with self-diagnosis function)
ABS actuator and electric unit Wheel sensor connectors (sensor side) Rear LH Front LH Front RH
Rear RH NBR420
INSPECTION STARTS 1. Disconnect connectors from ABS actuator and electric unit and wheel sensor of malfunction code No. Check terminals for damage or loose connections. Then reconnect connectors. 2. Carry out self-diagnosis again. Does warning lamp activate again?
ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR
No
E
Inspection end
Yes H
NBR414
Front sensor
Rear sensor
YBR173
CHECK WHEEL SENSOR ELECTRICAL. 1. Disconnect ABS actuator and electric unit connector. 2. Check resistance between ABS actuator and electric unit connector E78 (body side) terminals. Code No. 21 or 22 (Front RH wheel) Terminals p 11 and p 12 Code No. 25 or 26 (Front LH wheel) Terminals p 9 and p 10 Code No. 31 or 32 (Rear RH wheel) Terminals p 13 and p 15 Code No. 35 or 36 (Rear LH wheel) Terminals p 7 and p 8 Resistance: Front 1.44 - 1.76 kΩ Rear 1.44 - 1.76 kΩ
OK
p
E A
(Go to next page.)
NG H
CHECK WHEEL SENSOR. Check each sensor for resistance. Resistance: Front 1.44 - 1.76 kΩ Rear 1.44 - 1.76 kΩ NG
H
REPLACE. Replace wheel sensor.
BR-77
OK
E
Check the following. ● Harness connectors E78
Harness for open or short between wheel sensor connectors and ABS actuator and electric unit If NG, repair harness or connectors.
●
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Diagnostic Procedure 1 (Wheel sensor or rotor) (Cont’d) Front sensor
A p
Feeler gauge
Note
Note
H
CHECK TYRE. Check for inflation pressure, wear and size of each tyre.
NG
E
Adjust tyre pressure or replace tyre(s).
E
Clean sensor fixing portion, or replace sensor.
OK Sensor
Note Rotor Sensor
Feeler gauge
H
CHECK WHEEL BEARING Check wheel bearing axial end play and clearance between sensor and rotor. Clearance Front 0.1 - 1.1 mm (0.004 - 0.043 in) Rear 0.536 - 1.551 mm (0.021 - 0.061 in)
NG
OK NBR391
Note
Note
H
CHECK SENSOR ROTOR. Check sensor rotor for teeth damage.
NG
E
Replace sensor rotor.
OK H
CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.
Note: Wheel position should be indentified by code numbers except code No. 18 (sensor rotor).
BR-78
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay)
Fusible link Fuse ABS actuator and electric unit To motor relay
Solenoid valve relay
(Malfunction code Nos. 41, 42, 45, 46, 51, 52, 55, 56, 63 for models with self-diagnosis function) CHECK FUSIBLE LINK. Check 40A fusible link g (petrol engine), fusible link h (diesel engine). For fusible link layout, refer to POWER SUPPLY ROUTING in EL section. H
H ABS actuator and electric unit connector : With petrol engine : With diesel engine
YBR174
NG
p
(Go to next page.)
E B
No
E
Inspection end
Yes
CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT. Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-75.
ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR
(Go to next page.)
OK
CHECK CONNECTOR. 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again? H
p
E A
OK
CHECK FUSE. Check 10A fuse 19 . For fuse layout, refer to POWER SUPPLY ROUTING in EL section.
ABS control unit
NG
NG
E
Repair harness and connector.
E
Check the following. ● Harness connector
OK YBR175
H
CHECK SOLENOID VALVE RELAY POWER SUPPLY CIRCUIT. 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E78 (body side) terminal p 29 and ground. Battery voltage should exist. H
OK
REPLACE. Replace ABS actuator and electric unit.
BR-79
NG
E78
Harness for open or short between ABS actuator and electric unit and fusible link If NG, repair harness or connector.
●
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay) (Cont’d) A p
H
ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR
REPLACE. Replace fusible link. Does the fusible link blow out when ignition switch is turned ON?
No
E
Inspection end
Yes YBR176
H
CHECK SOLENOID VALVE RELAY POWER SUPPLY CIRCUIT. 1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector E78 (body side) terminal p 29 and ground. Continuity should not exist. H
NG
E
Check the following ● Harness connector E78
Harness for open or short between ABS actuator and electric unit and fusible link If NG, repair harness or connector.
●
OK
REPLACE. Replace ABS actuator and electric unit.
B p
H
REPLACE. Replace fuse. Does the fuse blow out when ignition switch is turned ON? No
H
END Inspection end
BR-80
Yes
E
Check the following. ● Harness connector E78
Harness for open or short between ABS actuator and electric unit and fuse If NG, repair harness or connector.
●
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Diagnostic Procedure 3 (Motor Relay or motor)
Fuse Fusible link
ABS actuator and electric unit
Motor relay
To solenoid valve relay
CHECK FUSIBLE LINK. Check 40A fusible link i (Petrol engine), fusible link f (diesel engine). For fusible link layout, refer to POWER SUPPLY ROUTING in EL section. H
ABS control unit
NG
p
E A
(Go to next page.)
OK
CHECK CONNECTOR 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again?
ABS actuator and electric unit connector : With petrol engine : With diesel engine
(Malfunction code No. 61 for models with self-diagnosis function)
No
E
Inspection end
Yes YBR177
H
CHECK MOTOR RELAY POWER SUP- NG PLY CIRCUIT. 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E78 (body side) terminal p 30 and ground. Battery voltage should exist.
ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR
H YBR178
OK
REPLACE. Replace ABS actuator and electric unit.
BR-81
NG
Check the following. ● Harness connector E78
Harness for open or short between ABS actuator and electric unit and fusible link. If NG, repair harness or connector.
●
OK
CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND. Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-75. H
E
E
Repair harness and terminals.
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Diagnostic Procedure 3 (Motor Relay or motor) (Cont’d) A p
ABS ACTUATOR AND ELECTRIC UNIT AND CONNECTOR
H
REPLACE. Replace fusible link. Does the fusible link blow out when ignition switch is turned ON?
No
E
Inspection end
OK YBR179 H
CHECK ABS ACTUATOR MOTOR POWER SUPPLY CIRCUIT. 1. Disconnect battery cable and ABS actuator and electric unit connector E78 . 2. Check continuity between ABS actuator and electric unit connector E78 (body side) terminal p 30 and ground. Continuity should not exist. OK H
CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.
BR-82
NG
E
Check the following ● Harness connector E78
Harness for open or short between ABS actuator and electric unit and fusible link If NG, repair harness ro connector.
●
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS .
Diagnostic Procedure 4 (Low voltage)
Fuse
(Malfunction code No. 57 for models with self-diagnosis function)
ABS actuator and electric unit To solenoid valve relay
CHECK CONNECTOR. 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connections. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again?
ABS control unit
YBR180 H
YBR181
E
Inspection end
Yes CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E78 terminal p 1 and ground. Battery voltage should exist when ignition switch is turned ON.
ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR
No
H
A p
E
(See below.)
OK
CHECK ABS CONTROL UNIT GROUND Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-75. H
NG
NG E
Repair harness and connector.
OK
CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.
A p
H
CHECK FUSE. Check 10A fuse 19 . For fuse layout, refer to POWER SUPPLY ROUTING in EL section. H
OK
Check battery. Refer to BATTERY in EL section.
BR-83
E
Replace fuse.
OK
CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT Check continuity between fuse and ABS actuator and electric unit connector E78 (body side) terminal p 1 . H
NG
NG E
Check the following: ● Harness connector E78 ● Harness for open or short between ABS actuator and electric unit and fuse If NG, repair harness or connector.
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS .
Diagnostic Procedure 5 (Control unit)
Fuse
(Malfunctioning code No. 71 for models with self-diagnosis function) ABS actuator and electric unit
CHECK CONNECTOR. 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connections. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again?
ABS control unit
No E
Inspection end
YBR182 H
Yes
ABS CONTROL UNIT POWER SUPPLY CHECK Check voltage. Refer to in Diagnostic Procedure 4, BR-83. H
CHECK SELF-DIAGNOSTIC RESULTS Does warning lamp indicate code No. 71 again? H
No
INSPECTION Inspect the system according to the code No.
BR-84
Yes E
Replace ABS actuator and electric unit.
TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 6 (ABS works frequently) CHECK WHEEL SENSOR. 1. Check wheel sensor connector for terminal damage or loose connections. 2. Perform wheel sensor mechanical check. Refer to Diagnostic Procedure 1, BR-77. H
Go to BR-86.
OK
in Diagnostic Procedure 8,
BR-85
E
Perform Preliminary check. Refer to BR-59.
OK
CHECK FRONT AXLES Check front axles for excessive looseness. Refer to FA and RA section (“Front/Rear Wheel Bearing”, “ON-VEHICLE SERVICE”). H
NG
NG E
Repair.
TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 7 (Unexpected pedal action) CHECK BRAKE PEDAL STROKE. Check brake pedal stroke. Is stroke excessively large? H SBR540A
Yes
E
Perform Preliminary Check, refer to BR-59.
E
Perform Preliminary Check, refer to BR-59.
E
Carry out self-diagnosis. Refer to BR-67.
E
Repair.
No
CHECK BRAKE PERFORMANCE Disconnect ABS actuator and electric unit connector and check whether brake is effective.
No
Yes H
CHECK WARNING LAMP ACTIVATE. Ensure warning lamp remains off while driving.
NG
OK H ABS warning light NBR284
CHECK WHEEL SENSOR. 1. Check wheel sensor connector for terminal damage or loose connection. 2. Perform wheel sensor mechanical check. Refer to Diagnostic Procedure 1, BR-77.
NG
OK H
CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals fir damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.
Diagnostic Procedure 8 (Long stopping distance) CHECK ABS PERFORMANCE Disconnect ABS actuator and electric unit connector and check whether stopping distance is still long.
No
E
in Diagnostic Go to Procedure 7, BR-86.
Yes H
Perform Preliminary Check and air bleeding.
Note: Stopping distance may be larger than vehicles without ABS when road condition is slippery.
BR-86
TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 9 (ABS does not work.) CHECK WARNING LAMP ACTIVATE. Does the ABS warning lamp activate?
Yes
E
Carry out self-diagnosis. Refer to BR-67.
No H
Go to BR-86.
in Diagnostic Procedure 7,
Note: ABS does not work when vehicle speed is under 10 km/h (6 MPH).
Diagnostic Procedure 10 (Pedal vibration and noise)
Brake pedal
INSPECTION START 1. Apply brake. 2. Start engine. 3. Does the symptom appear only when engine is started?
Yes
E
Carry out self-diagnosis. Refer to BR-67.
E
Go to in Diagnostic Procedure 7, BR-86.
E
Repair wheel sensor.
No SAT797A
H
CHECK IF SYMPTOM APPEARS. Does the symptom appear when electrical equipment switches (such as headlamp) are operated?
No
Yes H
CHECK WHEEL SENSOR. Check wheel sensor shield ground. For location of shield ground, refer to wiring diagram and “HARNESS LAYOUT” in EL section.
NG
OK H
CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.
Note: ABS may operate and cause vibration under any of the following conditions.
BR-87
TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 10 (Pedal vibration and noise) (Cont’d) ● ● ● ● ●
Applying brake gradually when shifting or operating clutch. Low friction (slippery) road. High speed concerning. Driving over bumps and pot holes. Engine speed is over 5,000 rpm with vehicle stopped.
Diagnostic Procedure 11 (ABS Warning lamp does not come on when ignition switch is turned ON)
.
Fuse Combination meter ABS warning lamp
CHECK FUSE. Check 10A fuse 12 . For fuse layout, refer to POWER SUPPLY ROUTING in EL section.
ABS actuator and electric unit
NBR415
No
H
CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT. 1. Install 10A fuse. 2. Disconnect ABS actuator and electric unit connector. 3. Check voltage between control unit connector terminal 21, 22 and ground after turning ignition switch “ON”.
ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR
H
CVT models M/T models
E
Replace fuse.
OK
ABS control unit CVT models M/T models
NG
B p
NBR416
BR-88
Yes (Go to next page.)
p
E A
(Go to next page.)
TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 11 (ABS Warning lamp does not come on when ignition switch is turned ON) (Cont’d) A p
H
ABS warning light NBR284
CHECK WARNING LAMP INDICATION. Disconnect ABS actuator and electric unit connector. Does the warning lamp activate?
NG
p
E B
(See below)
Yes H
CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest
NG
E
REPLACE. Replace ABS actuator and electric unit.
OK H
Inspection end.
B p
H
ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR
.
21: CVT models 22: M/T models NBR417
CHECK HARNESS FOR SHORT. 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector (body side) terminal 21, 22, and ground. Battery voltage should not exist. OK H
CHECK COMBINATION METER. Check combination meter. Refer to WARNING LAMPS in EL section.
BR-89
NG
E
Repair harness or connector between fuse and ABS actuator and electric unit connector terminal.
TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 12 (Warning lamp stays on when ignition switch is turned ON)
.
Fuse Combination meter ABS warning lamp
ABS actuator and electric unit ABS control unit CVT models M/T models
NBR418
CHECK WARNING LAMP. 1. Disconnect ABS actuator and electric unit connector. 2. Connect suitable wire between ABS actuator and electric unit connector E78 (body side) terminal p 6 , p 22 and ground. Warning lamp should not activate.
NG
E
E78
Harness for open or short between ABS actuator and electric unit and fusible link If NG, repair harness ro connector
●
OK
H
ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR
CVT models M/T models
NBR419
CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.
Repair combination meter. Check the following ● Harness connector
OK
E
Inspection end.
NG H
ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR
YBR186
CHECK ABS MOTOR GROUND. 1. Turn ignition switch OFF. 2. Disconnect ABS actuator and electric unit connector. 3. Check continuity between ABS actuator and electric unit connector E78 (body side) terminal p 31 and ground. Continuity should exist. OK H
REPLACE. Replace ABS actuator and electric unit.
BR-90
NG
E
Check the following ● Harness connector E78
Harness for open or short between ABS actuator and electric unit and fusible link If NG, repair harness ro connector
●
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications Unit: mm (in)
Applied model
QG16DE, QG18DE and CD20T
QG16DE, QG18DE and CD20T
For LHD models (except Wagon)
For RHD models & Wagon models (LHD/RHD)
Without ABS
With ABS (optional for LHD models)
Front brake Brake model
SR20DE CVT models
M/T models
With ABS
CL25VG
CL25VBG
FN3-57/22
disc brake
disc brake
disc brake
Cylinder bore diameter
57.2 (2.252)
Pad length × width × thickness
109 x 50.1 x 11 (94.29 x 1.97 x 0.43)
109 x 50.1 x 11 (4.29 x 1.97 x 0.43)
257 × 22 (10.12 × 0.87)
Rotor outer diameter × thickness Rear brake Brake model Cylinder bore diameter Lining or pad length × width × thickness Drum inner diameter or rotor outer Diameter × thickness
280 × 22 (11.04 × 0.87)
CL9HCG
LT20N
CL9HDG
CL11HEG
disc brake
drum brake
disc brake
disc brake
34.4 (1.354)
17.46 (0.6874)
34.4 (1.354)
38.2 (1.504)
79.8 x 38.5 x 9.3 (3.14 x 1.52 x 0.37)
195 x 35 x 4.5 (7.68 x 1.38 x 0.18)
258 x 10 (10.2 x 0.39)
203.2 (8.00)
Master cylinder Cylinder bore diameter
79.8 x 38.5 x 9.3 (3.14 x 1.52 x 0.37) 278 x 10 (10.9 × 0.39)
258 x 10 (10.2 x 0.39)
23.81 (0.94)
Control valve Valve model
Dual proportioning valve
—
1.96 (0.0196, 0.0200, 0.284) x 0.4
—
2
Split point [kPa (bar, kg/cm , psi)] × reducing ratio
112 x 56.2 x 11 (4.41 x 2.21 x 0.43)
Brake booster Booster model
BJKCE
Diaphragm diameter
Primary: 205 (8.1) Secondary: 180 (7.1)
Specified brake fluid
DOT 4
BR-91
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment DISC BRAKE Unit: mm (in) CL25VG
CL25VBG
FN3-57/22
CL9HCG
CL9HDG
CL11HEG
Pad wear limit Minimum thickness Rotor repair limit Minimum thickness
2.0 (0.079) 20.0
20.0
20.0
9.0
9.0
9.0
(0.787)
(0.787)
(0.787)
(0.354)
(0.354)
(0.354)
Maximum runout
0.07 (0.0028)
Maximum thickness variation
0.02 (0.0008)
DRUM BRAKE Unit: mm (in) Brake model Lining wear limit
LT20N Minimum thickness
1.5 (0.059)
Maximum inner diameter
204.5 (8.051)
Maximum out-of-round
0.03 (0.0012)
Drum repair limit
BRAKE PEDAL Unit: mm (in) Applied model
RHD
LHD
M/T
160 - 170 (6.30 - 6.69)
151 - 161 (5.94 - 6.34)
CVT
169 - 179 (6.65 - 7.05)
160 - 170 (6.30 - 6.69)
M/T
80 - 90 (3.15 - 3.54)
71 - 81 (2.80 - 3.19)
CVT
89 - 99 (3.50 - 3.90)
80 - 91 (3.15 - 3.54)
Free height
Depressed height [under force of 490 N (50 kg, 110 lb) with engine running]
PARKING BRAKE CONTROL Control type
Center lever
Number of notches [under force of 196 N (20 kg, 44 lb)] Number of notches when warning switch comes on
6-8 1
BR-92
STEERING SYSTEM SECTION
ST
CONTENTS PRECAUTIONS AND PREPARATION.......................... 2 Precautions ................................................................ 2 Preparation ................................................................ 2 PREPARATION.............................................................. 3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................... 4 NVH Troubleshooting Chart....................................... 4 ON-VEHICLE INSPECTION .......................................... 5 Checking Steering Wheel Play.................................. 5 Checking Neutral Position on Steering Wheel .......... 5 Front Wheel Turning Angle........................................ 5 Checking Gear Housing Movement .......................... 5 Checking and Adjusting Drive Belts .......................... 6 Checking Fluid Level ................................................. 6 Checking Fluid Leakage ............................................ 6 Bleeding Hydraulic System........................................ 6 Checking Steering Wheel Turning Force .................. 7 Checking Hydraulic System....................................... 8 STEERING WHEEL AND STEERING COLUMN.......... 9 Removal and Installation ......................................... 10 Disassembly and Assembly......................................11 Inspection................................................................. 12
POWER STEERING GEAR AND LINKAGE .............. 14 Removal and Installation ......................................... 14 Disassembly............................................................. 17 Inspection................................................................. 17 Assembly ................................................................. 19
SR20DE POWER STEERING OIL PUMP.................................. 20
CD20T POWER STEERING OIL PUMP.................................. 21
QG16, 18DE POWER STEERING OIL PUMP.................................. 22
SR20DE, CD20T, QG16DE, QG18DE SERVICE DATA AND SPECIFICATIONS (SDS) ........ 23 General Specifications............................................. 23 Inspection and Adjustment ...................................... 23
ST
PRECAUTIONS AND PREPARATION Precautions Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System “Air Bag” and “Seat Belt Pre-tensioner”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. If the vehicle is equipped with side air bag as the Supplemental Restraint System, the side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (which is one of components of air bags for a frontal collision), wiring harness, warning lamp (which is one of components of air bags for a frontal collision). 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 dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to do so in this Service Manual. SRS wiring harnesses are covered with yellow insulation (either just before the harness connectors or for the complete harness), for easy identification.
STEERING SYSTEM ● ● ● ● ● ● ●
Before disassembly, thoroughly clean the outside of the unit. Disassembly should be done in a clean work area. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. When disassembling parts, be sure to place them in order on a part rack so they can be reinstalled in their correct positions. Only use nylon cloths or paper towels to clean parts. Do not use rags or other materials containing lint. Residual debris may damage the system. Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable solvent. Before assembly, apply a coat of recommended ATF* to hydraulic parts. Vaseline may be applied to O-rings and seals. Do not use any grease. Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during installation. Perform functional tests whenever designated. *: Automatic transmission fluid
Preparation SPECIAL SERVICE TOOL Tool number Tool name
Description
ST27180001 Steering wheel puller
Removing and installing steering wheel
NT170
ST-2
PREPARATION SPECIAL SERVICE TOOLS Tool number Tool name
Description
KV48100700 Torque adapter
Measuring pinion rotating torque
HT72520000 Ball joint remover
Removing ball joint
ST27091000 Pressure gauge
Measuring oil pressure
KV48102500 Pressure gauge adapter
Measuring oil pressure
ST3127S000 1 GG91030000 p Torque wrench 2 HT62940000 p Socket adapter 3 HT62900000 p Socket adapter
Measuring turning torque
ST-3
Symptom STEERING ST-18 ST-19 ST-6 ST-5 ST-7
Tie-rod ball joint rotating torque Tie-rod ball joint end play Steering gear fluid leakage Steering wheel play Steering wheel turning force Drive belt looseness
X X X X X X X X
Judder
X: Applicable
ST-4 X
X X X X X
X X X X X X
X X
ST-5 ST-13 ST-11 ST-14
Mounting rubber deterioration Steering column deformation or damage Improper installation or looseness of steering column Steering linkage looseness
NVH in BR section
X
X
BRAKES
X
X
NCH in FA section
X
X
ROAD WHEEL
X
Shimmy
NVH in FA section
Vibration TIRES
X
NVH in FA, RA section
X
AXLE AND SUSPENSION
X
NVH in FA section
Shake DRIVE SHAFT
ST-12
— Improper installation or looseness of tilt lock lever
Improper steering wheel
ST-18
Tie-rod ball joint swinging force
X
Refer to MA section.
ST-6
Noise Air in hydraulic system
Possible cause and SUSPECTED PARTS ST-6
Reference page
Fluid level
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart
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
ON-VEHICLE INSPECTION Checking Steering Wheel Play 1. With wheels in a straight-ahead position, check steering wheel play. Steering wheel play: 35 mm (1.38 in) or less 2. If it is not within specification, check steering gear assembly when front suspension and axle, steering gear assembly and steering column are mounted correctly. .
SST489B
Checking Neutral Position on Steering Wheel Pre-checking ●
●
Make sure that wheel alignment is correct. Wheel alignment: Refer to SDS in FA section Verify that the steering gear is centered before removing the steering wheel.
Checking SST490BA
1. Check that the steering wheel is in the neutral position when driving straight ahead. 2. If it is not in the neutral position, remove the steering wheel and reinstall it correctly. 3. If the neutral position is between two serrated teeth, loosen tie-rod lock nut and move tie-rod in the opposite direction by the same amount on both left and right sides to compensate for error in the neutral position.
Front Wheel Turning Angle 1. Rotate steering wheel all the way right and left; measure turning angle. Turning angle of full turns: Refer to SDS in FA section 2. If it is not within specification, check rack stroke. Rack stroke “S”: Refer to SDS (ST-23) SMA127
Checking Gear Housing Movement
.
SST059B
1. Check the movement of steering gear housing during stationary steering on a dry paved surface. ● Apply a force of 49 N (5 kg, 11 lb) to steering wheel to check the gear housing movement. Turn off ignition key while checking. Movement of gear housing: ±2 mm (±0.08 in) or less 2. If movement exceeds the limit, replace mount insulator after confirming correct installation of gear housing clamps.
ST-5
ON-VEHICLE INSPECTION Checking and Adjusting Drive Belts Refer to section MA for Drive Belt Inspection.
Checking Fluid Level COLD: 0 - 30°C (32 - 86°F)
HOT: 50 - 80°C (122 - 176°F)
Check fluid level. Fluid level should be checked using “HOT” range on dipstick at fluid temperatures of 50 to 80°C (122 to 176°F) or using “COLD” range on dipstick at fluid temperatures of 0 to 30°C (32 to 86°F). CAUTION: ● Do not overfill. ● Recommended fluid is Automatic Transmission Fluid “DEXRONTM” type.
NST031
Checking Fluid Leakage
SST681B
Check the lines for security, leaks, cracks, damage, loose connections, chafing or deterioration. 1. Run engine between idle speed and 1,000 rpm. Make sure temperature of fluid in oil tank rises to 60 to 80°C (140 to 176°F). 2. Turn steering wheel right-to-left several times. 3. Hold steering wheel at each “lock” position for five seconds and carefully check for fluid leakage. CAUTION: Do not hold the steering wheel in a locked position for more than 15 seconds. 4. If fluid leakage at connectors is noticed, loosen flare nut and then retighten. Do not overtighten connector as this can damage O-ring, washer and connector. 5. Check rack boots for accumulation of power steering fluid.
Bleeding Hydraulic System 1. Raise front end of vehicle until wheels are clear of the ground. 2. Add fluid into oil tank to specified level. Then quickly turn steering wheel fully to right and left and lightly touch steering stoppers. Repeat steering wheel operation until fluid level no longer decreases. 3. Start engine. Repeat step 2 above.
ST-6
ON-VEHICLE INSPECTION Bleeding Hydraulic System (Cont’d) Incomplete air bleeding will cause the following to occur. When this happens, bleed air again. a. Generation of air bubbles in reservoir tank b. Generation of clicking noise in oil pump c. Excessive buzzing in oil pump While the vehicle is stationary or while moving the steering wheel slowly, fluid noise may occur in the valve or oil pump. This noise is inherent in this steering system, and it will not affect performance or durability of the system. ●
Checking Steering Wheel Turning Force
SST491B
SST090B
1. Park vehicle on a level, dry surface and set parking brake. 2. Start engine. 3. Bring power steering fluid up to adequate operating temperature. [Make sure temperature of fluid is approximately 60 to 80°C (140 to 176°F).] Tires need to be inflated to normal pressure. 4. Check steering wheel turning force when steering wheel has been turned 360° from neutral position. Steering wheel turning force: 44.1 N (4.5 kg, 9.9 lb) or less
5. If steering wheel turning force is out of specification, check rack sliding force to detect condition of steering gear assembly. a. Disconnect steering column lower joint and knuckle arms from the gear. b. Start and run engine at idle to make sure steering fluid has reached normal operating temperature. c. While pulling tie-rod slowly from the neutral position, make sure rack sliding force is within specification. Rack sliding force: 284 N (29 kg, 64 lb) or less 6. If rack sliding force is not within specification, replace steering gear assembly.
ST-7
ON-VEHICLE INSPECTION Checking Hydraulic System
ST27091000
Highpressure hose Pump
Gear
Tank Direction of oil flow
Low-pressure hose
SST834
Before starting, check belt tension, driving pulley and tire pressure. 1. Set Tool. Open shut-off valve. Then bleed air. (See “Bleeding Hydraulic System”.) 2. Run engine. Make sure temperature of fluid in tank rises to 60 to 80°C (140 to 176°F). WARNING: Warm up engine with shut-off valve fully opened. If engine is started with shut-off valve closed, oil pressure in oil pump will increase to relief pressure, resulting in an abnormal rise in oil temperature. 3. Check pressure with steering wheel fully turned to left and right positions with engine idling at 1,000 rpm. CAUTION: Do not hold the steering wheel in a locked position for more than 15 seconds. Oil pump maximum standard pressure: QG: 7,502 - 8,101 kpa (75 - 81 bar, 76.5 - 82.6 kg/cm2, 1,088 - 1,175 psi) SR: 7,002 - 7,600 kPa (70 - 76 bar, 71.4 - 77.5 kg/cm2, 1,015 - 1,102 psi) CD: 7,690 - 8,493 kpa (77 - 85 bar, 78,5 - 86,6 kg/cm2, 1,116 - 1,231 psi) 4. If oil pressure is below the standard pressure, slowly close shut-off valve and check pressure. ● When pressure reaches above standard pressure, gear is damaged. ● When pressure remains below standard pressure, pump is damaged. CAUTION: Do not close shut-off valve for more than 15 seconds. 5. After checking hydraulic system, remove Tool and add fluid as necessary, then completely bleed air out of system.
ST-8
STEERING WHEEL AND STEERING COLUMN
SEC. 484⋅487⋅488
Spiral cable
Upper column cover
29 - 39 (3.0 - 4.0, 22 - 29)
Horn pad (Including Airbag module)
Steering column assembly
Ignition switch grommet
13 - 18 (1.3 - 1.8, 9 - 13)
Steering wheel
Lower column cover
15 - 19 (1.5 - 1.9, 11 - 14) : N·m (kg-m, ft-lb)
Push-on nut
NST019
CAUTION: ● The rotation of the spiral cable (SRS “Air bag” component part) is limited. If the steering gear must be removed, set the front wheels in the straight-ahead direction. Do not rotate the steering column while the steering gear is removed. ● Remove the steering wheel before removing the steering lower joint to avoid damaging the SRS spiral cable.
ST-9
STEERING WHEEL AND STEERING COLUMN Removal and Installation STEERING WHEEL ●
●
Remove screws from both sides of steering wheel and pull out horn pad. Refer to RS section for Air Bag Module and Spiral Cable Removal. Align spiral cable correctly when installing steering wheel. Refer to RS-section.
NBF004
STEERING COLUMN ●
●
When installing steering column, fingertighten all lower bracket and clamp retaining bolts; then tighten them securely. Do not apply undue stress to steering column. When attaching coupling joint, be sure tightening bolt faces cutout portion.
NST003
●
Align slit of lower joint with projection on dust cover. Insert joint until surface A contacts surface B.
CAUTION: After installing steering column, turn steering wheel to make sure it moves smoothly and that the number of turns from the straight forward position to left and right locks are equal. Be sure that the steering wheel is in a neutral position when driving straight ahead. Steering gear SST491C
ST-10
STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly SEC. 488
Combination switch assembly
Spiral cable assy
Snap ring Washer O-ring
Jacket tube assembly
Boot
24 - 29 (2.4 - 3.0, 17 - 22)
24 - 29 (2.4 - 3.0, 17 - 22) Column shaft assembly : N·m (kg-m, ft-lb) : Do not re-use
Lower joint
NST020
WARNING: Refer to ‘PRECAUTIONS” (on page ST-2) and to RS section for spiral cable servicing information.
● Screws remain captive in switch
Remove
To remove combination switch, remove attaching screws, disconnect harnesses and remove switch.
NST021
ST-11
STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly (Cont’d) ● ●
Ensure that rounded surface of snap ring faces toward bearing when snap ring is installed. Install snap ring on upper shaft with a suitable tool.
SST770A
● Steering lock a. Break self-shear type screws with a drill or other appropriate tool.
SST741A
b. Install self-shear type screws and then cut off self-shear type screw heads.
SST742A
Inspection Tilt mechanism ● After installing steering column, check tilt mechanism operation.
SST582B
ST-12
STEERING WHEEL AND STEERING COLUMN Inspection (Cont’d) When steering wheel does not turn smoothly, check the steering column as follows and replace damaged parts. a. Check column bearings for damage or unevenness. Lubricate with recommended multi-purpose grease or replace steering column as an assembly, if necessary. b. Check jacket tube for deformation or breakage. Replace if necessary. ● When the vehicle is involved in a light collision, check column length “L”. If it is not within specifications, replace steering column as an assembly. Column length “L”: 536.0 - 538.0 mm (21.10 - 21.18 in) ●
SST583B
ST-13
POWER STEERING GEAR AND LINKAGE Removal and Installation SEC. 492
: Do not re-use SST584B
●
Detach tie-rod outer sockets from knuckle arms with Tool.
CAUTION: ● The rotation of the spiral cable (SRS “Air bag” component part) is limited. If the steering gear must be removed, set the front wheels in the straight-ahead direction. Do not rotate the steering column while the steering gear is removed. ● Remove the steering wheel before removing the steering lower joint to avoid damaging the SRS spiral cable.
HT72520000
SFA372
● ●
Remove low and high pressure connectors Remove exhaust front tube.
SST574B
ST-14
1 p
and
2 . p
POWER STEERING GEAR AND LINKAGE Removal and Installation (Cont’d) ●
Remove dust cover from steering lower joint. Remove joint.
●
Remove harness from subframe mounting bracket.
●
Remove gear housing brackets.
●
Support transmission housing with engine jack. Remove center member with engine mounting rear bracket.
SST578B
UST003
SST577B
●
SST579B
●
.
Guide transfer tube over harness mounting bracket. Slide gear to left side of vehicle, lower and remove from right side as illustrated.
SST581B
ST-15
POWER STEERING GEAR AND LINKAGE Removal and Installation (Cont’d) ● ●
●
SST574B
●
●
Install pipe connector. Observe specified tightening torque when tightening highpressure and low-pressure pipe connectors. Excessive tightening can damage threads or damage connector O- ring. The O-ring in low-pressure pipe connector is larger than that in high-pressure connector. Take care to install the correct O-ring. Connector tightening torque: Low-pressure side “p 1 ” 20 - 25 N·m (2.0 - 2.6 kg-m, 14 - 19 ft-lb) High-pressure side “p 2 ” 15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb) Ensure that steering gear is correctly aligned in housing brackets, and that transfer tubes do not foul bulkhead or subframe.
Initially, tighten nut on tie-rod outer socket and knuckle arm to 29 to 39 N·m (3 to 4 kg-m, 22 to 29 ft-lb). Then tighten further to align nut groove with first pin hole so that cotter pin can be installed.
CAUTION: Tightening torque must not exceed 49 N·m (5 kg-m, 36 ft-lb).
SST824A
ST-16
POWER STEERING GEAR AND LINKAGE Removal and Installation (Cont’d) SEC. 492
SST585B
Disassembly Always use soft jaws when clamping steering gear housing in a vise. Handle gear housing carefully, as it is made of aluminum. 1. Remove outer tie-rod. 2. Remove dust boot. .
Jaw protectors
NST022
Inspection Thoroughly clean all parts in cleaning solvent or automatic transmission fluid “DexronTM” type, and blow dry with compressed air, if available.
ST-17
POWER STEERING GEAR AND LINKAGE Inspection (Cont’d) STEERING GEAR ASSEMBLY ● ● ●
Check for smooth operation through a full stroke. Check rack and tie-rod for cracks, deformation or other damage. Check pinion rotating torque. Pinion rotating torque: 0.8 - 1.3 N·m (8 - 13 kg-cm, 6.9 - 11.3 in-lb)
SST587B
●
Check rack sliding force. Rack sliding force: 284 N (29 kg, 64 lb) or less
SST090B
BOOT Check condition of boot. If cracked, replace it.
TIE-ROD OUTER AND INNER SOCKET ●
Check ball joint for swinging force. A Tie-rod outer ball joint: 3.3 - 67 N (0.34 - 6.8 kg, 0.74 - 15.1 lb) B Tie-rod inner ball joint: 0.3 - 24.5 N (0.03 - 2.5 kg, 0.07 - 5.5 lb)
●
Check ball joint for rotating torque. Tie-rod outer ball joint: 0.15 - 2.9 N·m (1.5 - 30 kg-cm, 1.3 - 26.0 in-lb)
Measuring point
SST588B
ST3127S000
SST751A
ST-18
POWER STEERING GEAR AND LINKAGE Inspection (Cont’d) ●
●
Check ball joint for axial end play. Tie-rod outer ball joint: 0 mm (0 in) Tie-rod inner ball joint: 0 mm (0 in) Check condition of dust cover. If cracked excessively, replace it.
SST334B
Assembly 1. Measure rack stroke. Rack stroke “S”: Refer to SDS (ST-23)
NST023
2. Before installing boot, coat the contact surfaces between boot and tie-rod with grease.
SST589B
3. Tighten outer socket lock nut. Tie-rod length “L”: Refer to SDS (ST-24)
SST093B
ST-19
POWER STEERING OIL PUMP
Adjuster bolt
SR20DE
Bracket 49 - 68 (5.0 - 6.9, 37 - 50)
13.4 - 18 (1.4 - 1.8, 10 - 13)
: N·m (kg-m, ft-lb) : Do not re-use NST043
ST-20
POWER STEERING OIL PUMP
Adjuster bolt
CD20T
Bracket
38 - 49 (3.9 - 4.9, 28 - 36)
49 - 68 (5.0 - 6.9, 28 - 36)
: N·m (kg-m, ft-lb) : Do not re-use NST044
ST-21
QG16, 18DE
POWER STEERING OIL PUMP
Align so that white mark on hose aligns with mark on suction port Adjuster bolt
CLIP TO FACE REARWARDS 49 - 68 (5.0 - 6.9, 28 - 36)
Bracket
Switch
Hose
: N·m (kg-m, ft-lb) : Do not re-use NST045
ST-22
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications Applied model 15″ tire Steering model
16″ tire
Power steering
Steering gear type
PR25T
Steering overall gear ratio Turn of steering wheel (Lock to lock)
16.7 2.7
Steering column type
2.6
Tilt / collapsible
Inspection and Adjustment STEERING WHEEL AND COLUMN Applied model
STEERING GEAR
Tilt
Power PR25T Steering gear type
Steering wheel axial play mm (in)
0 (0) Rack stroke “S”
Steering wheel play
35 (1.38) or less
mm (in) Steering column length “L” mm (in)
mm (in)
Pinion rotating torque N·m (kg-cm, in-lb)
536 - 538 (21.10 - 21.18 in)
Rack sliding force N (kg, lb)
L
15” tire
16” tire
68 (2.68)
66 (2.60)
0.8 - 1.3 (8 - 13, 6.9 - 11.3) 284 (29, 64) or less
Steering wheel turning force (Measured at one full turn from neutral) N (kg, lb)
44.1 (4.5, 9.9) or less
Fluid capacity (Approximate) (Imp qt)
0.9 (3/4)
Oil pump relief pressure kPa (bar, kg/cm2, psi)
SR: 7,002 - 7,600, (70 - 76, 71.4 - 77.5, 1,109 - 1,194) QG: 7,502 - 8,101, (75 - 81, 76.5 - 82,6) CD: 7,748 - 8,532 (77.5 - 85.3, 79 - 87, 1,123 - 1,237)
SST583B
NST023
ST-23
SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d) STEERING LINKAGE Power PR25T
Steering gear type Movement of gear housing mm (in)
±2 (±0.08) or less
Tie-rod outer ball joint A
Swinging force at cotter pin hole N (kg, lb)
3.3 - 67 (0.34 - 6.8, 0.74 - 15.1)
Rotating torque N·m (kg-cm, in-lb)
0.15 - 2.4 (1.5 - 30, 1.3 - 26.0)
Axial end play mm (in)
0 (0)
Tie-rod inner ball joint B
Swinging force* N (kg, lb)
0.3 - 24.5 (0.03 - 2.5, 0.07 - 5.5)
Axial end play mm (in)
0 (0)
Tie-rod standard length “L” mm (in)
183.6 (7.23)
*Measuring point
SST588B
SST093B
ST-24
RESTRAINT SYSTEM SECTION
RS
CONTENTS PRECAUTION................................................................ 2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 2 SEAT BELT.................................................................... 3 Front Seat Belt........................................................... 3 Rear Seat Belt (4-door models) ................................ 4 Rear Seat Belt (Wagon and 5-door models)............. 6 SUPPLEMENTAL RESTRAINT SYSTEM (SRS).......... 8 Precautions for SRS ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″ Service............................. 8 Special Service Tools ................................................ 8 Description ............................................................... 10 SRS Component Parts Location ..............................11 Maintenance Items .................................................. 12 Removal and Installation - Diagnosis Sensor Unit, Seat Belt Pre-tensioner and Satellite Sensor...................................................................... 13 Removal - Air Bag Module and Spiral Cable .......... 14 Installation - Air Bag Module and Spiral Cable ....... 16
Removal - Front Passenger’s Air Bag Module........ 17 Installation - Front Passenger’s Air Bag Module..... 18 Removal - Side Air Bag Module .............................. 19 Installation - Side Air Bag Module ........................... 20 Disposal of Air Bag Module and Seat Belt Pretensioner .................................................................. 22 TROUBLE DIAGNOSES - SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ...................................... 28 Trouble Diagnoses Introduction............................... 28 How to Perform Trouble Diagnoses for Quick and Accurate Repair ................................................ 30 Schematic ................................................................ 32 Wiring Diagram - SRS -........................................... 33 SRS-Operation Check ............................................. 37 Trouble Diagnoses with CONSULT-II................. 38 Trouble Diagnoses without CONSULT-II............ 48 Trouble Diagnoses for Air Bag Warning Lamp........ 56 COLLISION DIAGNOSIS............................................. 57
When you read wiring diagrams: ● Read GI section, “HOW TO READ WIRING DIAGRAMS”. ● See EL section, “POWER SUPPLY ROUTING” for power distribution circuit. ● See EL section for NATS information and wiring diagram. When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.
RS
PRECAUTION Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in certain types of collision. The SRS system composition which is available to NISSAN MODEL P11 is as follows (The composition varies according to the destination and optional equipment): ● For a frontal collision The Supplemental Restraint System consists of driver’s air bag module (located in the center of the steering wheel), front passenger’s air bag module (located on the instrument panel on passenger’s side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. ● For a side collision The Supplemental Restraint System consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). 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 dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and SRS wiring harnesses except “SEAT BELT PRE-TENSIONER” connectors can be identified by yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors). CAUTION: ● Before removing the seat belt pre-tensioner assembly, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. ● Do not use electrical test equipment for seat belt pre-tensioner connector. ● After replacing or installing seat belt pre-tensioner assembly, or reconnecting seat belt pre-tensioner connector, check the system function. Refer to “SRS Operation Check” (RS-37) for details. ● Do not 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 any collision, inspect all seat belt assemblies, including retractors and other attached hardwares (i.e., guide rail set).
RS-2
SEAT BELT Front Seat Belt 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p
Slide the seat all the way forward. Remove center pillar lower garnish. Refer to “INTERIOR TRIM” in BT section for details. Disconnect seat belt pre-tensioner subharness connector from the main harness. Remove the cover of the shoulder adjustment. Remove the seat belt from the shoulder adjuster. Remove center pillar upper garnish. Refer to “INTERIOR TRIM” in BT section for details. Remove bolts securing sash guide, then remove sash guide. Remove the seat belt pre-tensioner retractor anchor bolt. Remove the bolt securing seat belt pre-tensioner retractor, then remove seat belt and seat belt pre-tensioner retractor. Remove shoulder adjustment, taking care not to damage plastic garnish. 43 - 55 (4.4 - 5.6, 32 - 41)
Adjuster cover
43 - 55 (4.4 - 5.6, 32 - 41)
.
Washer
5.1 - 6.3 (0.52 - 0.64, 45 - 56) .
5.1 - 6.3 (0.52 - 0.64, 45 - 56)
Bush Washer Washer Anchor bolt
Bush Washer
.
: N·m (kg-m, ft-lb) Washer 43 - 55 (4.4 - 5.6, 32 - 41)
: N·m (kg-m, in-lb) .
Anchor bolt
RS-3
43 - 55 (4.4 - 5.6, 32 - 41)
: Do not re-use NRS054
SEAT BELT Rear Seat Belt (4-door models) MODELS WITH 2-POINT CENTER SEAT BELT 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p
Remove rear seat cushion. Refer to “SEAT” in BT-section for details. Remove each anchor bolt. Remove both sides of the back of the seat. Fold down rear seat. Remove high mounted stop lamp from parcel shelf (where fitted). Remove rear pillar garnish. Remove the parcel shelf. Remove the bolt and screw which secure the rear seat belt retractors.
.
20.6 - 26.5 (2.1 - 2.7, 16 - 19)
Child seat anchorage 43 - 55 (4.4 - 5.6, 32 - 41) 20.6 - 26.5 (2.1 - 2.7, 16 - 19)
2.0 - 3.0 (0.2 - 0.31, 1 - 2) 43 - 55 (4.4 - 5.6, 32 - 41)
.
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) NRS055
RS-4
SEAT BELT Rear Seat Belt (4-door models) (Cont’d) MODELS WITH 3-POINT CENTER SEAT BELT: For outboard seat belts refer to “models with 2 point center seat belt”. 1 Remove rear seat cushion. Refer to “SEAT” in BT section for details. p 2 Remove anchor bolts. p 3 Fold down LH-side backrest. p 4 Remove finisher located behind the armrest (where fitted). p 5 Remove trim on the rearside of the backrest. p 6 Remove finisher. p 7 Remove anchor bolt. p 8 Pull the retractor out of the backrest. p
.
.
20.6 - 26.5 (2.1 - 2.7, 16 - 19)
43 - 55 (4.4 - 5.6, 32 - 41)
Child seat anchorage 43 - 55 (4.4 - 5.6, 32 - 41)
20.6 - 26.5 (2.1 - 2.7, 16 - 19)
B Tightening sequence A: finger tight B: 43 - 55 (4.4 - 5.6, 32 - 41) C: 43 - 55 (4.4 - 5.6, 32 - 41)
43 - 55 (4.4 - 5.6, 32 - 41)
A, C
N·m (kg-m, ft-lb)
RS-5
NRS056
SEAT BELT Rear Seat Belt (Wagon and 5-door models) MODELS WITH 2-POINT CENTER SEAT BELT 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p
Remove rear seat cushion. Refer to “SEAT” in BT-section for details. Remove each anchor bolt. Fold down rear seat back. Remove rear seat back carpet and clips. Remove seat belt retractor escutcheon. Unclip rear seat back lock release button then remove the lock release escutcheon. Remove fabric covering portion of the seat belt retractor. Remove the seat belt retractor cover. Loosen the seat belt retractor anchor bolt, then remove the seat belt retractor. Remove interlock cable end from the seat belt retractor. (If necessary)
MODELS WITH 3-POINT CENTER SEAT BELT The procedure is same as 2-point center seat belt models. 6 should be skipped. When removing 3-point center seatbelt, the procedure p
RS-6
SEAT BELT Rear Seat Belt (Wagon and 5-door models) (Cont’d)
.
.
Child seat anchorage 43 - 55 (4.4 - 5.6, 32 - 41) . 20.6 - 26.5 20.6 - 26.5 (2.1 - 2.7, (2.1 - 2.7, 16 - 19) 16 - 19)
Clip
.
Rear seat back Suitable tool
43 - 55 (4.4 - 5.6, 32 - 41) Clip Seat belt retractor
Seat belt retractor
Pawl
RS-7
Pawl
NRS057
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Precautions for SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” Service ● ●
●
● ●
● ●
Do not use electrical test equipment to check the SRS unless instructed to do in this Service Manual. Before servicing the SRS, turn ignition switch “OFF”, disconnect both battery cables and wait at least 3 minutes. For approximately 3 minutes after the cables are removed, it is still possible for the air bag and seat belt 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 “S” pointing towards the front of the 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 turn steering wheel or column after removal of steering gear. Handle air bag module carefully. Always place driver’s and passenger’s air bag modules with the pad side facing upward and place side air bag module (built-in type) standing with stud bolt side setting bottom. 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.
Special Service Tools Tool number Tool name
Description
KV99106400 Deployment tool
Disposing of air bag module
NT357
KV99105300 Air bag module bracket
Anchoring air bag module
NRS016
HT61961000 and HT62152000 combined *Special torx bit
Use for special bolts [TAMPER RESISTANT TORX (Size T50)] a: 3.5 (0.138) dia. b: 8.5 - 8.6 (0.335 - 0.339) dia. c: approx. 10 (0.39) sq. Unit: mm (in)
NT361
Tamper resistant torx socket
Size: T30
NT757
*: Special tool or commercial equivalent
RS-8
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Special Service Tools (Cont’d) Tool number Tool name
Description
KV99108200 Deployment tool adapter for front seat belt pretensioner
For front seat belt pre-tensioner
NT796 -
KV99108300 Deployment tool adapters for Passenger and built-in type side air bag modules
For passenger airbag module and side airbag
NT744
*: Special tool or commercial equivalent
RS-9
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Description Driver’s air bag module
Seat belt pre-tensioner (Driver’s side)
Satellite sensor (LH) (G sensor for side air bag LH)
Passenger’s air bag module
Seat belt pre-tensioner (passenger’s side)
Diagnosis sensor unit
● ● ● ●
Auxiliary power source (condenser) Drive circuit CPU
Satellite sensor (RH) (G sensor for side air bag RH)
G sensor (for driver’s and passenger’s air bags, seat belt pre-tensioner)
● Safing sensor Side air bag module (LH) (Built-in type)
(for driver’s and passenger’s air bags, seat belt pre-tensioner)
Side air bag module (RH) (Built-in type)
● Safing sensor (for side air bag)
SRS585
The air bag deploys if the diagnosis sensor unit activates while the ignition switch is in “ON” or “START” position. The collision modes for which supplemental restraint systems are activated are different among the SRS systems. For example, the driver’s air bag module and passenger’s 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’s air bag module
q
—
—
Passenger’s air bag module
q
—
—
Seat belt pre-tensioner (Driver’s side)
q
—
—
Seat belt pre-tensioner (Passenger’s side)
q
—
—
Side air bag module (LH)
—
q
—
Side air bag module (RH)
—
—
q
RS-10
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .
Built-in Type Side Air Bag
Front seat back with front side air bag (Built-in type)
Front side air bag is built-in type. The front seat back with built-in type side air bag has the labels as shown on the left figure.
NRS059
SRS Component Parts Location .
Passenger’s air bag module
Side air bag modules (Built-in type)
Driver’s air bag module Spiral cable
.
.
Diagnosis sensor unit
Seat belt pretensioner retractors Satellite sensors
Wiring harness
NRS125
RS-11
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Maintenance Items
SRS797-A
CAUTION: Do not use electrical test equipment to check SRS circuit. 1. Check operation of “AIR BAG” warning lamp. After turning ignition key to “ON” position, the “AIR BAG” warning lamp illuminates. The “AIR BAG” warning lamp will go off after about 7 seconds if no malfunction is detected. If any of the following warning lamp conditions occur, immediately check the air bag system. Refer to “SRS-Operation Check” for details. (RS-37) ● The “AIR BAG” warning lamp does not come on when the ignition switch is turned “ON”. ● The “AIR BAG” warning lamp does not go off about 7 seconds after the ignition switch is turned “ON”. ● The “AIR BAG” warning lamp blinks about 7 seconds after the ignition switch is turned “ON”. 2. Visually check SRS components. (1) Diagnosis sensor unit ● Check diagnosis sensor unit and bracket for dents, cracks or deformities. ● Check connectors for damage, and terminals for deformities. (2) Air bag module and steering wheel ● Remove air bag module from steering wheel, instrument panel or seat back. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. ● Install driver’s air bag module to steering wheel to check fit or alignment with the wheel. ● Check steering wheel for excessive free play. ● Install passenger’s air bag module to instrument panel to check fit or alignment with the instrument panel. ● Install side air bag module to seatback to check fit and alignment with the seat. (3) Spiral cable ● Check spiral cable for dents, cracks, or deformities. ● Check connectors and protective tape for damage. ● Check steering wheel for noise, binding or heavy operation. (4) Main harness, body harness and air bag harness ● Check connectors for poor connections, damage, and terminals for deformities. ● Check harnesses for binding, chafing or cuts. (5) Seat belt pre-tensioner ● Check harness cover and connectors for damage, terminals for deformities, and harness for binding. ● Check belts for damage and anchors for loose mounting. ● Check retractor for smooth operation. ● Perform self-diagnosis for seat belt pre-tensioner using “AIR BAG” warning lamp or CONSULT-II. Refer to “SRS Operation Check” for details. (RS-37) (6) Side airbag (Satellite) sensor ● Check Side airbag (Satellite) sensor (including bracket portion) for dents, cracks or deformities. ● Check connectors for damage, and terminals for deformities.
RS-12
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CAUTION: Replace previously used special bolts, ground bolt and nuts coated with bonding agent and also the anchor bolt with new ones.
Removal and Installation — Diagnosis Sensor Unit, Seat Belt Pre-tensioner and Satellite Sensor CAUTION: ● Before servicing SRS, turn the ignition switch “OFF”, disconnect both battery cables and wait at least 3 minutes. ● The special bolts are coated with bonding agent while the other bolt is for ground. Do not use old bolts after removal; replace with new ones. ● Check diagnosis sensor unit, seat belt pre-tensioner and satellite sensor for proper installation. ● Check diagnosis sensor unit and satellite sensor to ensure they are free of deformities, dents, cracks or rust. If it shows any visible signs of damage, replace them with new ones. ● Check diagnosis sensor unit brackets to ensure they are free of deformities and rust. ● After replacement of diagnosis sensor unit, seat belt pre-tensioner and satellite sensor check SRS function and perform self-diagnosis for SRS. Refer to “SRS Operation Check” for details. (RS-37) ● Do not attempt to disassemble diagosis sensor unit,seat belt pre-tensioner and satellite sensor ● Replace diagnosis sensor unit, seat belt pre-tensioner and satellite sensor if it has been dropped or sustained an impact. ● Do not expose seat belt pre-tensioner to temperatures exceeding 80°C (176°F).
REMOVAL OF DIAGNOSIS SENSOR UNIT
Diagnosis sensor unit .
Forward mark
Ground bolt
Special bolt 15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb)
FRONT
NRS061
.
5.1 - 6.3 N·m (0.52 - 0.64 kg-m, 45 - 56 in-lb) .
.
Connector
Seat belt pre-tensioner
1. Disconnect driver’s, passenger’s- and side air bag module connectors. Also, disconnect seat belt pre-tensioner connector. 2. Remove lower instrument center panel. Refer to “INSTRUMENT PANEL” in BT section. 3. Disconnect diagnosis sensor unit connector. 4. Remove ground bolt and the special bolts by using the TAMPER RESISTANT TORX (Size T50), from diagnosis sensor unit. Then remove the diagnosis sensor unit. NOTE: ● To install, reverse the removal procedure sequence. ● Diagnosis sensor unit must always be installed with their arrow marks “S” pointing towards the front of the vehicle for proper installation.
REMOVAL OF SEAT BELT PRE-TENSIONER For removal of seat belt pre-tensioner, refer to “Front Seat Belt” for details. (RS-3) NOTE: ● To install, reverse the removal procedure sequence.
.
Anchor bolt 43 - 55 N·m (4.4 - 5.6 kg-m, 32 - 41 ft-lb)
NRS062
RS-13
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal and Installation — Diagnosis Sensor Unit, Seat Belt Pre-tensioner and Satellite Sensor (Cont’d) REMOVAL SATELLITE SENSOR Connector .
Ground bolt 2.94 - 4.9 (0.30 - 0.50, 26 - 43)
1. Remove seat belt pre-tensioner. Refer to “Front Seat Belt” for details. (RS-3) 2. Disconnect satellite sensor connector. 3. Remove bolt and nuts from satellite sensor unit. Then remove the satellite sensor. NOTE: ● To install, reverse the removal procedure sequence.
14.5 - 24.5 (1.5 - 2.5, 11 - 18)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)
7 - 13 (0.8 - 1.3, 62 - 115)
NRS126
Removal — Air Bag Module and Spiral Cable SEC. 253⋅484
Special bolt
Audio steering switch (where fitted)
Side lid RH (where fitted)
7.8 - 13.7 N·m (0.8 - 1.4 kg-m, 69 - 121 in-lb)
Side lid RH
29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
Spiral cable
Lower lid Air bag module Combination switch Special bolt Side lid LH
7.8 - 13.7 N·m (0.8 - 1.4 kg-m, 69 - 121 in-lb) NRS123
RS-14
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal — Air Bag Module and Spiral Cable (Cont’d) CAUTION: ● Before servicing SRS, turn the ignition switch “OFF”, disconnect both battery cables and wait for at least 3 minutes. ● Always work from the side of air bag module. 1. Remove lower lid from steering wheel, and disconnect air bag module connector. SBF811E
2. Remove side lids. Using the TAMPER RESISTANT TORX (Size T50), remove left and right special bolts. Air bag module can then be removed.
Special bolt SBF812E
CAUTION: ● Always place air bag module with pad side facing upward. ● Do not attempt to disassemble air bag module. ● The special bolts are coated with bonding agent. Do not use old bolts after removal; replace with new ones. ● Do not insert any foreign objects (screwdriver, etc.) into air bag module connector.
Up
SRS443
● ● Air bag module
●
Replace 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 air bag module.
SBF814E
3. Set steering wheel in the neutral position, with the front wheels straight ahead. 4. Disconnect horn connector and remove nut. 5. Using steering wheel puller, remove steering wheel. Be careful not to over-tighten puller bolt on steering wheel. CAUTION: ● Do not tap or bump the steering wheel. 6. Remove steering column cover. SBF239F
RS-15
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal — Air Bag Module and Spiral Cable (Cont’d) Connector Unlock Lock
7. Disconnect connector and remove the four screws. The spiral cable can then be removed. CAUTION: ● Do not attempt to disassemble spiral cable. ● Do not apply lubricant to the spiral cable.
SRS384
Right end
Installation — Air Bag Module and Spiral Cable 1. Set the front wheels in the straight-ahead position. 2. Make sure that the spiral cable is in the neutral position. The neutral position is detected by turning left (clock wise) about 3.5 revolutions from the right end position. Align the two marks ( ) or make sure the white indicator is visible in the upper part of the indicator window, with the cable pointed down wards.
Indicator not visible
Indicator window
CAUTION: The spiral cable may snap during steering operation if the cable is installed incorrectly. ● 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 up to 3.5 turns from the neutral position to both the right and left.) 3. Connect spiral cable connector and tighten with screws. Install steering column cover. ●
Indicator is visible
Indicator window Neutral position
NRS121
4. Install steering wheel setting spiral cable pin guides, and pull spiral cable through. 5. Connect horn connector and engage spiral cable with pawls in steering wheel. Move other connectors away from steering wheel lower lid opener. 6. Tighten nut. : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
SRS076
Special bolt 7.8 - 13.7 N·m (0.8 - 1.4 kg-m, 57 - 99 ft-lb)
SBF812EA
7. Position the driver’s air bag module and tighten with new special bolts. ● Always service the air bag module from the side. 8. Connect other connectors. 9. Install all lids and steering switch (where fitted). 10. Connect both battery cables. 11. Conduct self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or warning lamp check.) 12. Turn steering wheel to the left end and then to the right end fully to make sure that spiral cable is set in the neutral position.
RS-16
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Installation — Air Bag Module and Spiral Cable (Cont’d) If air bag warning lamp blinks or stays ON (at the user mode), it shows the spiral cable may be snapped due to its improper position. Perform self-diagnosis again (use CONSULT-II or warning lamp). If a malfunction is detected, replace the spiral cable with a new one. 13. Perform self-diagnosis again to check that no malfunction is detected.
Removal — Front Passenger’s Air Bag Module .
Connector
.
NRS009
.
Remove special bolts
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 or under air bag module. 1. Open the glove box lid. 2. Disconnect inflator connector from body harness air bag connector. 3. Remove glove box assembly. Refer to “INSTRUMENT PANEL” in BT section for details. 4. Remove the bolts and special bolts using the TAMPER RESISTANT TORX (Size T50) from front passenger’s air bag module. Take out the air bag module from the instrument panel. ● The air bag module is heavy and should be supported using both hands during removal.
.
NRS010
5.2 - 7.0 N·m (0.53 - 0.71 kg-m, 46 - 61 in-lb)
5.2 - 7.0 N·m (0.53 - 0.71 kg-m, 46 - 61 in-lb)
NRS124
Bolts Nuts
CAUTION: ● Always place air bag module with pad side facing upward. ● Do not attempt to disassemble air bag module. ● The special bolts are coated with bonding agent. Do not use old bolts after removal; replace with new coated bolts. ● Do not insert any foreign objects (screwdriver, etc.) into air bag module connector.
Passenger’s air bag module NRS011
RS-17
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal — Front Passenger’s Air Bag Module (Cont’d) ● ●
Air bag module
● ●
Replace 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 air bag module. After air bag inflates, the front instrument panel assembly should be replaced if damaged.
SBF814E
5.2 - 7.0 N·m (0.53 - 0.71 kg-m, 46 - 61 in-lb)
5.2 - 7.0 N·m (0.53 - 0.71 kg-m, 46 - 61 in-lb) .
Installation — Front Passenger’s Air Bag Module ● Always work from the side of or under air bag module. 1. Install front passenger’s air bag module on steering member. ● Ensure harness is not caught between rear of air bag module and steering member. 2. Install lower instrument panel.
NRS124
15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb)
.
.
NRS014
3. Connect air bag module connector to air bag harness connector. 4. Install glove box. 5. Connect both battery cables. 6. Conduct self-diagnosis to ensure entire SRS operates correctly. (Use CONSULT-II or warning lamp check).
Connector
.
NRS009
RS-18
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal — Side Air Bag Module CAUTION: ● Before servicing SRS, turn the ignition switch “OFF”, disconnect both battery cables and wait at least 3 minutes. 1. Slide the front seat all the way forward. 2. Disconnect side air bag module connector under the seat. (The connector with a different shape is for a side air bag module of Renault make.)
Connector
Connector
NRS064
3. Remove screw securing the front seat convenience hook (where fitted). ● When using a clip removal tool to remove the seat back finisher, take care not to damage the air bag harness. 4. Remove the seat back board.
NRS068
5. Pull up the seat back trim. 6. Remove the bolts securing the inner cloth with seat back frame. Then pull up the inner cloth. 7. Remove the seat back trim. Refer to “Front Seat” in BT section for details.
Inner cloth
6.1 - 7.7 N·m . (0.62 - 0.79 kg-m, 54 - 68 in-lb)
NRS065
.
6.1 - 7.7 N·m (0.62 - 0.79 kg-m, 54 - 68 in-lb)
8. Remove the torx nuts coated with bonding agent from the side air bag module. 9. Remove side air bag connector. Side air bag module can then be removed.
Side air bag module
NRS066
RS-19
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal — Side Air Bag Module (Cont’d) CAUTION: ● Always place the air bag module with the stud bolts side facing down. ● Do not attempt to disassemble air bag module. ● The torx nuts are coated with bonding agent. Do not use old nuts after removal; replace with new coated nuts. ● Do not insert any foreign objects (screwdriver, etc.) into air bag module connector.
UP
SRS483
● ● Air bag module
● ●
Replace 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 air bag module. After air bag inflates, all parts of front seat back (including front seat back frame) should be replaced.
SBF814E
Installation — Side Air Bag Module
.
6.1 - 7.7 N·m (0.62 - 0.79 kg-m, 54 - 68 in-lb)
1. Install side air bag module on seat back frame with new torx nuts coated with bonding agent.
Side air bag module
NRS066
2. Install the seat back trim. Refer to “Front Seat” in BT-section. 3. Secure the inner cloth which covers the side air bag module with bolts.
Inner cloth
.
6.1 - 7.7 N·m (0.62 - 0.79 kg-m, 53.8 - 68.6 ft-lb)
NRS065
4. Install the seat back board with new clips. 5. Install the front seat convenience hook (where fitted) and secure with screw.
NRS081
RS-20
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Installation — Side Air Bag Module (Cont’d) 6. Connect side air bag module connector. 7. Connect both battery cables. 8. Go to “SRS Operation Check”, RS-37 and perform self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or AIR BAG warning lamp).
Connector
Connector
NRS082
RS-21
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner ●
● ● ●
● ● ● ● ● ● ● ●
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 as indicated in “DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER” (RS-27). When deploying the air bag module and seat belt pre-tensioner, always use the Special Service Tool; Deployment tool KV99106400. When deploying the air bag module and seat belt pre-tensioner, stand at least 5 m (16 ft) away from deployment component. When deploying air bag module and seat belt pre-tensioner a fairly loud noise is made, followed by 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. 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. Never apply water to a 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 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.
CHECKING DEPLOYMENT TOOL
Red
Connecting to battery
Black Deployment tool (KV99106400)
SRS019-A
CAUTION: The battery must show voltage of 9.6V 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.
RS-22
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) Deployment tool check
Lamp
Press the deployment tool push button 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.
Push
Air bag deployment tool lamp illumination chart (Battery connected)
SBF266H
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 AND SEAT BELT PRE-TENSIONER (OUTSIDE OF VEHICLE) Unless the vehicle is being scrapped, deploying the air bag module and seat belt pre-tensioner in the vehicle is not recommended. This may cause damage to the vehicle interior. Anchor air bag module and seat belt pre-tensioner in a vise secured to a firm foundation during deployment. Wire
Wire Air bag module bracket [KV99105300]
Deployment of Driver’s Air Bag Module (Outside of vehicle) 1. Using wire, secure air bag module to air bag module bracket [SST: KV99105300] at two places. CAUTION: Use wire of at least 1 mm (0.04 in) diameter. 2. Attach tightly the air bag module bracket [SST: KV99105300] with air bag module in a vise.
SRS233 Wire
Wire
3. Connect deployment tool [SST: KV99106400] to air bag module connector.
Deployment tool [KV99106400] Air bag module connector
Air bag module bracket [KV99105300]
SRS234
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 “air bag connector voltage”, will illuminate and the air bag module will deploy. CAUTION: When deploying the air bag module, stand at least 5 m (16 ft) away from the air bag module.
Air bag module
Deployment tool (KV99106400)
SRS235
RS-23
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) 15 (0.59) 15 (0.59)
Deployment of Passenger’s Air bag Module (outside of vehicle)
8.5 (0.335 dia.)
1. Make an 8.5 mm (0.335 in) diameter hole in air bag module bracket [SST: KV99105300] at the position as shown in the left figure. 2. Attach tightly the air bag module bracket [SST: KV99105300] in a vise.
144 (5.67)
Unit: mm (in)
Air bag module bracket [KV99105300]
NRS084
Air bag bracket [KV99105300]
Bolt M 8 x 25 - 30 mm (0.98 - 1.18 in)
3. Match the two holes in air bag module bracket (held in vise) and passenger’s air bag module and fix them with two bolts [M8 x 25 - 30 mm (0.98 - 1.18 in)]. CAUTION: If a gap exists between passenger’s air bag module and air bag module bracket, use a piece of wood inserted in the gap to stabilize the air bag module.
NRS022
4. Connect deployment tool adapter [SST: KV99108300] to deployment tool [SST: KV99106400] connector and air bag module connector.
Deployment tool adapter Deployment tool [KV99108300] [KV99106400]
.
NRS023
Air bag module
Deployment tool [KV99106400]
SRS020-B
.
6.5 (0.256) dia.
13 (0.51)
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 air bag module, stand at least 5 m (16 ft) away from the air bag module and do not stand on the deploying side.
Deployment of Side Air bag Module (outside of vehicle) 1. Make 6.5 mm (0.256 in) diameter holes in air bag module bracket [SST: KV99105300] at the position as shown on the left figure.
(2.76)
Unit: mm (in)
(3.15)
Air bag module bracket [KV99105300] SRS490
RS-24
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) Front side air bag module UP
Metal portion M6 nut
Air bag module bracket [KV99105300]
SRS491
Deployment tool KV99106400]
Deployment tool adapter [KV99108300]
2. Attach tightly the air bag module bracket [SST: KV99105300] in a vise. 3. 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 metal portion facing down. 4. Connect deployment tool adapter [SST: KV99108300] to deployment tool [SST: KV99106400] connector and connector on air bag module.
SRS492
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 illumminate and the air bag module will deploy. CAUTION: When deploying the air bag module, stand at least 5 m (16 ft) away from the air bag module.
Air bag module
Deployment tool [KV99106400]
SRS020-A
Deployment of seat belt pre-tensioner (outside of vehicle) Firmly place pre-tensioner and webbing in the vise
1. Firmly anchor seat belt pre-tensioner in a vise. CAUTION: Ensure bracket and webbing are place in the vise.
SBF272H
Deployment tool adapter (KV99108200)
2. Connect deployment tool adapter [SST: KV99108200] to deployment tool [SST: KV99106400] connector and seat belt pre-tensioner connector.
Deployment tool (KV99106400)
NRS025
RS-25
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) Deployment tool (KV99106400)
SRS021-A
3. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 4. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 5. 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 seat belt pretensioner, stand at least 5 m (16 ft) away from the seat belt pre-tensioner.
DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE
SBF811E
.
Deployment tool [KV99106400]
SRS006
When disposing of a vehicle, deploy air bag modules and seat belt pre-tensioners while they are mounted in vehicle. CAUTION: When deploying air bag modules or seat belt pre-tensioner, ensure vehicle is empty. 1. Disconnect both the vehicle battery cables and wait 3 minutes. 2. Disconnect air bag modules and seat belt pre-tensioners connector. 3. Connect deployment tool [SST: KV99106400] to air bag module or seat belt pre-tensioner. For front passenger’s air bag module and front side air bag module (built-in type), attach deployment tool adapter [SST: KV99108300] to the tool connector. For seat belt pre-tensioner attach deployment tool adapter [SST: KV99108200]. 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 “air bag connector voltage”, will illuminate and the air bag module or seat belt pre-tensioner will deploy. CAUTION: Activate only one passenger’s air bag module or seat belt pre-tensioner at a time.
RS-26
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
SBF276H
Deployed air bag modules and seat belt pre-tensioners are very hot. Before disposing of air bag module, and seat belt pretensioner, 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 re-used. ● Wash your hands clean after finishing work.
RS-27
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses Introduction CAUTION: ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER CONNECTOR”) can be identified by yellow harness connector (and with yellow harness protector or yellow insulation tape before the 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 reading of these results is accomplished using one of two modes — “User mode” and “Diagnosis mode”. 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
Seat belt pre-tensioner system can only be diagnosed by CONSULT-II.
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 (also indicated by the warning lamp flashes in the Diagnosis mode) 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 (refer to the table below). This number will be displayed on the CONSULT-II screen. 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.
For NISSAN MODEL P11, the diagnosis sensor unit classification numbers are as follows: MODEL
ECU DISCRIMINATED NO.
Models with single air bag and seat belt pre-tensioner
A914
Models with dual air bags and seat belt pre-tensioner
A915
Models with dual air bags, side air bag and seat belt pre-tensioner
A916
RS-28
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses Introduction (Cont’d) 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.
“AIRBAG” warning lamp operation indicates Diagnosis mode.
NRS115
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.
“AIRBAG” warning lamp operation indicates User mode.
NRS116
How to Change Self-diagnosis Mode without CONSULT-II From User Mode to Diagnosis Mode Diagnosis mode activates only when a malfunction is detected, by turning ignition switch as follows: 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 steps 1 to 3 three times. 5) Turn ignition switch “ON”. SRS will not enter Diagnosis mode, if no malfunction is detected.
From Diagnosis Mode to User Mode After a malfunction is repaired, switch the ignition “OFF” for at least one second, then back “ON”. Diagnosis mode is returned to User mode. If switching Diagnosis mode to User mode is required while malfunction is being detected, by turning ignition switch as follows: 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 steps 1 to 3 three times. 5) Turn ignition switch “ON”.
RS-29
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses Introduction (Cont’d) HOW TO ERASE SELF-DIAGNOSIS RESULTS With CONSULT-II ●
“SELF-DAIG [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 pushing “BACK” key of CONSULT-II and select “SELFDIAG [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. ●
C2SDC02
●
“TROUBLE DIAG RECORD” The memory of “TROUBLE DIAG RECORD” cannot be erased. Without CONSULT-II
After a malfunction is repaired, return to User mode from Diagnosis mode by switching the ignition “OFF” for at least 1 second, then back “ON”. Diagnosis mode returns to the User mode. At that time, self-diagnosis result is cleared.
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 ....... WHEN ...... WHERE .... HOW ........
Vehicle model Date, Frequencies Road conditions Operating conditions, Symptoms
PRELIMINARY CHECK Check that the following parts are in good order. ● Battery [Refer to EL section (“BATTERY”).] ● Fuse [Refer to EL section (“Fuse”, “POWER SUPPLY ROUTING”).] ● System component-to-harness connections
RS-30
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont’d)
ACTION ITEM
REFERENCE ITEM
Check in
H
Listen to customer complaints and requests.
H
Perform preliminary check.
F
Preliminary check (RS-30)
F
SRS Operation Check DIAGNOSTIC PROCEDURE 1 (RS-37)
H
Check for any Service Bulletin.
H
Check air bag system operation by using “AIR BAG” warning lamp. — User mode
H E
Inspect malfunctioning part. — Diagnosis mode
F
Perform self-diagnosis using CONSULT-II. ------------------------------------------------------------------------------------------------------------------ OR -----------------------------------------------------------------------------------------------------------------Perform self-diagnosis using “AIR BAG” warning lamp.
● ●
DIAGNOSTIC PROCEDURE 2: Using CONSULT-II (RS-38) DIAGNOSTIC PROCEDURE 6: Using “AIR BAG” warning lamp (RS-48)
H
Repair/Replace
NG
H
Final check — Diagnosis mode and User mode OK
F
● ●
H
Check out
RS-31
DIAGNOSTIC PROCEDURE 3: Using CONSULT-II (RS-42) DIAGNOSTIC PROCEDURE 7: Using “AIR BAG” warning lamp (RS-53)
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Schematic
YRS058
RS-32
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Wiring Diagram — SRS —
YRS059
RS-33
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Wiring Diagram — SRS — (Cont’d)
DIAGNOSIS SENSOR UNIT
SPIRAL CABLE AIR BAG MODULE (PASSENGER’S SIDE)
AIR BAG MODULE (DRIVER’S SIDE)
: With dual air bag
: This connector is not shown in “HARNESS LAYOUT” of EL section.
YRS049
RS-34
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Wiring Diagram — SRS — (Cont’d)
YRS060
RS-35
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Wiring Diagram — SRS — (Cont’d)
YRS061
RS-36
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) SRS-Operation Check DIAGNOSTIC PROCEDURE 1 Checking Air Bag Operation by using “AIR BAG” Warning Lamp — User mode 1. After turning ignition switch from “OFF” to “ON”, “AIR BAG” warning lamp operates. 2. Compare “AIR BAG” warning lamp operation to the chart below. SRS800
“AIR BAG” warning lamp operation — User mode —
SRS condition No malfunction is detected. No further action is necessary.
IGN ON ON OFF
Reference item
— 7 sec.
MRS095A IGN ON ON
The system is malfunctioning and needs to be repaired as indicated.
Go to DIAGNOSTIC PROCEDURE 2, or 6 (RS-38 or 48 ).
Air bag or/and seat belt pre-tensioner is deployed.
Go to COLLISION DIAGNOSIS (RS-57).
Air bag fuse, diagnosis sensor unit or harness is malfuncitoning and needs to be repaired.
Go to DIAGNOSTIC PROCEDURE 9 (RS-56).
One of the following has occurred and needs to be repaired. ● Meter fuse is blown. ● “AIR BAG” warning lamp circuit has open or short. ● Diagnosis sensor unit is malfunctioning.
Go to DIAGNOSTIC PROCEDURE 10 (RS56).
OFF 0.5 sec.
0.5 sec.
MRS096A IGN ON ON OFF
MRS097A IGN ON ON OFF
MRS098A
NOTE: If “AIR BAG” warning lamp operates differently from the operations shown above, refer to “AIR BAG” warning lamp operation — Diagnosis mode —, DIAGNOSTIC PROCEDURE 6 (step 4), RS-48.
RS-37
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II
Data link connector
DIAGNOSTIC PROCEDURE 2 Inspecting SRS malfunctioning parts by using CONSULT-II — Diagnosis mode 1. Turn ignition switch to the “OFF”. 2. Connect “CONSULT-II” to Data link connector.
NRS071
3. Turn ignition switch “ON”. 4. Touch “START”.
SRS695
5. Touch “AIRBAG”.
C2SSE01
6. Touch “SELF-DIAG [CURRENT]”.
C2SDM02
7. Diagnostic codes are displayed on “SELF-DIAG [CURRENT]”.
SRS772
RS-38
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) If no malfunction is detected on “SELF-DIAG [CURRENT]” but malfunction is indicated by the “AIR BAG”, warning lamp, go to DIAGNOSTIC PROCEDURE 4, page RS-43, to diagnose the following situations: ● Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. ● The SRS system malfunctions intermittently.
C2SDC02
8. Touch “PRINT”. 9. Compare diagnostic codes to “CONSULT-II Diagnostic Code Chart”, page RS-39. 10. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM ” appears in order to return to User mode from Diagnosis mode. 11. Turn ignition switch “OFF”, then turn off and disconnect CONSULT-II and both battery cables. 12. Repair the system as outlined by the “Repair order” in “CONSULT-II Diagnostic Code Chart”, that corresponds to the selfdiagnostic result. For replacement procedure of component parts, refer to RS-13. 13. After repairing the system, go to DIAGNOSTIC PROCEDURE 3, page RS-42 for final checking.
CONSULT-II Diagnostic Code Chart (“SELF-DIAGNOSIS”) Diagnostic item NO DTC IS DETECTED.
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. AIRBAG MODULE [OPEN]
Repair order Recheck SRS at each replacement.
Explanation
●
Driver’s air bag module circuit is open. (including the spiral cable)
RS-39
●
Go to DIAGNOSTIC PROCEDURE 3 (RS-42) after charging battery.
Go to DIAGNOSTIC PROCEDURE 4 (RS-43).
●
Go to DIAGNOSTIC PROCEDURE 3 (RS-42).
1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace driver’s air bag module. (Before disposing of it, it must be deployed.) 4. Replace the spiral cable. 5. Replace the diagnosis sensor unit. 6. Replace the related harness.
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Diagnostic item
Explanation
AIRBAG MODULE [VB-SHORT]
●
Driver’s air bag module circuit is shorted to a power supply circuit. (including the spiral cable)
AIRBAG MODULE [GND-SHORT]
●
Driver’s air bag module circuit is shorted to ground. (including the spiral cable)
AIRBAG MODULE [SHORT]
●
Driver’s air bag module circuits are shorted to each other.
ASSIST A/B MODULE [VB/SHORT]
●
Passenger’s air bag module circuit is shorted to some power supply circuit.
ASSIST A/B MODULE [OPEN]
●
Passenger’s air bag module circuit is open.
ASSIST A/B MODULE [GND-SHORT]
●
Passenger’s air bag module circuit is shorted to ground.
ASSIST A/B MODULE [SHORT]
●
Passenger’s air bag module circuits are shorted to each other.
SIDE MODULE LH [OPEN]
●
Side air bag module (LH) circuit is open.
SIDE MODULE LH [VB-SHORT]
●
Side air bag module (LH) circuit is shorted to some power supply circuits.
SIDE MODULE LH [GND-SHORT]
●
Side air bag module (LH) circuit is shorted to ground.
SIDE MODULE LH [SHORT]
●
Side air bag module (LH) circuits are shorted to each other.
SIDE MODULE RH [OPEN]
●
Side air bag module (RH) circuit is open.
SIDE MODULE RH [VB-SHORT]
●
Side air bag module (RH) circuit is shorted to some power supply circuits.
SIDE MODULE RH [GND-SHORT]
●
Side air bag module (RH) circuit is shorted to ground.
SIDE MODULE RH [SHORT]
●
Side air bag module (RH) circuits are shorted to each other.
SATELLITE SENS LH [UNIT FAIL] SATELLITE SENS LH [COMM FAIL]
●
Satellite sensor (LH)
Repair order Recheck SRS at each replacement. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the spriral cable. 4. Replace driver’s air bag module. (Before disposing of it, it must be deployed.) 5. Replace the diagnosis sensor unit. 6. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace passenger’s air bag module. (Before disposal of it, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the side air bag module (LH). (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the side air bag module (RH). (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the satellite sensor (LH). 4. Replace the diagnosis sensor unit. 5. Replace the related harness.
RS-40
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Diagnostic item
Repair order Recheck SRS at each replacement.
Explanation
SATELLITE SENS RH [UNIT FAIL] SATELLITE SENS RH [COMM FAIL]
●
Satellite sensor (RH)
1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the satellite sensor (RH). 4. Replace the diagnosis sensor unit. 5. Replace the related harness.
PRE-TEN LH [OPEN/VB-SHORT]
●
The circuit for LH pre-tensioner is open or shorted to some power supply circuit.
PRE-TEN LH [GND-SHORT]
●
The circuit for LH pre-tensioner is shorted to ground.
1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace LH seat belt. (Before disposing, it must be deactivated.) 4. Replace the diagnosis sensor unit 5. Replace the related harness.
PRE-TEN RH [OPEN/VB-SHORT]
●
The circuit for RH pre-tensioner is open or shorted to some power supply circuit.
PRE-TEN RH [GND-SHORT]
●
The circuit for RH pre-tensioner is shorted to ground.
CONTROL UNIT
●
Low battery voltage or diagnosis sensor unit is out of order.
1. Charge battery. 2. Visually check wiring harness connections. 3. Replace diagnosis sensor unit.
CONTROL UNIT
●
Low battery voltage (Less than 9V)
●
●
Diagnosis sensor unit is malfunctioning.
1. Visually check wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace diagnosis sensor unit. 4. Replace the related harness.
1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace RH seat belt. (Before disposing, it must be deactivated.) 4. Replace the diagnosis sensor unit 5. Replace the related harness.
Go to DIAGNOSTIC PROCEDURE 3 (RS-42) to after charging battery.
* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated using the 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.
RS-41
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Data link connector DIAGNOSTIC PROCEDURE 3 Final checking after repairing SRS by using CONSULT-II — Diagnosis mode 1. After repairing SRS, connect both battery cables. 2. Connect CONSULT-II to Data link connector. 3. Turn ignition switch from “OFF” to “ON”.
NRS071
4. Touch “START”.
SRS695
5. Touch “AIRBAG”.
C2SSE01
6. Touch “SELF-DIAG [CURRENT]”.
C2SDM02
7. If no malfunction is detected on “SELF-DIAG [CURRENT]”, repair of SRS is completed. Go to step 8. If any malfunction is displayed on “SELF-DIAG [CURRENT]”, the malfunctioning part is not repaired completely or another malfunctioning part is detected. Go to DIAGNOSTIC PROCEDURE 2, page RS-38, and repair malfunctioning part completely.
C2SDC02
RS-42
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) 8. Touch “ERASE”. NOTE: Touch “ERASE” to clear the memory of the malfunction (“SELF-DIAG [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. C2SDC01
9. Touch “BACK” key of CONSULT-II to “SELECT SYSTEM” screen. Touch “SELF-DIAG [PAST]”.
C2SDM02
10. Check that no malfunction is detected on “SELF-DIAG [PAST]”.
C2SDP02
11. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears in order to return to User mode from Diagnosis mode. 12. Turn ignition switch “OFF” then turn off and disconnect CONSULT-II. 13. Go to “SRS Operation Check”, page RS-37 to check SRS operation by using “AIR BAG” warning lamp with User mode.
DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) Inspecting SRS malfunctioning record Is it the first time for maintenance of SRS? Yes
H
Go to DIAGNOSTIC PROCEDURE 5 (RS-44).
RS-43
No E
Self-diagnostic results “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. Go to DIAGNOSTIC PROCEDURE 3, step 8 (RS-42).
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Data link connector DIAGNOSTIC PROCEDURE 5 Inspecting SRS intermittent malfunction by using CONSULT-II — Diagnosis mode 1. Turn ignition switch “OFF”. 2. Connect CONSULT-II to Data link connector.
SRS701
3. Turn ignition switch “ON”. 4. Touch “START”.
SRS695
5. Touch “AIR BAG”.
C2SSE01
6. Touch “SELF-DIAG [PAST]”.
C2SDM02
7. If diagnostic codes are displayed on “SELF-DIAG [PAST]”, go to step 10.
C2SDP01
RS-44
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) If no malfunction is detected on “SELF-DIAG [PAST]”, touch “BACK” and go back to “SELECT DIAG MODE”.
C2SDP02
8. Touch “TROUBLE DIAG RECORD”. NOTE: With “TROUBLE DIAG RECORD”, diagnosis results previously erased by a reset operation can be displayed.
C2SDM02
9. Diagnostic code RECORD”.
is
displayed
on
“TROUBLE
DIAG
C2TDR02
10. Touch “PRINT”. 11. Compare diagnostic codes to “Intermittent Malfunction Diagnostic Code Chart”, page RS-46. 12. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears. 13. Turn ignition switch “OFF”, then turn off and disconnect CONSULT-II, and both battery cables. 14. Repair the system as outlined by the “Repair order” in “Intermittent Malfunction Diagnostic Code Chart”, that corresponds to the self-diagnostic result. For replacement procedure of component parts, refer to RS-13. 15. Go to DIAGNOSTIC PROCEDURE 3, page RS-42, for final checking.
RS-45
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Intermittent Malfunction 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).
No malfunction is detected. AIRBAG MODULE [OPEN]
●
Driver’s air bag module circuit is open. (including the spiral cable)
AIRBAG MODULE [VB-SHORT]
●
Driver’s air bag module circuit is shorted to some power supply circuit. (including the spiral cable)
AIRBAG MODULE [GND-SHORT]
●
Driver’s air bag module circuit is shorted to ground. (including the spiral cable)
AIRBAG MODULE [SHORT]
●
Driver’s air bag module circuits are shorted to each other.
ASSIST A/B MODULE [VB/SHORT]
●
Passenger’s air bag module circuit is shorted to some power supply circuit.
ASSIST A/B MODULE [OPEN]
●
Passenger’s air bag module is open.
ASSIST A/B MODULE [GND-SHORT]
●
Passenger’s air bag module circuit is shorted to ground.
ASSIST A/B MODULE [SHORT]
●
Passenger’s air bag module circuits are shorted to each other.
SIDE MODULE LH [OPEN]
●
Side air bag module (LH) circuit is open.
SIDE MODULE LH [VB-SHORT]
●
Side air bag module (LH) circuit is shorted to some power supply circuits.
SIDE MODULE LH [GND-SHORT]
●
Side air bag module (LH) circuit is shorted to ground.
SIDE MODULE LH [SHORT]
●
Side air bag module (LH) circuits are shorted to each other.
SIDE MODULE RH [OPEN]
●
Side air bag module (RH) circuit is open.
SIDE MODULE RH [VB-SHORT]
●
Side air bag module (RH) circuit is shorted to some power supply circuits.
SIDE MODULE RH [GND-SHORT]
●
Side air bag module (RH) circuit is shorted to ground.
SIDE MODULE RH [SHORT]
●
Side air bag module (RH) circuits are shorted to each other.
SATELLITE SENS LH [UNIT FAIL] SATELLITE SENS LH [COMM FAIL]
●
Satellite sensor (LH)
Repair order ●
Go to DIAGNOSTIC PROCEDURE 3 (RS-42) after charging battery.
●
Go to DIAGNOSTIC PROCEDURE 3 (RS-42).
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 driver’s air bag module (Before disposal of it, it must be deployed.), diagnosis sensor unit and spiral cable. 1. Visually check the wiring harness connection. 2. Replace the air bag harness if it has visible damage. 3. If the harness check result is OK, replace front air bag module (Before disposal of it, it must be deployed.), and diagnosis sensor unit. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and side air bag module (LH). (Before disposing the side air bag module (LH), it must be deployed.) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and side air bag module (RH). (Before disposing the side air bag module (RH), it must be deployed.) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and satellite sensor (LH).
RS-46
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Diagnostic item
Explanation
Repair order
SATELLITE SENS RH [UNIT FAIL] SATELLITE SENS RH [COMM FAIL]
●
Satellite sensor (RH)
1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and satellite sensor (RH).
PRE-TEN LH [OPEN/VB-SHORT]
●
The circuit for LH seat belt pre-tensioner is open or shorted to some power supply circuit.
PRE-TEN LH [GND-SHORT]
●
The circuit for LH seat belt pre-tensioner is shorted to ground.
1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and LH seat belt. (Before disposing the LH seat belt pre-tensioner, if must be deployed.)
PRE-TEN RH [OPEN/VB-SHORT]
●
The circuit for RH seat belt pre-tensioner is open or shorted to some power supply circuit.
PRE-TEN RH [GND-SHORT]
●
The circuit for RH seat belt pre-tensioner is shorted to ground.
CONTROL UNIT
●
Diagnosis sensor unit is malfunctioning.
1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and RH seat belt. (Before disposing the RH seat belt pre-tensioner, if must be deployed.) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit.
* Follow the procedures in numerical order when repairing malfunctioning parts, then make the final system check.
RS-47
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II DIAGNOSTIC PROCEDURE 6
SRS800
Inspecting SRS malfunction 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 steps 1 to 3 three times. 5. Turn ignition switch “ON”. SRS is now in Diagnosis mode. 6. “AIR BAG” warning lamp operates in Diagnosis mode as follows: NOTE: If SRS does not enter Diagnosis mode even though malfunction is detected in User mode, check the battery voltage. If the battery voltage is less than 9V, charge the battery. Then go to DIAGNOSTIC PROCEDURE 7, page RS-53. If the battery voltage is OK, replace the diagnosis sensor unit.
RS-48
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) No.
“AIR BAG” warning lamp flash pattern — Diagnosis mode — a p
through
SRS condition b p
are repeated.
IGN ON ON OFF 3 sec.
7 sec.
2 sec.
1
SRS333
a p b p
through p d are repeated. — Driver and passenger’s air bag marker (For identifying driver’s passenger’s air bag and/or front seat belt pre-tensioner malfunctioning) d — Indicates malfunctioning p part. The number of flash varies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.)
IGN ON ON OFF
2
3 sec.
7 sec. 2 sec.
2 sec.
Diagnosis results (previously stored in the memory) might not be erased after repair. ● Intermittent malfunction has been detected in the past. Go to DIAGNOSTIC PROCEDURE 8 (RS-55). ●
The system is malfunctioning and needs to be repaired.
SRS341 a through p f are repeated. p b , c , d — Side air bag p p p
IGN ON ON
marker (For identifying side air bag malfunctioning) pf — Indicates malfunctioning part. The number of flash varies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.)
OFF
3
7 sec.
2 sec. 2sec. 1.5 sec. 1.5 sec. 0.5 sec.
SRS342-A
7. Malfunctioning part is indicated by the number of flashes (part p d or p f ). Compare the number of flashes to “Air Bag Warning Lamp Flash Code Chart”, page RS-50, and locate malfunctioning part. 8. Turn ignition switch “OFF”, and disconnect both battery cables. 9. Repair the system as outlined by the “Repair order” in “Warning Lamp Flash Code Chart” that corresponds to the flash code. For replacement procedure of component parts, refer to RS-13. 10. After repairing the system, go to DIAGNOSTIC PROCEDURE 7, page RS-53.
RS-49
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Air Bag Warning Lamp Flash Code Chart (Diagnosis mode) Flash pattern IGN ON ●
●
Diagnosis results (previously stored in the memory) might not be erased after repair. Intermittent malfunction has been detected in the past.
ON
a p
through p b are repeated.
OFF 3 sec.
7 sec.
2 sec. SRS333
Repair order ●
Go to DIAGNOSTIC PROCEDURE 8 (RS-55). Flash pattern IGN ON a p
through p d are repeated. d — Two flashes p indicated malfunctioning driver’s air bag module circuit.
ON OFF 3 sec.
7 sec.
The driver’s air bag module circuit is malfunctioning. (p d : 2 flashes)
2 sec.
2 sec. SRS334
Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4.
Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the spiral cable. Replace driver’s air bag module. (Before disposal, it must be deployed.) 5. Replace the diagnosis sensor unit. 6. Replace the related harness. Flash pattern IGN ON a p
through p d are repeated. d — Seven p flashes indicate malfunctioning diagnosis sensor unit.
ON OFF 2 sec.
7 sec.
The diagnosis sensor unit is malfunctioning. (p d : 7 flashes)
2 sec.
1.5 sec. SRS335
Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4.
Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the diagnosis sensor unit. Replace the related harness.
RS-50
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Flash pattern IGN ON
a p
through p d are repeated. d — Eight p flashes indicated malfunctioning passenger’s air bag module circuit.
ON OFF
The passenger’s air bag module circuit is malfunctioning. d : 8 flashes) (p
3 sec.
7 sec.
2 sec.
2 sec.
SRS336
Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace passenger’s air bag module. (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern
IGN ON
a p
through p d are repeated. d — One flash p indicates malfunctioning RH seat belt pre-tensioner circuit.
ON OFF 3 sec.
7 sec.
The RH seat belt pre-tensioner circuit is malfunctioning. (p d 1 flash)
2 sec.
2 sec.
SRS801
Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace RH seat belt pre-tensioner. (Before disposing, it must be deactivated.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern IGN ON a p
through p d are repeated. d — Three flash p indicates malfunctioning LH seat belt pre-tensioner circuit.
ON OFF 7 sec.
The LH seat belt pre-tensioner circuit is malfunctioning. (p d 3 flash)
3 sec. 2 sec.
2 sec.
SRS802
Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace LH seat belt pre-tensioner. (Before disposing, it must be deactivated.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness.
RS-51
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Flash pattern IGN ON a p
through p f are repeated. pf — One flash indicates malfunctioning side air bag module (RH) circuit.
ON OFF 2 sec.
7 sec.
The side air bag module (RH) circuit is malfunctioning. (p f : 1 flash)
2 sec. 1.5 sec. 0.5 sec.1.5 sec. SRS338
Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace side air bag module (RH). (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern IGN ON a p
through p f are repeated. pf — Two flashes indicate malfunctioning side air bag module (LH) circuit.
ON OFF 7 sec.
The side air bag module (LH) circuit is malfunctioning. (p f : 2 flashes)
2 sec. 2 sec. 1.5 sec.
1.5 sec. 0.5 sec. SRS337
Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace side air bag module (LH). (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern IGN ON a p
through p f are repeated. pf — Three flashes indicated malfunctioning satellite sensor (RH) circuit.
ON OFF 7 sec.
The satellite sensor (RH) is malfunctioning. (p f : 3 flashes)
2 sec. 2 sec. 1.5 sec.
0.5 sec. 1.5 sec. SRS340
Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4. 5.
Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the satellite sensor (RH). Replace the diagnosis sensor unit. Replace the related harness.
RS-52
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Flash pattern IGN ON a p
through p f are repeated. pf — Four flashes indicate malfunctioning satellite sensor (LH) circuit.
ON OFF 2 sec.
7 sec.
The satellite sensor (LH) is malfunctioning. (p f : 4 flashes)
2 sec. 1.5 sec. 1.5 sec. 0.5 sec. SRS339-A
Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4. 5.
Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the satellite sensor (LH). Replace the diagnosis sensor unit. Replace the related harness.
* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated using the 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.
DIAGNOSTIC PROCEDURE 7 Final checking after repairing SRS by using “AIR BAG” warning lamp — Diagnosis mode and User mode 1. After repairing SRS connect both battery cables. 2. Turn ignition switch from “OFF” to “ON”. 3. “AIR BAG” warning lamp operates in Diagnosis mode as follows:
SRS800
RS-53
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) No.
“AIR BAG” warning lamp flash pattern — Diagnosis mode — a p
through
SRS condition b p
are repeated.
IGN ON ON
1 OFF 3 sec.
7 sec.
2 sec.
No malfunction is detected or repair is completed. No further action is necessary.
SRS333 a p b p
IGN ON ON OFF
2
3 sec.
7 sec. 2 sec.
2 sec.
SRS341
The system is malfunctioning and needs to be repaired.
a through p f are repeated. p b , c , d — Side air bag p p p
IGN ON ON
marker (For identifying side air bag malfunctioning) pf — Indicates malfunctioning part. The number of flashes varies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.)
OFF
3
through p d are repeated. — Driver, passenger’s air bag, seat belt pre-tensioner marker (For identifying driver’s, passenger’s air bag and/or seat belt pre-tensioner malfunctioning) d — Indicates malfunctioning p part. The number of flashes varies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.)
7 sec.
2 sec. 2sec. 1.5 sec. 0.5 sec.1.5 sec.
SRS342-A
NOTE: When diagnosis sensor unit is replaced with a new one, “AIR BAG” warning lamp will operate in User mode. Checking “AIR BAG” warning lamp operation in Diagnosis mode is not required. Go to step 6. 4. If “AIR BAG” warning lamp operates as shown in No. 1 in chart above, turn ignition switch “OFF” to reset from Diagnosis mode to User mode and to erase memory of the malfunction. Then go to step 6. If “AIR BAG” warning lamp operates as shown in No. 2 or No. 3 in chart above, the malfunctioning part is not repaired completely, or another malfunctioning part is detected. Go to DIAGNOSTIC PROCEDURE 6, page RS-48, and repair malfunctioning part completely. 5. Turn ignition switch “ON”. “AIR BAG” warning lamp operates in User mode. Compare “AIR BAG” warning lamp operation to the chart on the next page. NOTE: When a malfunction is detected, switch from Diagnosis mode to user mode by turning the ignition switch as follows: 1) Turn ignition switch “ON”. 2) After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second.
RS-54
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) 3) Wait more than 3 seconds. 4) Repeat steps 1 to 3 three times. 5) Turn ignition switch “ON”. SRS is now in User mode. “AIR BAG” warning lamp operation — User mode —
SRS condition No malfunction is detected. No further action is necessary.
IGN ON ON OFF
Reference item
— 7 sec.
MRS095A IGN ON ON
The system is malfunctioning and needs to be repaired as indicated.
Go to DIAGNOSTIC PROCEDURE 6 (RS-48).
Air bag and/or seat belt pre-tensioner is deployed.
Go to COLLISION DIAGNOSIS (RS-57).
Air bag fuse, diagnosis sensor unit or harness is malfunctioning and needs to be repaired.
Go to DIAGNOSTIC PROCEDURE 9 (RS-56).
One of the following has occurred and needs to be repaired. ● Meter fuse is blown. ● “AIR BAG” warning lamp circuit has open or short. ● Diagnosis sensor unit is malfunctioning.
Go to DIAGNOSTIC PROCEDURE 10 (RS56).
OFF 0.5 sec.
0.5 sec.
MRS096A IGN ON ON OFF
MRS097A
IGN ON ON OFF
MRS098A
DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6) Inspecting SRS malfunctioning record Is it the first time for maintenance of SRS? Yes
H
Go to DIAGNOSTIC PROCEDURE 5 (RS-44). (Further inspection cannot be performed without CONSULT-II).
RS-55
No
E
Diagnosis results (previously stored in the memory) might not be erased after repair. Go to DIAGNOSTIC PROCEDURE 7, step 5 (RS-53).
TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses for Air Bag Warning Lamp
FUSE
DIAGNOSTIC PROCEDURE 9 AIR BAG
SYMPTOM: “AIR BAG” warning lamp does not turn off. Up side
Is air bag module deployed?
Yes E
Replace or repair SRS components. Refer to COLLISION DIAGNOSIS, (RS-57).
E
Replace fuse and turn ignition switch ON. If SRS “Air Bag” fuse is blown again, repair related harness.
E
Visually check the wiring harness connection of diagnosis sensor unit. If the harness connection check is OK, replace diagnosis sensor unit.
E
Connect warning lamp and diagnosis sensor unit properly. If warning lamp still does not go off, replace harness.
No H YRS036
Is SRS “Air Bag” fuse OK?
No
Yes
H
Connect CONSULT-II and touch “START”. ● Is “AIRBAG” displayed on CONSULT-II?
No
Yes H C2SSE01
Is harness connection between warning lamp and diagnosis sensor unit OK?
No
Yes
H
Replace diagnosis sensor unit.
DIAGNOSTIC PROCEDURE 10 FUSE
SYMPTOM: “AIR BAG” warning lamp does not turn on. METER
Is warning lamp fuse OK?
No E
Replace fuse and turn ignition swtich ON. If meter fuse is blown again, repair related harness.
E
Replace warning lamp LED.
E
Connect warning lamp and diagnosis sensor unit properly. If warning lamp still does not come on, replace harness.
Yes Up side
H
Is warning lamp LED OK?
No
Yes YRS038
H
1. Disconnect diagnosis sensor unit connector. 2. Turn the ignition key to ON position. ● Does warning lamp turn on? Yes H
Replace diagnosis sensor unit.
RS-56
No
COLLISION DIAGNOSIS FOR FRONTAL COLLISION To repair the SRS for a frontal collision, perform the following steps. When SRS (except the side airbag) is activated in a collision: 1 Replace the diagnosis sensor unit. p 2 Remove the air bag modules (except the side airbag module) and seat belt pre-tensioner assemblies. p 3 Check the SRS components using the table shown below: p ● Replace any SRS components showing visible signs of damage (dents, cracks, deformation). 4 Install new air bag modules (except the side airbag module) and seat belt pre-tensioner assemblies. p 5 Conduct self-diagnosis using CONSULT-II, and “AIR BAG” warning lamp. Refer to “SRS Operation p Check” for details (RS-37). Ensure entire SRS operates properly. When SRS is not activated in a collision: 1 Check the SRS components using the table shown below: p ● Replace any SRS components showing visible signs of damage (dents, cracks, deformation). 2 p Conduct self-diagnosis using CONSULT-II, and “AIR BAG” warning lamp. Refer to “SRS Operation Check” for details (RS-37). Ensure entire SRS operates properly.
SRS inspection Part
SRS (except the side air bag) is activated
SRS is NOT activated
Air bag module (driver’s and passenger’s side)
REPLACE Install air bag module with new bolts coated with bonding agent.
1. Remove air bag module. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. 2-1. Install driver’s air bag module into the steering wheel to check fit and alignment with the wheel. 2-2. Install passenger’s air bag module into the instrument panel to check fit with the instrument panel. 3. No damage found, reinstall with new bolts coated with bonding agent. 4. If damaged—REPLACE. Install airbag modules with new special bolt coated with bonding agent. Air bag must be deployed before discarding.
Seat belt pre-tensioner assembly
REPLACE Install seat belt pretensioner with new bolts coated with bonding agent.
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. If no damage is found, reinstall with new bolts coated with bonding agent. 5. If damaged—REPLACE. Install the seat belt pre-tensioners with new bolts coated with bonding agent. Seat belt pre-tensioners must be deployed before discarding.
Diagnosis sensor unit
REPLACE Install diagnosis sensor unit with new bolts coated with bonding agent.
1. Check case and bracket for dents, cracks or deformities. 2. Check connectors for damage, and terminals for deformities. 3. If no damage is found, reinstall with new special bolts and ground bolt coated with bonding agent. 4. If damaged—REPLACE. Install diagnosis sensor unit with new bolts and ground bolt coated with bonding agent.
Steering wheel
1. 2. 3. 4. 5. 6.
Visually check steering wheel for deformities. Check harness (built into steering wheel) and connectors for damage, and terminals for deformities. Install driver’s air bag module to check fit or alignment with steering wheel. Check steering wheel for excessive free play. If no damage is found, reinstall the steering wheel. If damaged—REPLACE.
Spiral cable
1. 2. 3. 4. 5.
Visually check spiral cable and combination switch for damage. Check connectors, flat cable and protective tape for damage. Check steering wheel for noise, binding or heavy operation. If no damage is found, reinstall the spiral cable. If damaged—REPLACE.
Harness and Connectors
1. 2. 3. 4.
Check connectors for poor connection, damage, and terminals for deformities. Check harness for binding, chafing, cuts, or deformities. If no damage is found, reinstall harness and connectors. Damaged—REPLACE damaged section of harness. Do not attempt to repair, splice or modify any SRS harness.
Instrument panel
Refer to the table on the next page.
RS-57
COLLISION DIAGNOSIS Part
Instrument panel
SRS (except the side air bag) is activated
SRS is NOT activated
1. When passenger’s air bag inflates, check the following points for bending, deformities or cracks. ● Opening portion for passenger’s air bag
Check points NRS072 ●
Passenger’s air bag module brackets Back face of instrument panel
Check points NRS079 ●
The portions securing the instrument panel
Check points NRS073
2. If no damage is found, reinstall the instrument panel. 3. If damaged—REPLACE the instrument panel with bolts.
RS-58
COLLISION DIAGNOSIS FOR SIDE COLLISION To repair the SRS for a side collision, perform the following steps. When the built-in type front side air bag is activated in the side collision: 1 Replace the following components: p − All parts of front seat back (including front seat back frame) with side air bag modules (on the side on which side air bag is activated) − Diagnosis sensor unit − Satellite sensor (on the side on which side air bag is activated) 2 Check the SRS components and the related parts using the table shown below. p ● Replace the SRS components and the related parts showing visible signs of damage (dents, cracks, deformation). 3 Conduct self-diagnosis using CONSULT-II, or “AIR BAG” warning lamp. Refer to “SRS Operation Check” p for details (RS-37). Ensure entire SRS operates properly. When SRS is not activated in the side collision: 1 Check the SRS components and the related parts using the table shown below. p ● Replace any SRS components and the related parts showing visible signs of damage (dents, cracks, deformation). 2 Conduct self-diagnosis using CONSULT-II, or “AIR BAG” warning lamp. Refer to “SRS Operation Check” p for details (RS-37). Ensure entire SRS operates properly. In the case of the side collision Part
Side air bag is activated
SRS is NOT activated
Built-in type front side air bags module (LH or RH)
REPLACE all parts of seat back with deployed side air bag module.
1. Check for visible sign of damage (dents, tears, deformation) of the seat back on the collision side. 2. If damaged—REPLACE the damaged seat parts with new bolts and remove the side air bag module. 3. Check for visible signs of damage (tears etc.) of the side air bag module. 4. Check harness and connectors for damage, and terminals for deformities. 5. If no damage is found, reinstall the side air bag module with new torx nuts coated with bonding agent. 6. If damaged—REPLACE the side air bag module with new torx nuts coated with bonding agent. Air bag must be deployed before disposing of it.
Satellite sensor (LH or RH)
REPLACE the satellite sensor on the collision side with new nuts. (Repair the center pillar inner, etc. before installing new one if damaged.)
1. Remove the satellite sensor on the collision side. Check harness connectors for damage, terminals for deformities, and harness for binding. 2. Check for visible signs of damage (dents, cracks, deformation) of the satellite sensor. 3. Install the satellite sensor to check fit. 4. If no damage is found, reinstall the satellite sensor with new nuts coated with bonding agent. 5. If damaged—REPLACE the satellite sensor with new nuts coated with bonding agent.
Diagnosis sensor
REPLACE the diagnosis sensor unit with the new bolts.
1. Check case and bracket for dents, cracks or deformities. 2. Check connectors for damage, and terminals for deformities. 3. If no damage is found, reinstall the diagnosis sensor unit with new special bolts and ground bolt coated with bonding agent. 4. If damaged—REPLACE the diagnosis sensor unit with new special bolts and ground bolt coated with bonding agent.
Seat belt pre-tensioner assembly
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 ad connectors for damage, terminals for deformities, and harness for binding. 3. Check for visible signs of damage (dents, cracks, deformation) of the seat belt pre-tensioner assembly. 4. If no damage is found, reinstall the seat belt pre-tensioner assembly with new bolts coated with bonding agent. 5. If damaged—REPLACE the seat belt pre-tensioner assembly with new bolts coated with bonding agent. The seat belt pre-tensioner assembly must be deployed before disposing of it.
RS-59
COLLISION DIAGNOSIS
Part
Side air bag is activated
SRS is NOT activated
Seat with built-in type front side air bag
REPLACE all parts of seat back (including seat back frame)
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 seat), and also adjuster and slides (for front seat) 3. If no damage is found, reinstall the seat. 4. If damaged—REPLACE the damaged seat parts with new bolts.
Center pillar inner
1. Check the center pillar inner on the collision side for damage (dents, cracks, deformation). 2. If damaged—REPAIR the center pillar inner.
Trim
1. Check for visible signs of damage (dents, racks, deformation) of the interior trim on the collision side. 2. If damaged—REPLACE the damaged trim parts.
RS-60
BODY & TRIM SECTION
BT
CONTENTS PRECAUTIONS ............................................................. 2 Service Notice............................................................ 2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 2 GENERAL SERVICING ................................................. 3 Clip and Fastener ...................................................... 3 BODY END .................................................................... 5 Body Front End.......................................................... 5 Body Rear End and Opener...................................... 7 DOOR........................................................................... 13 Front Door................................................................ 13 Rear Door ................................................................ 14 INSTRUMENT PANEL................................................. 15 INTERIOR TRIM .......................................................... 18 Side and Floor Trim ................................................. 18 Door Trim ................................................................. 24 Roof Trim ................................................................. 25 Trunk Room Trim ..................................................... 28 Luggage Room Trim ................................................ 29
Back Door Trim........................................................ 30 EXTERIOR ................................................................... 31 SEAT ............................................................................ 40 Front Seat ................................................................ 40 Heated Seat............................................................. 42 Rear Seat................................................................. 43 SUNROOF.................................................................... 46 Trouble Diagnoses................................................... 49 WINDSHIELD AND WINDOWS .................................. 53 Windshield and Rear Window ................................. 54 Side Window............................................................ 55 Back Door Window .................................................. 56 MIRROR ....................................................................... 58 Door Mirror............................................................... 58 Rearview Mirror ....................................................... 59 BODY ALIGNMENT..................................................... 60 Engine Compartment............................................... 60 Underbody ............................................................... 62
BT
PRECAUTIONS Service Notice ● ● ● ● ●
When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent scratches. Handle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to soil or damage them. Apply sealing compound where necessary when installing parts. When applying sealing compound, be careful that the sealing compound does not protrude from parts. When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust prevention measures.
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System “Air Bag” and “Seat Belt Pre-tensioner”, used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of the Service Manual. If the vehicle is equipped with side air bag as the Supplemental Restraint System, the side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (which is one of components of air bags for a frontal collision), wiring harness, warning lamp (which is one of components of air bags for a frontal collision). 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 dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to do so in this Service Manual. SRS wiring harnesses are covered with yellow insulation (either just before the harness connectors or for the complete harness) for easy identification.
BT-2
GENERAL SERVICING Clip and Fastener ● ●
Clips and fasteners in BT section correspond to the following numbers and symbols. Replace any clips and/or fasteners which are damaged during removal or installation. Symbol No.
Shapes
Removal & Installation Removal: Remove by bending up with flat-bladed screwdrivers or clip remover.
C101
SBF367BA
SBF302H
C103
Removal: Remove with a clip remover.
SBT095
SBF423H
Push
Push center pin to catching position. (Do not remove center pin by hitting it.)
C203 Push
Installation: SBF708E
SBF258G Removal:
Screwdriver C205
Clip Finisher
MBT080A
BT-3
SBF638C
GENERAL SERVICING Clip and Fastener (Cont’d) Symbol No.
Shapes
Removal & Installation Removal: Remove by bending up with a flat-bladed screwdriver or pliers.
CE117
SBF175DA
SBF174D Removal:
Flat-bladed screwdriver
Clip-A
Finisher
CF118 Clip-B (Grommet)
Body panel
Sealing washer
Clip-B (Grommet) Clip-A Sealing washers
SBF151D
SBF259G Removal: Holder portion of clip must be spread out to remove rod
CR103
SBF770B
SBF768B Removal: 1. Screw out with a Phillips screwdriver. 2. Remove female portion with flat-bladed screw-driver.
CS101
SBF078B
BT-4
SBF992G
BODY END Body Front End ● ● ● ● ●
When removing or installing hood, place a cloth or other padding on the front fender panels and cowl top. This prevents vehicle body from being scratched. Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it. Hood adjustment: Adjust at hinge portion. Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood locks engaging mechanism. Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood.
REMOVAL — Front bumper assembly 1 p 2 p 3 p 4 p 5 p 6 p 7 p
Remove clips C205 securing bumper fascia to engine undercover. Remove screws and clips C205 securing left and right sides of front fender protector. Remove screws securing radiator core support to bumper fascia. Remove screws securing left and right front fenders to bumper fascia. Remove clips CS101 securing retainer to bumper fascia. Extract bumper fascia assembly. Remove screws securing fog lamps. Then remove fog lamps.
10.8 - 14.6 N·m (1.1 - 1.5 kg-m, 8.0 - 10.8 ft-lb)
YBT001
BT-5
BODY END Body Front End (Cont’d) SEC. 261⋅620⋅623⋅650⋅656 Hood lock adjustment ● Adjust hood so that hood primary lock meshes at a position 1 to 1.5 mm (0.039 to 0.059 in) lower than fender. ● After hood lock adjustment, adjust bumper rubber. ● When securing hood lock, ensure it does not tilt. Striker must be positioned at the center of hood primary lock. ● After adjustment, ensure that hood primary and secondary lock operate properly. .
Hood adjustment
Hood lock secondary latch hooking length More than 5.0 mm (0.197 in) Hood
Secondary latch Bumper rubber adjustment ● Adjust so that hood is aligned
with fender. At that time deflection is approx. 2 mm (0.08 in). [Bumper rubber free height is approx. 13 mm (0.51 in).]
20.6 - 26.5 (2.1 - 2.7, 15 - 20)
C205
★
CS101
C205 ★
Fog lamp
★ Bumper fascia assembly
★
★ ★
: Bumper assembly mounting bolts, screw & clips : N·m (kg-m, ft-lb) NBT033
BT-6
BODY END Body Rear End and Opener 4-DOOR SEDAN When removing or installing trunk lid, place a cloth or other padding on rear fender panels. This prevents vehicle body from being scratched. ● Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it. ● Trunk lid adjustment: Adjust at hinge-trunk lid portion for proper trunk lid fit. ● Trunk lid lock system adjustment: Adjust striker so that it is in the center of the lock. After adjustment, check trunk lid lock operation. WARNING: ● Be careful not to scratch trunk lid stay when installing trunk lid. A scratched stay may cause gas leakage. ● The contents of the trunk lid stay are under pressure. Do not take apart puncture, apply heat or allow fire near it. ● Opener cable: Do not attempt to bend cable using excessive force. ● After installation, make sure that trunk lid and fuel filler lid open smoothly. ●
5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)
.
.
Actuator
Trunk lid lock key cylinder Trunk lid lock
.
Upper Spring holder
5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)
Opener handle
20.6 - 26.5 (2.1 - 2.7, 15 - 20)
Opener cable Lock nut
Lower
Fuel filler lid opener & control
Trunk lid striker
.
5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4) Cloth
: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) NBT034
BT-7
BODY END Body Rear End and Opener (Cont’d) REMOVAL — Rear bumper assembly 1 p 2 p 3 p 4 p 5 p 6 p
Remove license plate lamp. Remove clips C203 securing left and right chipping protector. Remove screws securing bumper fascia to left and right rear fenders. Remove clips CS101 securing bumper fascia to real panel. Remove clips C205 securing bumper fascia to rear panel upper. Extract bumper fascia assembly.
YBT062
BT-8
BODY END Body Rear End and Opener (Cont’d) 5-DOOR HATCHBACK Back door adjustment: Adjust at hinge-body portion for proper back door fit. Back door lock system adjustment: Adjust lock & striker so that they are in the center. After adjustment, check back door lock operation. WARNING: ● Be careful not to scratch back door stay when installing back door. A scratched stay may cause gas leakage. ● The contents of the back door stay are under pressure. Do not take apart, puncture, apply heat or allow fire near it. ● Opener cable: Do not attempt to bend cable using excessive force. ● After installation, make sure that back door and fuel filler lid open smoothly. ● ●
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
20.6 - 26.5 (2.10 - 2.70, 15.2 - 19.5)
Opener handle
Opener cable Lock nut
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
Fuel filler lid opener & control
.
5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4) Actuator
Key cylinder
Cloth 20.6 - 26.5 (2.10 - 2.70, 15.2 - 19.5) : N·m (kg-m, ft-lb)
REMOVAL — Rear bumper assembly 1 p 2 p 3 p 4 p 5 p 6 p
Remove license plate lamp Remove clips C203 securing left and right chipping protector. Remove screws securing bumper fascia to left and right rear fenders. Remove clips CS101 securing bumper fascia to rear panel. Remove clips C205 securing bumper fascia to rear panel upper. Extract bumper fascia assembly.
BT-9
NBT036
BODY END Body Rear End and Opener (Cont’d)
YBT061
BT-10
BODY END Body Rear End and Opener (Cont’d) WAGON Back door adjustment: Adjust at hinge-body portion for proper back door fit. Back door lock system adjustment: Adjust lock & striker so that they are in the center. After adjustment, check back door lock operation. WARNING: ● Be careful not to scratch back door stay when installing back door. A scratched stay may cause gas leakage. ● The contents of the back door stay are under pressure. Do not take apart, puncture, apply heat or allow fire near it. ● Fuel filler lid opener cable: Do not attempt to bend cable using excessive force. ● After installation, make sure that back door and fuel filler lid open smoothly. ● ●
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
.
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
20.6 - 26.5 (2.10 - 2.70, 15.2 - 19.5)
Opener handle Lock nut
Opener cable
.
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
Fuel filler lid opener & control
.
2.9 - 3.8 N·m (0.30 - 0.39 kg-m, 25.7 - 33.6 in-lb)
.
5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)
Key cylinder
Actuator .
12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)
NBF270
REMOVAL — Rear bumper assembly 1 p 2 p 3 p 4 p 5 p
Remove clips C203 securing left and right chipping protector. Remove screws securing bumper fascia to left and right rear fenders. Remove clips C205 (small) securing bumper fascia to rear panel. Remove clips C205 (large) securing bumper fascia to rear panel upper. Extract bumper fascia assembly.
BT-11
BODY END Body Rear End and Opener (Cont’d) Back door lock control Back door lock adjustment
Back door stay installation
Back door hinge adjustment
Opener handle Fuel filler lid control
Rear fender cover
Back door striker adjustment
Bumper fascia assembly
* : Bumper assembly mounting clips and screws. NBF271
BT-12
DOOR Front Door ● ●
For removal of door trim, refer to “Door Trim” in “INTERIOR TRIM” for details, BT-24. After adjusting door or door lock, check door lock operation. SEC. 800⋅803⋅805
2.93 - 3.82 (0.30 - 0.39, 25.9 - 33.8) Door-hinge adjustment
5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)
5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)
5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)
6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6)
20.6 - 26.5 (2.1 - 2.7, 15 - 20)
6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6) 6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6)
Door-hinge adjustment
6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6)
Striker adjustment 13 - 16 (1.3 - 1.6, 9 - 12)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)
20.6 - 26.5 (2.1 - 2.7, 15 - 20)
: Apply grease
NBT038
BT-13
DOOR Rear Door SEC. 820⋅823⋅825 1.47- 1.86 (0.15 - 0.19, 13.0 - 16.5)
5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4) 6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6) Door-hinge adjustment 20.6 - 26.5 (2.1 - 2.7, 15 - 20)
5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)
5.1 - 6.37 (0.52 -0.65, 45.1 - 56.4)
6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6)
6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6)
Door-hinge adjustment
Striker adjustment
13 - 16 (1.3 - 1.6, 9 - 12)
20.6 - 26.5 (2.1 - 2.7, 15 - 20)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Apply grease
NBT039
BT-14
INSTRUMENT PANEL CAUTION: ● 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.
REMOVAL — Instrument panel assembly Instrument panel assembly
Combination meter
Remove air bag module (driver’s) and steering wheel. Refer to “SUPPLEMENTAL RESTRAINT SYSTEM” in RS section for details.
p1
Steering column cover and combination switch ● Remove screws.
p2
Instrument lower panel on driver side ● Remove screws.
p3
Cluster lid A ● Remove screws.
p4
Combination meter ● Remove screws and disconnect harness connectors.
p5
Audio
p6
Center ventilator ● Remove screws. ● Pull out with a miniature flat-bladed screwdriver.
p7
A/C or heated control ● Remove screws.
p8
Audio bracket
p9
Glove box assembly ● Remove glove box pin. ● Then disconnect passenger air bag module connector.
10 p
11 p
12 p 13 p
14 p
15 p
16 p
17 p
Passenger air bag module ● Refer to “SUPPLEMENTAL RESTRAINT SYSTEM” in RS section for details.
Lower cover ● Remove clip
AT finisher or MT shift lever boot
Rear console box ● Remove console mask and screws.
Front console box ● Remove screws and bolts.
Front defroster grill ● Disconnect harness connector.
Front pillar garnish ● Refer to “Side and Floor Trim” in “INTERIOR TRIM” for details, BT-18.
Instrument panel and pads ● Remove nuts and bolts. ● Remove door mirror switch and disconnect the connector.
BT-15
Audio & A/C control
Console box
INSTRUMENT PANEL SEC. 248⋅251⋅272⋅487⋅680⋅685⋅969
2.8 - 4.8 (0.29 - 0.49, 24.8 - 42.5)
★
★
★ ★
★ 14.7 - 24.5 (1.50 - 2.5, 10.8 - 18.1)
★
Metal clip Metal clip Metal clip
Metal clip Metal clip
: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) ★ : Instrument panel assembly mounting bolts & nuts. NBT040
BT-16
INSTRUMENT PANEL
Hook .
Cloth
.
Pull
Metal clip
Bracket Metal clip
Metal clip
Bolt Metal clip
NBT041
BT-17
INTERIOR TRIM Side and Floor Trim CAUTION: Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnishes.
REMOVAL — Body side trim 4-door sedan 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p 11 p 12 p 13 p
Remove front and rear seats. Refer to “SEAT” for details, BT-40. Remove front and rear kicking plates. Remove dash side lower finishers. Remove front and rear body side welts. Remove front pillar garnishes. Remove center pillar lower garnishes. Remove front seat belt shoulder adjustment anchor bolt covers and anchor bolts (Refer to “SEAT BELTS” in RS section for anchor bolt details). Remove center pillar upper garnishes. Remove rear pillar garnishes. High-mount stop lamp. Remove rear parcel shelf finisher. Remove welt. Remove seatback finisher.
SEC. 678⋅749⋅769⋅799 Metal clip Metal clip Metal clip
Metal clip
Metal clip
Metal clip
X: Metal clips YBT011
BT-18
INTERIOR TRIM Side and Floor Trim (Cont’d)
Metal clip
Metal clip
üüMetal clip
Garnish
Metal clip
Metal clip Metal clip
Metal clip
Metal clip
YBT012
BT-19
INTERIOR TRIM Side and Floor Trim (Cont’d) REMOVAL — Body side trim 5-door hatchback ●
p 2 p 3 p 4 p 5 p 6 p 7 p 1
8 p 9 p 10 p 11 p 12 p 13 p
Remove parcel shelf before removing body side trim. Remove front and rear seats. Refer to “SEAT” for details, BT-40. Remove front and rear kicking plates. Remove dash side lower finishers. Remove front and rear body side welts. Remove front pillar garnishes. Remove center pillar lower garnishes. Remove front seat belt shoulder adjustment anchor bolt covers and anchor bolts (Refer to “SEAT BELTS” in RS section for anchor bolt details). Remove center pillar upper garnishes. Remove rear parcel shelf side finishers. Remove rear pillar finishers. Remove luggage room rear plate. Remove luggage room rear finisher. Remove luggage room side lower finishers.
SEC. 678⋅749⋅769⋅799
Metal clips Metal clip Metal clip Metal clip
Metal clip
Metal clip Metal clip
Metal clip
Metal clip
Metal clip
X : Metal clips NBT042
BT-20
INTERIOR TRIM Side and Floor Trim (Cont’d)
Metal clip
Metal clip Metal clip
Garnish
Metal clip
Metal clip Metal clip
Metal clip Metal clip
Metal clip
Metal clip Metal clip
Metal clip
YBT014
BT-21
INTERIOR TRIM Side and Floor Trim (Cont’d) REMOVAL — Body side trim Wagon ●
p 2 p 3 p 4 p 5 p 6 p 7 p 1
8 p 9 p 10 p 11 p 12 p 13 p
Remove parcel shelf before removing body side trim. Remove front and rear seats. Refer to “SEAT” for details, BT-40. Remove front and rear kicking plates. Remove dash side lower finishers. Remove front and rear body side welts. Remove front pillar garnishes. Remove center pillar lower garnishes. Remove front seat belt shoulder adjustment anchor bolt covers and anchor bolts (Refer to “SEAT BELTS” in RS section for anchor bolt details). Remove center pillar upper garnishes. Remove luggage room side center finisher. Remove luggage room side upper finisher. Remove luggage room rear plate. Remove luggage room rear finisher. Remove luggage room side lower finisher.
Metal clip Metal clips Metal clip
.
Clip Metal clip
Metal clip
Clip Metal clip Guard net hook
Metal clip
: Metal clips NBF273
BT-22
INTERIOR TRIM Side and Floor Trim (Cont’d) Metal clip Metal clip
Metal clip
Garnish
Metal clip
Metal clip Metal clip
12.7 - 15.7 N·m (1.30 - 1.60 kg-m, 9.4 - 11.6 ft-lb)
Metal clip Metal clip
Metal clip
NBF272
BT-23
INTERIOR TRIM Door Trim REMOVAL — Door trim 1 p 2 p 3 p 4 p 5 p
Remove pull handle. Remove power window switch assembly and disconnect the connector (Power window models). Remove window regulator handle (Manual window models). Remove bolts, screws and clips C101 securing door finisher. Lift out door finisher.
SEC. 251⋅267⋅809⋅828
clips
Manual window regulator handle Hook
Removal Push Flat-bladed screwdriver
Metal clip Squeeze the regulator handle clip in place with a screwdriver and remove the regulator handle from the regulator shaft. Set the regulator handle clip as shown in figure p 1 . Installation
Front
Push the regulator handle to install it into the regulator shaft. Install the regulator handle in place as shown in the figure with the window completely closed.
YBT015
BT-24
INTERIOR TRIM Roof Trim REMOVAL — Headlining 4-door sedan 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p 11 p
Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove
front and rear seats. Refer to “SEAT” for details, BT-40. front and rear seat belts. Refer to “SEAT BELTS” in RS section for details. body side trim. Refer to “Side and Floor Trim” for details, BT-18. sunroof switch. (Models equipped with electric sunroof) handle and lamp cover. (Models equipped with manual sunroof) sunroof welt. (Models equipped with sunroof) sun visors. interior lamp assembly. assist grips. clips C103 securing headlining. headlining.
SEC. 264⋅738⋅963⋅964
C103 Manual type
NBT043
BT-25
INTERIOR TRIM Roof Trim (Cont’d) REMOVAL — Headlining 5-door hatchback 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p 11 p
Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove
front and rear seats. Refer to “SEAT” for details, BT-40. front and rear seat belts. Refer to “SEAT BELTS” in RS section for details. body side trim. Refer to “Side and Floor Trim” for details, BT-20. sunroof switch. (Models equipped with electric sunroof) handle and lamp cover. (Models equipped with manual sunroof) sunroof welt. (Models equipped with sunroof) sun visors. interior lamp assembly. assist grips. roof rear garnish. headlining.
SEC. 264⋅738⋅963⋅964
Manual type Metal clip
Metal clip
NBT044
BT-26
INTERIOR TRIM Roof Trim (Cont’d) REMOVAL — Headlining Wagon 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p 11 p 12 p 13 p 14 p
Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove
front and rear seats. Refer to “SEAT” for details, BT-40. front and rear seat belts. Refer to “SEAT BELTS” in RS section for details. body side trim. Refer to “Side and Floor Trim” for details, BT-22. sunroof switch. (Models equipped with electric sunroof) handle and lamp cover. (Models equipped with manual sunroof) sunroof welt. (Models equipped with sunroof) sun visors. interior lamp (center) and interior lamp (rear). assist grips. clips C103 . luggage net escutcheons. roof rear garnish. speakers. headlining.
9 p
C103
Manual type Metal clip
Metal clip
NBT045
BT-27
INTERIOR TRIM Trunk Room Trim SEC. 849
Metal clip
Front
Metal clip
YBT018
BT-28
INTERIOR TRIM Luggage Room Trim
NBF275
BT-29
INTERIOR TRIM Back Door Trim REMOVAL — Back door trim 1 p 2 p 3 p 4 p
Remove Remove Remove Remove
back door lower finisher. back door upper finisher. back door side finisher. high-mounted stop lamp.
Metal clip
Metal clip
Metal clip 2.9 - 3.8 N·m (0.30 - 0.39 kg-m, 26.0 - 33.9 in-lb)
Metal clip
Metal clip
Metal clip
Metal clip
NBT054
BT-30
EXTERIOR
NBT051
BT-31
EXTERIOR
NBT052
BT-32
EXTERIOR 1 p 2 p
6 p
Hood front sealing rubber
Windshield upper molding
SEC. 720
SEC. 650 Hood front sealing rubber
Radiator core support sealing rubber
1. Cut off sealant at glass end. 2. Clean the side on which panel was mounted. 3. Set molding fastener and apply primer to body panel, and apply sealant to body.
Molding Clip
YBT020
3 p 4 p
Fastener
Cowl top seal and cowl top grille Glass
SEC. 660
Double-faced adhesive tape
Cowl top seal
Apply primer
Dam rubber
Apply sealant Sealant
4. Install molding by aligning the molding mark located on center with vehicle center. Be sure to install tightly so that there is no gap around the corner. Cowl top grille
SBF342H
7 p
YBT021
5 p
Drip weatherstrip
Windshield side molding
Mounted with screws.
Drip weatherstrip
Front pillar
Drip weatherstrip
Body panel
Upper
Front
SEC. 720
Screw Windshield side molding YBT022
NBT058
BT-33
EXTERIOR 8 p
10 p
Body side welt
Door outside molding
Front door SEC. 800
Screw
Door outer molding Clip Door outer panel
Rear door SEC. 820
Outside SBT043
9 p
Screw
Door weatherstrip
Door outer molding
EC. 800⋅820 Clip
Clip
Clip
Door panel
11 p
SBT067
Sunroof lid weatherstrip
SEC. 736 Roof panel Clip
Clip
Glass lid
YBT024
Sunroof lid weatherstrip Sunroof rail assembly Front YBT025
BT-34
EXTERIOR 12 p
14 p
Side guard molding
Rear window lower molding
SEC. 766 Rear window glass
Rear window lower molding
Locating pins
Removal: Remove molding by cutting around its perimeter. Installation: Refer to “Rear window”. YBT027
15 p
Trunk lid weatherstrip
SEC. 843 Marking at vehicle center : Double-faced adhesive tape Vehicle center
Heat gun YBT026
●
p 13
With a vehicle coated with Hard Clear Coat, use double-faced 3M adhesive tape Product No. 5572 or equivalent, after priming with 3M primer Product No. N-200 or C-100 or equivalent.
Bonding portion
16 p
SBT069
Back door window molding
5-door hatchback Back door molding
Back door molding
Rear window upper molding
Basically the same as windshield upper molding. Refer to p 6 Windshield upper molding.
Glass
Glass Double side adhesive tape Back door molding
300 (11.81)
60 (2.36)
Glass Back door molding
Back door molding Unit: mm (in) Glass YBT050
Wagon See “Back door window”. Refer to BT-57.
BT-35
EXTERIOR 17 p
Back door weatherstrip
Wagon
Vehicle center
Bonding point
NBF278
5-door hatchback
Vehicle center
Bonding portion YBT056
BT-36
EXTERIOR 18 p ● ●
Rear combination lamp Rear combination lamps are installed with nuts and butyl sealant. When removing inside rear combination lamp (installed on back door), first remove “Back door finisher”. Refer to p 22 Back door finisher.
SEC. 265 Heat gun Heat gun
Heat gun
Butyl seal
Heat gun ● Apply butyl seal evenly as it tends to become thin in
the corners. ● Warm up lamp assembly area to a temperature of a
Butyl seal
little below 60°C (140°F). NBT056
19 p
Center mud guard
SEC. 767
CF118
C205
Double-faced adhesive tape
NBT046
BT-37
EXTERIOR 20 p
Front hood grille
Hook Hook
Hook
NBT047
21 p
Roof rail
Roof rail 5.1 - 6.4 N·m (0.52 - 0.65 kg-m, 45.1 - 56.6 in-lb)
Clip
Pawl Hook
Front
Center
Clip Hook
Rear NBF280
BT-38
EXTERIOR 22 p
Back door finisher
Nut x 8
NBF279
BT-39
SEAT When removing or installing seats with side air bag module, be sure to disconnect or connect side air bag sub harness connector. ● When removing or installing the seat trim, handle it carefully to keep dirt out and avoid damage. ★ For Wiring Diagram, refer to “POWER SEAT” in EL section. ●
Front Seat Manual seat
18 - 24 (1.9 - 2.4, 14 - 17)
18 - 24 (1.9 - 2.4, 14 - 17)
Side airbag sub harness connector
21 - 26 (2.1 - 2.7, 15.5 - 19.2)
18 - 24 (1.9 - 2.4, 14 - 17)
: N·m (kg-m, ft-lb)
BT-40
NBT048
SEAT Front Seat (Cont’d) Power Seat
18 - 24 (1.9 - 2.4, 14 - 17)
21 - 26 (2.1 - 2.7, 15.5 - 19.2)
Side airbag sub harness connector
18 - 24 (1.9 - 2.4, 14 - 17)
18 - 24 (1.9 - 2.4, 14 - 17) : N·m (kg-m, ft-lb) NBF266
BT-41
SEAT Heated Seat ● ● ●
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, gasoline, etc. to clean trims.
Seatback heating unit removal & installation Seatback trim
Heating unit
Thermostat
Trim temperature °C (°F)
Increasing to 35 - 45 (95 - 113)
Decreasing to 15 - 25 (59 - 77)
Thermostat operation
OFF
ON
Seat cushion trim SBF424H
★ For Wiring Diagram, refer to “HEATED SEAT” in EL section.
BT-42
SEAT ●
When removing or installing the seat trim, carefully handle it to keep dirt out and avoid damage.
Rear Seat
Rear seat back hinge (center) & hook
Rear seat back striker (RH)
Rear seat back hinge (LH)
Rear seat hook
.
43.1 - 54.9 (4.4 - 5.6, 31.8 - 40.5)
20.6 - 26.5 (2.1 - 2.7, 15.2 - 19.5)
12.7 - 15.7 (1.3 - 1.6, 9.4 - 11.6)
.
23.0 - 28.0 (2.4 - 2.9, 16.9 - 20.6)
Rear seat back hinge (center)
Suitable tool
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb) NBF285
BT-43
SEAT Rear Seat (Cont’d) Type 1 SEC. 880
Rear seat hinge
12.7 - 15.7 (1.3 - 1.6, 9.4 - 11.6) Rear seat hook : N·m (kg-m, ft-lb) YBT054
BT-44
SEAT Rear Seat (Cont’d) Type 2 SEC. 880
Rear seat back striker (LH) Rear seat back striker (RH)
Rear seat side back hinge
Rear seat back hinge
Rear seat hinge
Rear seat hook
12.7 - 15.7 (1.3 - 1.6, 9.4 - 11.6)
12.7 - 15.7 (1.3 - 1.6, 9.4 - 11.6)
5.1 - 6.47 (0.52 - 0.66, 45.1 - 57.3)
43.1 - 54.8 (4.4 - 5.5, 32 - 40)
Tightening sequence A: Finger B tight B: 43.1 - 54.8 (4.4 - 5.5, 32 - 40) C: 43.1 - 54.8 (4.4 - 5.5, 32 - 40)
43.1 - 54.8 (4.4 - 5.5, 32 - 40)
A, C
.
12.7 - 15.7 (1.3 - 1.6, 9.4 - 11.6)
: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)
NBT057
BT-45
SUNROOF ADJUSTMENT Install motor & limit SW assembly and sunroof rail assembly in the following sequence: 1. 2. 3. 4. 5. 6. 7. 8. 9.
Arrange equal lengths of link and wire assemblies on both sides of sunroof opening. Connect sunroof connector to sunroof switch and positive (+) power supply. Set lid assembly to fully closed position by operating open/tilt sunroof switch. Fit outer side of lid assembly to the surface of roof on body outer panel. Remove motor, and keep sunroof switch pressed to rear side until motor pinion gear reaches the end of its rotating range. Install motor. Check that motor drive gear fits properly in wires. Press front side of sunroof switch to check lid assembly for normal tilting. Check sunroof lid assembly for normal operations (tilt-up, tilt-down, open, and close). Front
Rear Lid assembly
Tilting up & down range
Outer body panel Closing & opening range
Closing & opening range SBF920F
BT-46
SUNROOF REMOVAL After any adjustment, check sunroof operation and lid alignment. Handle finisher plate and glass lid with care so not to cause damage. ● It is desirable for easy installation to mark each point before removal. CAUTION: Always work with a helper. ● ●
Link and wire assembly
Sunroof frame assembly
Shade assembly
Tilt glass lid up. 1 p
Sunroof lid mount screws
2 p
Lid assembly
3 p
Rear drain mount screws
4 p
Rear drain assembly
Operate sunroof switch to tilt glass lid down. 5 p
Shade assembly
Sunroof switch/interior accessories/headlining (Models equipped with sunroof) ● Refer to “Roof Trim” in “INTERIOR TRIM” for details, BT-25, BT-26, BT-27. 6 p
Motor switch bracket
7 p
Motor assembly
8 p
Wind deflector mount nuts
9 p
Wind deflector mount screws
10 p
Wind deflector assembly
11 p
Drain hoses
12 p
Sunroof unit bracket
13 p
Sunroof frame assembly
14 p
Guide stopper
15 p
Link and wire assembly
BT-47
Lid assembly
Motor assembly
SUNROOF ★ For Wiring Diagram, refer to “ELECTRIC SUNROOF” in EL section. SEC. 736 Screw
Lid assembly
Guide stopper
Rear drain screw
Rear drain assembly Shade assembly
Link and wire assembly
Guide stopper Wind deflector mounting screws Wind deflector assembly
Wind deflector mounting nuts
Sunroof frame assembly
Drain hose
5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.4)
Motor assembly Sunroof unit bracket Motor switch bracket
Manual type
5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.4)
Drive Handle
: N·m (kg-m, in-lb) : Apply grease NBT049
BT-48
SUNROOF Using flat-bladed screwdriver, pry shade assembly holder off rail. Then pull shade assembly forward to remove it from rail.
Holder
Front Shade holder
Shade ASSY
Rail
YBT060
Trouble Diagnoses DIAGNOSTIC TABLE NOTE: For diagnosing electric problem, refer to “ELECTRIC SUNROOF” in EL section. Check item (Components) Wind deflector
Adjustment
Drain hoses
Weatherstrip
Link and wire assembly
Reference page
BT-49
BT-50
BT-51
BT-51
BT-52
Excessive wind noise
1
2
3
Water leaks
1
2
3
Sunroof rattles
1
4
2
3
Excessive operation noise
1
2
3
Symptom
The numbers in this table mean checking order.
WIND DEFLECTOR Roof panel
1. Open lid 2. Check visually for proper installation. 3. Check to ensure a proper amount of petroleum jelly has been applied to wind deflector connection points; apply if necessary.
Wind reflector arm Wind reflector SBT331
Roof panel
4. Check that wind deflector is properly retracted by hand. If it is not, remove and visually check condition. (Refer to removal procedures, BT-47). If wind deflector is damage, replace with new one. If wind deflector is not damage, re-install properly.
Wind reflector arm Wind reflector
SBT332
BT-49
SUNROOF Trouble Diagnoses (Cont’d) ADJUSTMENT If any gap or height differences between lid and roof is found, check lid and adjust as follows: SEC. 736
5.4 - 6.3 (0.213 - 0.248) Roof panel
0.7 ± 0.028 ± 0.039
Lid
33.1 ± 5 (1.303 ± 0.197) Roof panel
12+1.2 -2.0 (0.47+0.047 -0.079 )
Lid
Unit: mm (in)
SBT381
Gap Adjustment 1. Remove shade assembly. (Refer to removal procedures BT-47, for details). 2. Tilt lid up. 3. Loosen lid securing nuts (3 each on left and right sides), then tilt lid down. 4. Adjust lid from outside of vehicle so it resembles “A-A” as shown in the figure above. 5. Tilt lid up and down until it is adjusted to “B-B” as shown in the figure above. 6. After adjusting lid, tilt lid up and tighten nuts. 7. Tilt lid up and down several times to check that it moves smoothly.
Height difference adjustment 1. Tilt lid up and down. 2. Check height difference between roof panel and lid to see if it is as “A-A” as shown in the figure above. 3. If necessary, adjust it by using one of following procedures: ● Adjust by adding or removing adjustments shim(s) between lid and link assembly. ● If lid protrudes above roof panel, add shim(s) or plain washer(s) at sunroof mounting bracket or stud bolt locations to adjust sunroof installation as required.
BT-50
SUNROOF Trouble Diagnoses (Cont’d) DRAIN HOSES
Drain hose
SBT335
1. Remove headlining to access drain hose connections. (Refer to “REMOVAL — Headlining” in “INTERIOR TRIM”, BT-25, BT-26, BT-27 for detail). 2. Check visually for proper connections, damage or deterioration. (The figure shows only the front side.) Sunroof frame assembly
Drain hose SBT333
.
3. If leakage occur around trunk room, remove trunk room side trim and check connecting area. Check for proper connection, damage or tear. 4. Pour water into drain hoses and find damaged portion. ● If any damaged portion is found at each step, replace the damaged part.
Sunroof drain hose Front
Grommet
Rear wheel house inner LH
Rear fender inner LH SBT334
WEATHERSTRIP In the case of leakage around lid, close lid and pour water over lid to find damaged or gap portion. 1. Remove lid assembly. (Refer to removal procedures, BT-47, for details). 2. Visually check weatherstrip for proper installation. If a gap exists between lid and weatherstrip, check for sufficient amount of butyl seal. If required, remove weatherstrip and apply butyl seal. Refer to “EXTERIOR” BT-31 for details. ●
BT-51
SUNROOF Trouble Diagnoses (Cont’d) 3. Check weatherstrip visually for damage, deterioration, or flattening. ● If any damage is found, replace weatherstrip. CAUTION: Do not remove weatherstrip except when replacing, or filling up butyl seal.
LINK AND WIRE ASSEMBLY Before replacing a suspect part, carefully ensure it is the source of noise being experienced. 1. Check link to determine if coating film has been peeled of to such an extent that substrate is visible. Check also to determine if link is the source of noise. If it is, replace it. 2. Visually check to determine if a sufficient amount of petroleum jelly has been applied to wire or rail groove. If not, add petroleum jelly as required. 3. Check wire for any damage or deterioration. If any damage is found, remove rear guide (refer to removal procedures, BT-47 for details), then replace wire.
BT-52
WINDSHIELD AND WINDOWS REMOVAL
Cutting sealant
After removing moldings, remove glass using piano wire or power cutting tool and inflatable pump bag. WARNING: ● Be careful not to scratch the glass when removing. ● Do not set or stand the glass on its edges. Small chips may develop into cracks.
Glass
SBF034B
INSTALLATION Use a genuine Nissan Urethane Adhesive Kit 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 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 urethane adhesive has completed cured (preferably 24 hours). Curing time varies with temperature and humidity. WARNING: ● Keep heat and open flames away as primers and adhesive are flameable. ● The materials contained in the kit are harmful if swallowed, and may irritate 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 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 and 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 times varies depending on temperature and humidities. The curing time will increase under higher temperatures lower humidities. ●
Windshield glass
Interior auto glass cut-out knife kit
Windshield glass
SBT472 Inflatable pump bag
SBT473
BT-53
WINDSHIELD AND WINDOWS Windshield and Rear Window Glass side
Body side Windshield Install spacer to panel
Install dam rubber. Windshield and rear window
Cowl top Glass
8 (0.31)
8 (0.31)
8 (0.31)
Spacer
joint portion
455.4 mm (17.93 in)
Apply sealant evenly 12 - 15 (0.47 - 0.59)
YBT033
Install molding fastener. When installing it, heat body panel and fastener to approx. 30 to 40°C (86 to 104°F). Windshield
Vehicle center
Upper & side molding fasteners Fastener
Unit: mm (in)
Rear window
7 - 8 (0.28 - 0.31) Dam rubber
Glass
YBT034
Panel
Double-faced adhesive tape SBF017A
REPAIRING WATER LEAKS FOR WINDSHIELD Leaks can be repaired without removing and reinstalling glass. If water is leaking between caulking material and body or glass, determine the extent of leakage. This can be determined by applying water while pushing glass outward. To stop the leak, apply primer (if necessary) and then sealant to the leak point.
BT-54
WINDSHIELD AND WINDOWS Side Window Primer portion Glass side
Body side
.
Window glass A
A A
A
B B
B Primer portion
B
Primer portion
B-B
A-A
Primer portion
Primer portion Primer portion B-B
A-A Primer portion
Glass
Glass
NBF283
Sealing portion and installation
Clip (bonded on glass)
C-C
Glass
D D Clip (bonded on glass)
Glass
A
D-D
A
More than 7 (0.28) More than 8 (0.32)
More than 8 (0.32)
More than 7 (0.28)
B B
Glass Glass
Molding Apply sealant evenly
BT-55
Unit: mm (in) NBF281
WINDSHIELD AND WINDOWS Back Door Window Construction and removal/reinstallation method of back door window are basically the same as those of windshield. 5-door hatchback ● For details of moldings, refer to “EXTERIOR”, BT-31. ●
Dam rubber portion (Glass side)
Primer portion (Glass side)
Primer Back door molding
Back door molding
Back door molding Primer
Dam rubber
Back door molding
Primer
Sealant portion (Body side)
400 (15.75)
28 (1.10) 41 (1.61) 33 (1.30)
Primer 33 (1.30) Primer portion (Body side)
18.4 (0.724)
41.2 (1.622)
Primer
33 (1.30) 30 (1.18)
8.75 (0.3445) Sealant quantity Primer
12 - 15 (0.47 - 0.59) 7-8 (0.28 - 0.31)
Unit: mm (in)
YBT035
BT-56
WINDSHIELD AND WINDOWS Back Door Window (Cont’d) Wagon
4.5 (0.2)
2 (0.1)
7 (0.28)
Sealant 12 (0.47) Back door molding Glass Glass side Glass
Body side 16 (0.6)
17 (0.7)
Pin Back door molding
.
Glass A-A
Primer portion
B-B
C-C
Primer portion
Unit: mm (in) NBT055
BT-57
MIRROR Door Mirror CAUTION: Be careful not to scratch door rearview mirror body. ★ For Wiring Diagram, refer to “POWER DOOR MIRROR” in EL section.
REMOVAL — Door mirror 1 p 2 p 3 p 4 p
Remove door trim. Refer to “Door Trim” for details, BT-24. Remove inner cover from front corner of door. Disconnect door mirror harness connector. Remove bolts securing door mirror, then remove door mirror assembly.
SEC. 963
Pawl
Removal: ● Wrap flat-blade of screwdriver with a cloth to prevent scratching. Do not insert too far. Push mirror away from car to release.
Mirror
Inside Cloth
Outside
Flat-bladed screwdriver
YBT036
BT-58
MIRROR Rearview Mirror REMOVAL Remove rearview mirror by pushing deflect spring with screwdriver as shown in the figure.
Windshield
Mirror assembly
Mounting bracket Windshield
Mirror assembly
Mounting bracket
Side view
Mounting bracket location Bracket
NBT059
INSTALLATION
85 - 90 mm (3.34 - 3.54 in)
Center of windshield YBT049
1. Install mounting bracket as follows: (1) Determine mounting bracket position on windshield by measuring from top of windshield to top of mounting bracket as shown in the figure. (2) Mark location on outside of windshield with wax pencil or equivalent. (3) Clean attaching point on inside of windshield with an alcoholsaturated paper towel. (4) Sand bonding surface of mounting bracket with sandpaper (No. 320 or No. 360). (5) Clean bonding surface of mounting bracket with an alcoholsaturated paper towel. (6) Apply Loctite Adhesive 11067-2 or equivalent to bonding surface of mounting bracket. (7) Install mounting bracket at premarked position and press mounting bracket against glass for 30 to 60 seconds. (8) After five minutes, wipe off excess adhesive with an alcoholmoistened paper towel. 2. Install rearview mirror.
BT-59
BODY ALIGNMENT ● ● ● ● ● ●
All dimensions indicated in figures are actual ones. When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself to make sure there is no free play. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. Measurements should be taken at the center of the mounting holes. An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side is symmetrically the same value. The coordinates of the measurement points are the distances measured from the standard line of “X”, “Y” and “Z”.
Imaginary base line
Vehicle center
“Z”: Imaginary base line [200 mm below datum line (“0Z” at design plan)] Front axle center SBF874GB
Engine Compartment MEASUREMENT
Unit: mm YBT038
BT-60
BODY ALIGNMENT Engine Compartment (Cont’d) MEASUREMENT POINTS Unit: mm
Radiator core support side and Radiator core support
Cowl top
7 dia.
6.2 dia. 7 dia. Front YBT039 .
Front suspension spring support and cowl top side
YBT040
Front side member LH side
Front YBT041
YBT042
Hood lock stay and Radiator core support lower
Front side member RH side
Front .
YBT043
Radiator core support upper center and hood lock stay
YBT045
BT-61
YBT044
BT-62
Unit: mm
Front
Front
All dimension indicated in these figures are actual ones.
RH side
LH side
* This figure is underside view.
Below
Above
Rear
BODY ALIGNMENT Underbody
MEASUREMENT
YBT046
BODY ALIGNMENT Underbody (Cont’d) MEASUREMENT POINTS
Bottom view of vehicle
Rear
14 dia.
12 dia.
18 dia.
16 dia.
16 dia. 12.5 dia.
16 dia. 12.5 dia. LH side
RH side
16 dia.
Front coordinates A , p a p x : 330 y : −650 z : 213 B , p b p x : 495 y : −490 z : 356.6 C , p c p x : 455 y : −35 z : 377.6 D , p d p x : 450 y : 70 z : 254 E , p e p x : 410 y : 310 z : 133.8 F , p f p x : 587 y : 405 z : 169.4 G , p g p x : 393 y : 500 z : 128.6 H , p h p x : 414.5 y : 1,210 z : 124.9
Rear coordinates pJ , pj x : 412.5 y : 1,625 z : 123.2 K , p k p x : 524 y : 2,005 z : 209 L , p l p x : 555 y : 2,085 z : 259 M p
x : 145 y : 2,507 z : 250 N p
x : 300 y : 2,550 z : 402.3 n p
x : −300 y : 2,550 z : 428.3 P p
x : 512 y : 2,900 z : 346.5 p p
x : −544 y : 2,882 z : 347.7 Q p
x : 542 y : 3,385.6 z : 339.4
14 dia.
q p
x : −570.5 y : 3,380 z : 346.5
12 dia. 16 dia. Bolt head
Unit: mm
Bolt head
Front and rear strut tower centers
12 dia.
Coordinates: R , p r p x : 527.3 y : −5.1 z : 780.1 S , p s p x : 478 y : 2,522 z : 527.3
16 dia. 18 dia.
Front p R , p r 88 dia. S , p s 60.8 dia. Rear p
Front YBT047
BT-63
BODY ALIGNMENT NOTE
BT-64
HEATER & AIR CONDITIONER SECTION
HA
CONTENTS PRECAUTIONS AND PREPARATION.......................... 3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 3 Precautions for Working with HFC-134a (R-134a) ... 3 General Refrigerant Precautions ............................... 4 Precautions for Refrigerant Connection .................... 4 Precautions for Servicing Compressor...................... 7 Special Service Tools ................................................ 7 HFC-134a (R-134a) Service Tools and Equipment.................................................................. 8 Precautions for Service Equipment ......................... 10 DESCRIPTION ............................................................. 12 Refrigeration Cycle .................................................. 12 CSV613 Variable Displacement Compressor.......... 14 Component Layout .................................................. 18
HEATER DESCRIPTION ............................................................. 19 Control Operation .................................................... 19 Air Flow.................................................................... 19
AUTO DESCRIPTION ............................................................. 20 Introduction .............................................................. 20 Features................................................................... 20 Control Operation .................................................... 21 Discharge Air Flow................................................... 23
HEATER TROUBLE DIAGNOSES ............................................. 24 Operational Check ................................................... 24
AUTO TROUBLE DIAGNOSES ............................................. 26 How to Perform Trouble Diagnoses for Quick and Accurate Repair ................................................ 26 Symptom Chart........................................................ 28 Checking Resistor.................................................... 30 Preliminary Check.................................................... 30 Performance Test Diagnoses .................................. 33 A/C Performance Chart ........................................... 35 Trouble Diagnoses for Abnormal Pressure ............. 36 Component Location................................................ 39 Wiring Diagram - HEATER -.................................... 40 Circuit Diagram - Air Conditioner............................. 41 Wiring Diagram - A/C - ............................................ 42 Main Power Supply and Ground Circuit Check ...... 51 Diagnostic Procedure 1 ........................................... 52 Diagnostic Procedure 2: Models with relay type 1.. 54 Diagnostic Procedure 2: Models with relay type 2.. 56 Diagnostic Procedure 3: Models with relay type 1.. 57 Diagnostic Procedure 3: Models with relay type 2.. 59 Diagnostic Procedure 4: Models with relay type 1.. 61 Diagnostic Procedure 4: Models with relay type 2.. 63 Diagnostic Procedure 5 ........................................... 65 Diagnostic Procedure 6 ........................................... 66 Diagnostic Procedure 7 ........................................... 68 Diagnostic Procedure 9 ........................................... 69 Diagnostic Procedure 10 ......................................... 70 Diagnostic Procedure 11 ......................................... 74 Diagnostic Procedure 12 ......................................... 75 Diagnostic Procedure 13 ......................................... 76 Diagnostic Procedure 14 ......................................... 77 Electrical Components Inspection ........................... 78 Control Panel System.............................................. 80
HA
Removal and Installation ......................................... 81 Control Linkage Adjustment..................................... 82 SYSTEM DESCRIPTION ............................................. 84 Overview of Control System.................................... 84 Control System Input Components ......................... 84 Control System Auto Amplifier (Auto amp.)............. 87 Control System Output Components....................... 90 SERVICE PROCEDURES ......................................... 100 HFC-134a (R-134a) Service Procedure ................ 100 Maintenance of Lubricant Quantity in Compressor ........................................................... 102 Refrigerant Lines ................................................... 104
Checking Refrigerant Leaks .................................. 106 Compressor Mounting ........................................... 109 Compressor - Model CR-14 (Calsonic make) ........ 111 Compressor Clutch ................................................. 111 Thermal Protector ...................................................113 CSV613 Compressor..............................................114 Compressor Clutch .................................................114 Ventilation Air Filter.................................................117 SERVICE DATA AND SPECIFICATIONS (SDS) .......118 General Specifications............................................118 Inspection and Adjustment .....................................118
HA-2
PRECAUTIONS AND PREPARATION Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL P11 is as follows (The composition varies according to optional equipment): ● For a frontal collision The Supplemental Restraint System consists of driver’s air bag module (located in the center of the steering wheel), front passenger’s air bag module (located on the instrument panel on passenger’s side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. ● For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS 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 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 RS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and wiring harnesses covered with yellow insulation or tape either just before the harness connectors or for the complete harness are related to the SRS.
WARNING: ●
● ●
Precautions for Working with HFC-134a (R-134a)
CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants must never be mixed, even in the smallest amounts. If the refrigerants are mixed, compressor failure is likely to occur. 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 failure is likely to occur. The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: a: When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. b: 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. c: 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. d: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove R-134a from the A/C system, using certified service equipment meeting requirements of SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. e: Do not allow lubricant (Nissan A/C System Oil Type S or type R) to come in contact with styrofoam parts. Damage may result.
HA-3
PRECAUTIONS AND PREPARATION General Refrigerant Precautions 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. ● 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 (126°F). ● 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 introduce compressed air to any refrigerant container or refrigerant component.
Precautions for Refrigerant Connection A new type refrigerant connection has been introduced to all refrigerant lines except the following location. ● Expansion valve to cooling unit.
FEATURES OF NEW TYPE REFRIGERANT CONNECTION ●
●
The O-ring is relocated in a groove for proper installation. This eliminates the change 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 connecting surface of the mating part to improve sealing characteristics. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections. Flange portion
Union-nut portion New
Former
New
Former
Nut
Flange
O-ring
O-ring
O-ring
O-ring Union
O-ring
O-ring
O-ring
O-ring Sealed direction SHA815E
HA-4
PRECAUTIONS AND PREPARATION Precautions for Refrigerant Connection (Cont’d) O-RING AND REFRIGERANT CONNECTION N p
N p
Cooling unit
N p
N p
N p
F p
Compressor Condenser
N p N p
N : New type refrigerant connection p F : Formertype refrigerant connection p
F p
Expansion valve
Liquid tank
l : O-ring size
KHA101
CAUTION: The new and former connections use different O-ring configurations. Do not confuse O-rings since they are interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection.
O-ring parts number and specifications Connection type
O-ring size
Part number
D
mm (in)
W
mm (in)
92471 N8210
6.8 (0.268)
1.85 (0.0728)
Former
92470 N8200
6.07 (0.2390)
1.78 (0.0701)
New
9247 N8210
10.9 (0.429)
2.43 (0.0957)
92475 71L00
11.0 (0.433)
2.4 (0.094)
92473 N8210
13.6 (0.535)
2.43 (0.0957)
Former
92475 72L00
14.3 (0.563)
2.3 (0.091)
New
92474 72L00
14.3 (0.563)
2.43 (0.0957)
New 8
12 Former New 16 SHA814E 19
HA-5
PRECAUTIONS AND PREPARATION Precautions for Refrigerant Connection (Cont’d) WARNING: Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it. CAUTION: 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. Failure to do so will cause lubricant to enter the low pressure chamber. ● 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 operation. Do not remove the seal caps of pipes and other components until just before connection. ● Allow components stored in cool areas to warm to ambient temperature before removing seal 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. ● When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion. Lubricant name: Nissan A/C System Oil Type R for compressor-model CR-14 Part number: KLH00-PAGR0 Lubricant name: Nissan A/C System Oil Type S for compressor-model CSV613 Part number: 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. ● After connecting line, conduct leak test and make sure that there is no leakage from connections. When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque. Torque wrench
Apply lubricant
Do not apply lubricant to thread.
OK
NG
O-ring
NG
NG
Inflated portion OK
OK
NG
Plug RHA861F
HA-6
PRECAUTIONS AND PREPARATION Precautions for Servicing Compressor ● ● ● ● ●
●
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 HA-102. 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 normal operation.
Special Service Tools CR-14 compressor Tool number Tool name
Description
KV99106700 Clutch disc wrench
Removing shaft nut and clutch disc
NT351
KV99106800 Pulley installer
Installing pulley
NT352
CSV613 compressor Tool number Tool name
Description
KV99106100 Clutch disc wrench
Removing center bolt
When replacing the magnet clutch in the above compressor, use a clutch disc wrench with the pin side on the clutch disc to remove it.
NT232
Pin
Clutch disc wrench NT378
HA-7
PRECAUTIONS AND PREPARATION Special Service Tools (Cont’d) Tool number Tool name
Description
KV99232340 or KV99107400 Clutch disc puller
Removing clutch disc
NT376
KV99106200 Pulley installer
Installing pulley
NT235
HFC-134a (R-134a) Service Tools and Equipment Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubrication oil. Separate and non-interchangeable service equipment must be used for 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 failure will result. Tool name
Description
Note Container color: Light blue Container marking: HFC-134a (R-134a) Fitting size: Thread size ● large container 1/2”-16 ACME
HFC-134a (R-134a) refrigerant
NT196
Nissan A/C System Oil Type R (Part No.: KLH00-PAGR0) Type S (Part No: KLH00-PAGS0)
Type: Poly alkyline glycol oil (PAG), type R Application: HFC-134a (R-134a) vane rotary compressors (Nissan only) Capacity: 40m (1.4 Imp fl oz)
NT197
Recovery/Recycling/ Recharging equipment
Function: Refrigerant Recovery and Recycling and Recharging
NT195
HA-8
PRECAUTIONS AND PREPARATION HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool name
Description
Note Power supply: ● DC 12 V (Cigarette lighter)
Electrical leak detector
NT198
Manifold gauge set (with hoses and couplers)
Identification: ● The gauge face indicates R-134a. Fitting size: Thread size ● 1/2”-16 ACME
NT199
Service hoses High side hose ● Low side hose ● Utility hose
Hose color: ● 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: ● 1/2”-16 ACME
●
NT201
Hose fitting to service hose: ● M14 x 1,5 fitting is optional or permanently attached.
Service couplers High side coupler ● Low side coupler ●
NT202
Refrigerant weight scale
For measuring of refrigerant Fitting size: Thread size ● 1/2”-16 ACME
NT200
Vacuum pump (Including the isolator valve)
Capacity: ● Air displacement: 4 CFM ● Micron rating: 20 microns ● Oil capacity: 482 g (17 oz) Fitting size: Thread size ● 1/2”-16 ACME NT203
HA-9
PRECAUTIONS AND PREPARATION Precautions for Service Equipment RECOVERY/RECYCLING/RECHARGING 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. With isolator valve
Hose fittings: 1/2”-16ACME
Isolator valve Open
Close Without isolator valve Shut off valve
VACUUM PUMP 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 hose-to-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.
RHA270D
MANIFOLD GAUGE SET Be certain that the gauge face indicates R-134a or 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.
1/2′′-16ACME
SHA533D
Hose fittings to manifold gauge orrecovery/recycling equipment; 1/2”-16ACME
Black stripe M14 × 1.5 fitting optional (Hose may be permanentlyattached to coupler)
SERVICE HOSES Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shut off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge.
RHA272D
HA-10
PRECAUTIONS AND PREPARATION Precautions for Service Equipment (Cont’d) SERVICE COUPLERS
Shut-off valve
A/C service valve
M14 × 1.5 fitting optional (Hose may be permanentlyattached to coupler)
Never attempt to connect HFC-134a (R-134a) service couplers to an 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 Refrigerant container (HFC-134a)
Hose fittings: 1/2′′-16ACME
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.
To manifold gauge
Weight scale
RHA274D
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.
HA-11
DESCRIPTION Refrigeration Cycle REFRIGERANT FLOW The refrigerant flow is in the standard pattern. Refrigerant flows through the compressor, condenser, liquid tank, evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion valve, located inside the evaporator case.
FREEZE PROTECTION Variable displacement (CSV613) Under normal operating conditions, when the A/C is switched on, the compressor runs continuously, and the evaporator pressure, therefore temperature, is controlled by the CSV613 variable displacement compressor to prevent freeze up.
Vane rotary (CR-14) The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the compressor operation. When the evaporator coil temperature rises above the specification, the thermo control amplifier allows compressor operation.
REFRIGERANT SYSTEM PROTECTION Dual-pressure switch (System with CR-14 compressor) The refrigerant system is protected against excessively high or low pressure by the dual-pressure switch, located on the liquid tank. If the system pressure rises above, or falls below the specifications, the dualpressure switch opens to interrupt the compressor operation.
Pressure sensor (System with CSV613 compressor) The pressure sensor is located on the liquid tank. It converts the system pressure into a voltage value witch is then input into ECM. If the system pressure rises above, or falls below the specifications, ECM interrupt the compressor operation.
Fusible plug Open at temperatures above 105°C (221°F), thereby discharging refrigerant to the atmosphere. If this plug is melted and opened, check the refrigerant line and replace liquid tank.
Pressure relief valve (CSV613 compressor) 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 abnormal level [more than 3,727 kPa (38 kg/cm2, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere.
HA-12
DESCRIPTION Refrigeration Cycle (Cont’d) Pressure relief valve (CSV613 only)
Compressor
High-pressure gas
Low-pressure liquid
High-pressure liquid
Low-pressure gas
Outside air
Condenser
Evaporator Blower motor Liquid tank
Expansion valve Dual-pressure switch/ pressure sensor
HA-13
RHA896FA
DESCRIPTION CSV613 Variable Displacement Compressor GENERAL INFORMATION 1. The CSV613 compressor differs from previous units. The vent temperatures of the CSV613 compress or do not drop too far below 5°C (41°F) when: ● evaporator intake air temperature is less than 20°C (68°F) ● engine is running at speeds less than 1,500 rpm. This is because the CSV613 compressor provides a means of “capacity” control. 2. The CSV613 compressor provides refrigerant control under varying conditions. During cold winters, it may not produce high refrigerant pressure discharge (compared to previous units) when used with air conditioning systems. 3. A “clanking” sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt angle of the swash plate has changed and is not a problem. 4. For air conditioning systems with the CSV613 compressor, the clutch remains engaged unless: the system main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor. 5. A constant range of suction pressure is maintained when engine speed is greater than a certain value. It normally ranges from 147 to 177 kPa (1.47 to 1.77 bar, 1.5 to 1.8 kg/cm2, 21 to 26 psi) under varying conditions. In previous compressors, however, suction pressure was reduced with increases in engine speed.
HA-14
DESCRIPTION CSV613 Variable Displacement Compressor (Cont’d) DESCRIPTION General The variable compressor is basically a swash plate type that changes piston stroke in response to the required cooling capacity. The tilt of the swash plate allows the piston’s stroke to change so that refrigerant discharge can be continuously changed from 6 to 125 cm3 (0.366 to 7.63 cu in). Journal pin
Swash plate Rear Head
Seal
Discharge valve plate
Shaft
Control valve Oil drain bolt
Cylinder Piston
Long stroke (Large amount of refrigerant discharge) Swash plate tilting angle changes
Short stroke (Small amount of refrigerant discharge)
Discharge capacity cm3 (cu in)/rev.
Pistonstroke length mm (in)
Minimum
6 (0.366)
1.2(0.039)
Maximum
125 (7.63)
25.9 (1.02)
Discharge control
Journal pin
Drive lug
KHA103
HA-15
DESCRIPTION CSV613 Variable Displacement Compressor (Cont’d) Operation 1. Operation control valve Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response to changes in refrigerant suction pressure. Operation of the valve controls the internal pressure of the crankcase. The angle of the swash plate is controlled between the crankcase’s internal pressure and the piston cylinder pressure. 2. Maximum cooling Refrigerant pressure on the low-pressure side increases with an increase in heat loads. When this occurs, the control valve’s bellows compress to open the low-pressure side valve and close the high-pressure side valve. This causes the following pressure changes: ● the crankcase’s internal pressure to equal the pressure on the low-pressure side; ● the cylinder’s internal pressure to be greater than the crankcase’s internal pressure. Under this condition, the swash plate is set to the maximum stroke position.
Discharge port
Cylinder pressure
Crankcase
Suction port
Crankcase pressure
Low-pressure valve: Open Spring pressure Bellows
Forces needed to increase stroke Valve position for lowering crankcase pressure RHA473C
HA-16
DESCRIPTION CSV613 Variable Displacement Compressor (Cont’d) 3. Capacity control ● Refrigerant pressure on suction side is low during high speed driving or when ambient or interior temperature is low. ● The bellows expands when refrigerant pressure on the suction pressure side drops below approximately 177 kPa (1.77 bar, 1.8 kg/cm2, 26 psi). Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crankcase pressure becomes high as high pressure enters the crankcase. ● The force acts around the journal pin near the swash plate, and is generated by the pressure difference before and behind the piston. The drive lug and journal pin are located where the piston generates the highest pressure. Piston pressure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the swash plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure increase triggers pressure difference between the piston and the crankcase. The pressure difference changes the angle of the swash plate.
Discharge port
Low-pressure valve: Open
Crankcase
Cylinder pressure
Crankcase pressure Suction port
Spring pressure
Forces needed to increase stroke Valve position for lowering crankcase pressure RHA474C
HA-17
DESCRIPTION Component Layout SEC. 270⋅271⋅272⋅273
Side defroster nozzle
Defroster nozzle
Side defroster nozzle
Side ventilator duct Center ventilator duct
Side ventilator duct
Heater unit
Fresh vent control lever
Cooler unit Intake unit For Scandinavian models only: Rear heater duct (Whenremoving rear heater duct, it is necessary to remove frontseats.) Control assembly (Heater)
Control assembly (Air conditioner)
KHA104
HA-18
HEATER
DESCRIPTION Control Operation LHD models
Temperature control knob
Fan control knob
Mode control knob
.
Recirculation switch
Rear defroster switch
RHD models
Mode control knob
Temperature control knob
Fan control knob
Recirculation switch Rear defroster switch
KHA105
FAN CONTROL KNOB This knob turns the fan ON and OFF, and controls fan speed.
MODE CONTROL KNOB This knob controls the outlet air flow.
TEMPERATURE CONTROL KNOB This knob allows adjustment of the temperature of the outlet air.
RECIRCULATION (REC) SWITCH OFF position: Outside air is drawn into the passenger compartment. ON position: Interior air is recirculated inside the vehicle. The indicator lamp will also light.
Air Flow FRESH VENT SYSTEM This system is controlled by means of the fresh air vent lever which is mechanically linked to the fresh vent door by the control cable. Fresh vent air always comes from the center vent in any mode when the fresh air vent lever is set at the blue dot position. Fresh air vent control lever
Set at blue dot position
To defroster Heater core Evaporator Outside air
To floor Fresh air vent control cable
To floor
KHA064
HA-19
DESCRIPTION
AUTO
Introduction The automatic temperature control (ATC) system provides automatic regulation of the discharged air temperature and the discharged air volume (Blower speed). The air outlet door, intake door and compressor magnet clutch are controlled by the manual operation of each switch.
Features Air mix door control (Automatic temperature control) The air mix door is automatically controlled so that in-vehicle temperature will reach, and be maintained at the operator selected “set temperature”. For a given set temperature, the air mix door position will depend on: Ambient temperature, in-vehicle temperature, amount of sunload, set temperature and A/C switch signals. Fan speed control When the fan control switch is in the Auto position, the blower speed is automatically controlled, depending on: Ambient temperature, in-vehicle temperature, amount of sunload, set temperature, and A/C switch signals. It is also controlled by the manual operation of the fan control switch. Starting fan speed control When engine coolant temperature is low, the air outlet door position is detected by the A/C control panel and if this is set in B/L, FOOT or FOOT/DEF blower speed is controlled to prevent a large amount of cold air from being discharged into the floor area. Outlet door control This can be selected by operation of the mode control knob. Intake door control This can be selected by changing the REC switch position. Compressor magnet clutch control System with CR-14 compressor When the A/C switch is ON, the thermistor detects evaporator temperature. The thermo control amplifier controls clutch ON/OFF operation depending on the evaporator temperature. System with CSV613 compressor Under normal operating conditions, when the A/C is switched on, the compressor runs continuously, and the evaporator pressure, and therefore temperature, is controlled by the CSV613 variable displacement compressor to prevent freeze up.
HA-20
AUTO
DESCRIPTION Control Operation
The control system consist of a) input sensors and switches, b) the automatic amplifier (microcomputer), and c) outputs. The relationship of these components is shown in the diagram below: Control unit
● Set temperature Control (Potentio temperature control)
Ambient sensor
In-vehicle sensor
Sunload sensor
Air mix door motor
Automatic amplifier (Micro- computer)
Air mix door
PBR (Potentio Balance Resistor)built-into air mix door motor
Thermal transmitter Blower motor
Fan
KHA111
Auto air conditioner Air conditioner switch
Mode control knob
Auto switch
Fan control
Temperature control switch (PTC)
Rear window defogger switch
Recirculation switch
KHA112
HA-21
DESCRIPTION Control Operation (Cont’d)
AUTO
FAN CONTROL SWITCH Manual control of the blower speed. Four speeds are available for manual control (as shown on the display screen): low I, medium low II, medium high III, high IIII
MODE CONTROL KNOB This knob controls outlet air flow. ) mode, the intake door is set to “FRESH”, and the A/C on. In “DEF” (
AUTO SWITCH The air mix door, 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.
TEMPERATURE CONTROL SWITCH (POTENTIO TEMPERATURE CONTROL) Increases or decreases the set temperature.
RECIRCULATION (REC) SWITCH OFF position: Outside air is drawn into the passenger compartment. ON position: Interior air is recirculated inside the vehicle. RECIRC is canceled when DEF mode is selected.
AIR CONDITIONING SWITCH The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the compressor will turn ON. The display screen indicates “A/C”. A/C switch will turn on when DEF mode is selected. The air conditioner cooling function operates only when the engine is running.
HA-22
AUTO
DESCRIPTION Discharge Air Flow p1 p2
: Ventilation
p3
: Foot
★ : Air flow in REC position
: Defroster
p3
p3
Foot
p3
p3
To defroster
p3 Outside air
p2
p2
To floor
p2
To floor
Foot and defroster Vent
p3 p1
To ventilator
To defroster
Defroster door Fresh vent door Heater core Intake air ★ Outside air
p2
To floor
Floor door
p2
Air mix door Ventilator door
To floor
Intake door Defroster
Bi-level
p1
p3
To defroster
To ventilator Outside air
Outside air
p2
To floor
p2
Air passed through heater core
To floor
Mixed air (
+
)
Air not passed through heater core
This illustration is for LHD models. The layout for RHD models issymmetrically opposite.
KHA113
HA-23
TROUBLE DIAGNOSES
HEATER
Operational Check The purpose of the operational check is to confirm that the system operates as it should. The systems which are checked are the blower, mode (discharge air), intake air, temperature decrease, temperature increase.
CONDITIONS: Engine running at normal operating temperature.
PROCEDURE: 1. Check blower 1) Turn fan control knob to 1-speed. Blower should operate on 1-speed. 2) Then turn fan control knob to 2-speed. 3) Continue checking blower speed until all four speeds are checked. 4) Leave blower on 4-speed. KHA106
2. Check discharge air 1) Turn mode control knob.
KHA107
2) Confirm that discharge air comes out according to the air distribution table at left. Refer to “Discharge Air Flow” in “DESCRIPTION” (HA-23).
Discharge airflow
Switch mode/ indicator
Airoutlet/distribution Face
Foot
Defroster
100%
—
—
60%
40%
—
15%*
65%
20%
15%*
55%
30%
15%*
—
85%
* Face air from SIDE VENT only KHA032
HA-24
TROUBLE DIAGNOSES Operational Check (Cont’d)
HEATER
3. Check recirculation 1) Press recirculation switch. Recirculation indicator should light. 2) Listen for intake door position change (you should hear blower sound change slightly).
KHA108
4. Check temperature decrease 1) Turn temperature control knob to full cold. 2) Check for cold air at discharge air outlets.
KHA109
5. Check temperature increase 1) Turn temperature control knob to full hot. 2) Check for hot air at discharge air outlets.
KHA110
HA-25
AUTO
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick and Accurate Repair WORK FLOW F
CHECK IN
Reference item
H
LISTEN TO CUSTOMER COMPLAINT AND CONFIRM BY PERFORMING OPERATIONAL CHECK.
F
Operational check (Refer to HA-24.) Symptom Chart (Refer to HA-28.)
H
INVESTIGATE ITEMS YOU SHOULD CARRY OUT RELATED TO EACH SYMPTOM.
F
Symptom Chart (Refer to HA-28.)
H E
ELIMINATE GOOD SYSTEM(S)/PART(S).
F
Preliminary Check (Refer to HA-30.)
F
Main Power Supply and Ground Circuit Check (Refer to HA-51.)
H
CHECK MAIN POWER SUPPLY AND GROUND CIRCUITS. H ●
●
Diagnostic Procedure(s) (Refer to HA-32.) Circuit Diagram (Refer to HA-41.)
E
ELIMINATE GOOD PART(S)/HARNESS(ES)/ CONNECTOR(S) ELECTRICALLY.
F
Malfunctioning part(s)
Malfunctioning harness(es)/ connector(s)
H
INSPECT EACH COMPONENT. H
H
REPAIR.
NG
Harness layout (Refer to “HARNESS LAYOUT” in EL section for details.
REPAIR/REPLACE.
H
H
FINAL CHECK OK H
CHECK OUT
HA-26
F
Electrical Components Inspection (Refer to HA-78.)
TROUBLE DIAGNOSES
NOTE
HA-27
AUTO
AUTO
TROUBLE DIAGNOSES Symptom Chart
HA-51 Auto amp.
HA-51
q
q
q
q
Blower motor does not rotate at all. (Fan switch [AUTO] [1] [2] [3] [4])
q
q
Blower motor does not rotate at all when the fan speed is in AUTO. (It operates in 1, 2, 3 or 4-speed.)
q
q
q
Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in Hi or MH.)
q
q
q
Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in LO.)
q
q
q
SYMPTOM A/C does not blow cold air.
q
q
q
15A Fuses
A/C control panel
HA-77 Diagnostic Procedure 14
7.5A Fuse
HA-76
HA-69 Diagnostic Procedure 9
Diagnostic Procedure 13
HA-68 Diagnostic Procedure 7
HA-75
HA-66 Diagnostic Procedure 6
Diagnostic Procedure 12
HA-65 Diagnostic Procedure 5
HA-74
HA-61 Diagnostic Procedure 4
Diagnostic Procedure 11
HA-57 Diagnostic Procedure 3
HA-70
HA-56 Diagnostic Procedure 2
Diagnostic Procedure 10
HA-52
HA-32 Preliminary check 3
Diagnostic Procedure 1
HA-31
HA-51
Main Power Supply and Ground Circuit Check
Diagnostic Procedure
Preliminary check 2
Preliminary check 1
REFERENCE PAGE
HA-30
PROCEDURE
HA-51
Preliminary Check
DIAGNOSTIC TABLE
Starting fan speed control does not operate.
q
q
There is too much difference between setting temp. on P.T.C. and in-vehicle temp.
q
q
Air mix door motor does not operate normally.
q
q
Intake door does not change in VENT, B/L FOOT DEF or FOOT mode.
q
Magnetic clutch does not engage when A/C switch and fan switch are ON.
q
Ambient sensor circuit is open or shorted.
q
q
In-vehicle sensor circuit is open or shorted.
q
q
Sunload sensor circuit is open or shorted.
q
q
Thermal transmitter circuit is open or shorted.
q
q
Illumination or indicators of control unit do not come on.
q
Noise
, : The number means checking order. q: As for the order of inspection, refer to each flow chart. (It depends on malfunctioning portion.)
HA-28
q
—
REC switch
q q
q q q
q q q q
q q q q
q q q q
q q q
q
q q HA-86 Refer to EL section.
Air mix door PBR Intake door motor Auto amp. Ambient sensor In-vehicle sensor Sunload sensor Thermal transmitter
q q q q q q q q q
q q q
q q q q
q
q
HA-29 q
q
q q
q q q
q
q
q q q q q
q q q q q
Harness
Refer to EL section.
q
—
HA-113
HA-70
q
Compressor
Illumination system
HA-80
Thermo control amp.
Refer to EC section.
HA-98
HI relay
ECM
HA-98
MH relay
Thermal protector
HA-98
ML relay
HA-79
HA-98
LO relay
Magnetic clutch
q
Pressure switch/sensor
HA-87
A/C relay
HA-85
HA-86
HA-51
HA-81
HA-94
HA-93
HA-84
PTC
—
Fan switch
Control unit
—
A/C switch
q —
—
Fan resistor
Blower motor
TROUBLE DIAGNOSES Symptom Chart (Cont’d) AUTO
Electrical Components Inspection
q q
q q q
q q q
q
q q q q q
q
q q q q q
q
q q
q
q
q
q
AUTO
TROUBLE DIAGNOSES Checking Resistor
Checking resistors are used for trouble diagnoses of blower motor operation and air mix door motor operation. Use checking resistor when inspecting portions with C/R *1, C/R *2 in flow chart. CAUTION: Select checking resistors which have resistance values corresponding with those indicated in table below, and connect to respective sensors. Checking resistor Blower motor operation check Air mix door motor operation check
Ambient sensor
In-vehicle sensor
Wattage
1,500Ω
C/R *1 1,000Ω
1/4W 2,490Ω
C/R *2
1. Disconnect ambient sensor and in-vehicle sensor harness connectors. 2. Connect checking resistors to ambient sensor harness connector and in-vehicle sensor harness connector when inspecting portions with C/R *1, C/R *2 in flow chart in trouble diagnoses. 3. Turn ignition switch ON. 4. Turn A/C switch ON. 5. Turn VENT mode. 6. Keep sunload sensor away from sunlight by covering it.
Preliminary Check PRELIMINARY CHECK 1 Intake door is not set at “FRESH”. Is intake door in “Fresh” position when REC switch is turned from ON to OFF with ignition switch at ON? (Can you hear air moving from the intake unit?)
No
E
Go to Diagnostic Procedure 9 (HA-69).
E
Go to Diagnostic Procedure 9 (HA-69).
Yes H
Is intake door in “REC” position when REC switch is turned from OFF to ON with ignition switch at ON? (Can you hear air moving from the intake unit?) Yes H
INSPECTION END
HA-30
No
AUTO
TROUBLE DIAGNOSES Preliminary Check (Cont’d) PRELIMINARY CHECK 2 A/C does not blow cold air. DOES AIR FLOW FROM VENTS? Condition ● Engine running at operating temperature. ● Ignition switch, A/C switch, and fan switch are ON. ● Mode control knob is in VENT mode and temperature control knob is in full cold position.
No
E
IS BLOWER MOTOR OPERATING NORMALLY? Yes
CHECK BLOWER MOTOR OPERATION. Go to Diagnostic Procedure 1 (HA-52).
Yes
CHECK COMPRESSOR BELT TENSION. Refer to “Checking Drive Belts” in MA section. NG
NG F
H
H
CHECK COMPRESSOR OPERATION.
CHECK FOR EVAPORATOR COIL FREEZE UP. Remove intake unit. Check if evaporator freezes.
OK
OK
NG (Freezes up.) H
H
NG
OK
Go to Diagnostic Procedure 10 (HA-70).
H
CHECK VENTILATOR DUCT FOR AIR LEAKS.
OK
H
H
H
CHECK THERMO CONTROL AMP. AND A/C RELAY OPERATION.
Go to Performance Test Diagnoses.
CHECK AMOUNT OF REFRIGERANT. Check amount of refrigerant using refrigerant recovery & recharging equipment. NG
H
CHECK WATER COCK OPERA- NG TION. Warm up engine before checking.
CHECK FOR REFRIGERANT LEAKS.
CHECK VENTILATOR DUCT FOR AIR LEAKS.
OK (Does not freeze up.) H
CHECK REFRIGERATION CYCLE PRESSURE WITH RECOVERY/RECYCLING EQUIPMENT CONNECTED. Refer to Performance Chart.
Adjust or replace compressor belt. Refer to MA section (“ENGINE MAINTENANCE”).
H
No H
OK F
H
OK
CHECK EVAPORATOR OUTLET AIR TEMPERATURE. Refer to Performance Chart. H
NG
CHECK AIR MIX DOOR OPERATION. (Refer to HA-90.)
HA-31
E
Adjust or replace water cock.
AUTO
TROUBLE DIAGNOSES Preliminary Check (Cont’d) PRELIMINARY CHECK 3 Noise Check where noise comes from.
H
Blower motor
H
H
Check for noise in all modes and temperature settings.
H
Compressor H
OK
Replace expansion valve.
H
H
Check blower motor and fan for wear.
H
The line is fixed directly to the body.
NG
H
Check blower motor for foreign particles.
H
Refrigerant line
Belt
H
Inspect the compressor clutch and pulley and idler pulley.
Noise is constant.
H
Expansion valve
H
Replace compressor clutch and pulley. Refer to HA-111, 114.
Fix the line with rubber or some vibration absorbing material.
H
The line is not fixed.
H
Fix the line tightly.
H
Check disc-to-pulley clearance. Refer to HA-113, 116. OK H
Noise is intermittent. H Check air discharge ducts for obstructions, foreign materials or air leakage.
H
The belt vibration is intense.
Check and adjust lubricant.
H
Side of belt is worn out.
OK H
H
Replace compressor and liquid tank.
Readjust belt tension. Refer to MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”).
HA-32
H
The pulley center does not match. Readjust the pulley center.
AUTO
TROUBLE DIAGNOSES Performance Test Diagnoses INSUFFICIENT COOLING INSUFFICIENT COOLING H
NG
CHECK AIR FLOW. OK H
E
CHECK BLOWER MOTOR OPERATION. H
CHECK COMPRESSOR OPERATION. OK
OK
H
Clogged blower inlet/ Clogged duct/Loose duct connection/Air leakage, etc.
NG H
NG
A p
(Go to next page.)
B p
(Go to next page.) OK
H
CHECK HIGH AND LOW SIDE PRESSURE. USE PERFORMANCE CHART. (Refer to HA-35.)
RECOVER REFRIGERANT USING RECOVERY RECYCLING EQUIPMENT AND CHARGE SPECIFIED AMOUNT OF REFRIGERANT.
NG
F
H
H
CHECK HIGH AND LOW SIDE PRESSURE. USE PERFORMANCE CHART. (Refer to HA-35.)
BOTH HIGH AND LOW PRESSURE SIDES ARE TOO HIGH.
Note E
H E
CHECK DISCHARGE AIR TEMPERATURE. USE PERFORMANCE CHART. (Refer to HA-35.) NG
OK
HIGH PRESSURE SIDE IS TOO HIGH AND LOW PRESSURE SIDE IS TOO LOW.
E
HIGH PRESSURE SIDE IS TOO LOW AND LOW PRESSURE SIDE IS TOO HIGH.
E
BOTH HIGH AND LOW PRESSURE SIDES ARE TOO LOW.
E
LOW PRESSURE SIDE SOMETIMES BECOMES NEGATIVE.
E
LOW PRESSURE SIDE BECOMES NEGATIVE.
E
H
END
H
Malfunctioning temperature control operation (air mix door position improperly adjusted)/ Malfunctioning water cock operation (incorrect valve closure)
Note:
− correspond to those in TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE. (Refer to HA-36.)
HA-33
TROUBLE DIAGNOSES Performance Test Diagnoses (Cont’d)
AUTO
A p
H
Malfunctioning blower motor fan
H
Loose fan/Improper contact of fan and case/Deformed fan
H
H
Malfunctioning electrical circuit
Malfunctioning blower motor internal circuit
H
Discontinued wiring or component circuits or poor connection/ Malfunctioning resistor, amplifier, etc./ Burned out fuse or low battery voltage.
B p
H
Magnet clutch does not engage.
H
H
Magnet clutch slipping
Belt slipping
H
H
CHECK MAGNET CLUTCH (coil circuit, disc-to-pulley clearance).
CHECK COMPRESSOR BELT AND BELT TENSION.
H
CHECK ELECTRICAL CIRCUIT (wiring, components circuit).
E
Malfunctioning internal parts of clutch, compressor
H
CHECK ACTIVATION OF SAFETY/PROTECTION DEVICES (such as pressure switch, etc.).
E
E
HA-34
Foreign particles on clutch frictional surface or excessive disc clearance
Malfunctioning electrical circuit (poor connection, low battery voltage, etc.)
AUTO
TROUBLE DIAGNOSES A/C Performance Chart TEST CONDITION
Testing must be performed as follows: Vehicle location: Indoors or in shade (in a well ventilated place) Doors: Closed Door window: Open Temp lever position: Max COLD Mode switch position: Ventilation Intake switch position: Recirculation Fan switch position: Max Engine speed: Idling 825-850 rpm
TEST READING (RHD & LHD MODELS) 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)
6.4 - 8.0 (44 - 46)
25 (77)
10.6 - 12.4 (51 - 54)
30 (86)
14.6 - 17.0 (58 - 63)
35 (95)
19.0 - 22.0 (66 - 72)
40 (104)
23.3 - 27.2 (74 - 81)
20 (68)
8.0 - 9.6 (46 - 49)
25 (77)
12.4 - 14.6 (54 - 58)
30 (86)
17.0 - 19.7 (63 - 67)
35 (95)
22.0 - 24.9 (72 - 77)
40 (104)
27.2 - 30.2 (81 - 86)
Ambient air temperature-to-operating pressure table Ambient air Relative humidity %
50 - 70
High-pressure (Discharge side) kPa (bar, kg/cm2, psi)
Low-pressure (Suction side) kPa (bar, kg/cm2, psi)
20 (68)
736 - 902 (7.36 - 9.02, 7.5 - 9.2, 107 - 131)
118 - 186 (1.18 - 1.86, 1.2 - 1.9, 17 - 27)
25 (77)
873 - 1098 (8.73 - 10.98, 8.9 - 11.2, 127 - 159)
137 - 216 (1.37 - 2.16, 1.4 - 2.2, 20 - 31)
30 (86)
1,079 - 1,275 (10.79 - 12.75, 11.0 - 13.0, 156 - 185)
157 - 245 (1.57 - 2.45, 1.6 - 2.5, 23 - 36)
35 (95)
1,304 - 1,608 (13.04 - 16.08, 13.3 - 16.4, 189 - 233)
206 - 304 (2.06 - 3.04, 2.1 - 3.1, 30 - 44)
40 (104)
1,550 - 1,912 (15.50 - 19.13, 15.8 - 19.5, 225 - 277)
255 - 363 (2.55 - 3.63, 2.6 - 3.7, 37 - 53)
Air temperature °C (°F)
HA-35
TROUBLE DIAGNOSES
AUTO
Trouble Diagnoses for Abnormal Pressure Whenever the system’s high and/or low side pressure is abnormal, diagnose using a manifold gauge. The marker above the gauge scale in the following tables indicates the standard (normal) pressure range. Since the standard (normal) pressure, differs from vehicle to vehicle, refer to HA-35 (“Ambient air temperature-tooperating pressure table”). Gauge indication
Refrigerant cycle
Probable cause
Reduce refrigerant until specified pressure is obtained. Insufficient condenser cooling ● Clean condenser. performance ● Check and repair cooling " fan as necessary. 1 Condenser fins are p clogged. 2 Improper cooling fan p rotation. Evacuate repeatedly and ● Low-pressure pipe is not Poor heat exchange in conrecharge system. cold. denser (After compressor operation ● When compressor is stops, high pressure stopped high-pressure decreases too slowly.) value quickly drops by AC359A " approximately 196 kPa (2.0 Air in refrigeration cycle. bar, 2 kg/cm2, 28 psi). It then decreases gradually thereafter. Engine tends to overheat. Engine cooling systems mal- Check and repair each function. engine cooling system. ● An area of the low-pres● Excessive liquid refrigerant Replace expansion valve. sure pipe is colder than on low-pressure side areas near the evaporator ● Excessive refrigerant disoutlet. charge flow ● Plates are sometimes cov● Expansion valve is open a ered with frost. little compared with the specification. " 1 Improper thermal valve p installation. 2 Improper expansion p valve adjustment. High-pressure side is too high Upper side of condenser and High-pressure tube or parts ● Check and repair or and low-pressure side is too high-pressure side are hot, located between compressor replace malfunctioning low. however, liquid tank is not so and condenser are clogged parts. or crushed. hot. ● Check lubricant for contamination.
Both high and low-pressure sides are too high.
Pressure is reduced soon after water is splashed on condenser. Air suction by cooling fan is insufficient.
●
Excessive refrigerant charge in refrigeration cycle.
Corrective action
AC360A
HA-36
AUTO TROUBLE DIAGNOSES Trouble Diagnoses for Abnormal Pressure (Cont’d) Gauge indication
Refrigerant cycle
High-pressure side is too low and low-pressure side is too high.
Probable cause
Corrective action
High and low-pressure sides become equal soon after compressor operation stops.
Compressor pressure operation is incorrect. " Damage inside compressor packings.
Replace compressor.
No temperature difference between high and low-pressure sides.
Compressor operation is incorrect. " Damage inside compressor packings.
Replace compressor.
There is a big temperature difference between liquid tank outlet and inlet. Outlet temperature is extremely low. ● Liquid tank inlet and expansion valve are frosted. ● Temperature of expansion valve inlet is extremely low as compared with areas near liquid tank. ● Expansion valve inlet may be frosted. ● Temperature difference occurs somewhere in highpressure side. There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted.
Liquid tank inside is clogged a little.
●
High-pressure pipe located between liquid tank and expansion valve is clogged.
●
AC356A
Both high- and low-pressure sides are too low.
AC353A
Both high- and low-pressure sides are too low.
AC353A
●
Expansion valve closes a little compared with the specification. " 1 Improper expansion p valve adjustment. 2 Malfunctioning thermal p valve. 3 Outlet and inlet may be p clogged. Low-pressure pipe is clogged An area of the low-pressure pipe is colder than areas near or crushed. the evaporator outlet. Air flow volume is not enough Compressor operation is or is too low. incorrect. " Damaged inside compressor packings.
HA-37
●
●
●
●
Replace liquid tank. Check lubricant for contamination.
Check and repair malfunctioning parts. Check lubricant for contamination.
Remove foreign particles by using compressed air. Check lubricant for contamination.
Check and repair malfunctioning parts. ● Check lubricant for contamination. Replace compressor. ●
AUTO TROUBLE DIAGNOSES Trouble Diagnoses for Abnormal Pressure (Cont’d) Gauge indication
Refrigerant cycle
Low-pressure side sometimes becomes negative.
●
●
Probable cause
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.
Corrective action Drain water from refrigerant or replace refrigerant. Replace liquid tank.
Refrigerant does not discharge cyclically. " Moisture is frozen at expansion valve outlet and inlet. " Water is mixed with refrigerant.
●
High-pressure side is closed and refrigerant does not flow. " Expansion valve or liquid tank is frosted.
Leave the system at rest until no frost is present. Start it again to check whether or not the problem is caused by water or foreign particles. ● If water is the cause, initial 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 problem, replace expansion valve. ● Replace liquid tank. ● Check lubricant for contamination.
●
AC354A
Low-pressure side becomes negative.
Liquid tank or front/rear side of expansion valve’s pipe is frosted or dewed.
AC362A
HA-38
AUTO
TROUBLE DIAGNOSES Component Location
A/C control panel
In-vehicle sensor
A/C relay
Sunload sensor Intake door motor
Blower motor fan resistor .
Blower fan motor relay
.
Ambient sensor
Air mix door motor
Auto amp. HI.ML.LH.LO relay
Triple-pressure switch (With dieselengine) Dual-pressure switch (With GA engine) Pressure sensor (SRand QG engine)
Compressor
.
. .
Compressor
.
Triple-pressure switch
Dual-pressure switch/sensor
Ambient sensor .
A/C relay
LO relay .
.
Auto amp.
Fuse block (J/B)
.
. .
Blower fan motor relay ● Behind fuse block (J/B)
.
ML relay
HI relay
MH relay
.
Blower motor
Fan resistor
Air mix door motor
Intake door motor .
.
Sunload sensor
.
In-vehicle sensor
A/C control panel NHA290
HA-39
AUTO
TROUBLE DIAGNOSES Wiring Diagram — HEATER — IGNITION SWITCH ON
IGNITION SWITCH ON or START
FUSE BLOCK (J/B)
BLOWER MOTOR
Refer to EL-POWER.
INTAKE DOOR MOTOR FRE REC
FAN RESISTOR
RECIRCULATION SWITCH REC
FRE
REC
FRE
FAN SWITCH OFF
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YHA336
HA-40
AIR MIX DOOR MOTOR
FAN RESISTOR
BLOWER MOTOR
HA-41 INVEHICLE SENSOR
A/C AUTO AMP
A/C LOW RELAY
A/C ML RELAY
A/C MH RELAY
A/C HIGH RELAY
FUSE
IGNITION SWITCH ON
INTAKE DOOR MOTOR
AMBIENT SENSOR
SUN LOAD SENSOR
To illumination system
THERMAL TRANSMITTER
A/C CONTROL PANEL
COMBINATION METER (WATER TEMPERATURE GAUGE)
REFRIGENT PRESSURE SENSOR
THERMO CONTROL AMPLIFIER
FUSE
AIR CONDITIONER RELAY
IGNITION SWITCH ON or START
COMPRESSOR
THERMAL PROTECTOR
COOLING FAN MOTOR-1
COOLING FAN RELAY-1
IACV-FIDC SOLENOID VALVE
COOLING FAN MOTOR-2
DUALPRESSURE SWITCH
TRIPLEPRESSURE SWITCH
COOLING FAN MOTOR-2
COOLING FAN RELAY-1
COOLING FAN RELAY-3
FUSIBLE LINK
: With GA engine or diesel engine
: With SR engine or QG engine
: With GA engine
: With diesel engine
: With gasoline engine
COOLING FAN RELAY-2
COOLING FAN MOTOR-1
FUSIBLE LINK
BATTERY
TROUBLE DIAGNOSES AUTO
Circuit Diagram — Air Conditioner
YHA337
AUTO
TROUBLE DIAGNOSES Wiring Diagram — A/C — IGNITION SWITCH ON or START Refer to EL-POWER FUSE BLOCK (J/B)
To EL-ILL
SIDE LIGHT
SIDE LIGHT
A/C CONTROL PANEL
To HA-A/C-03
A/C AUTO AMP
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YHA338
HA-42
AUTO
TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)
HA-A/C-02 IGNITION SWITCH ON
15A 7
15A 10
FUSE BLOCK (J/B)
Refer to EL-POWER
M1
6B L/Y
L/Y 1
M
BLOWER MOTOR
M30
2 L/B
L/B
11
L/B
L/B
B
Next page
L/B 5 FAN RESISTOR
M29 6
7
8
L/R
L/Y
L/W
M84
M112
L/W
14
L/W
L/W
C
L/Y
13
L/Y
L/Y
D
L/R
12
L/R
L/R
E
Next page
REFER TO THE FOLLOWING
M1 6 8 5 7 M29 BR
1 2
M30 W
FUSE BLOCK - Junction Box (J/B)
16 14 13 12 11 15 M84 W
YHA229
HA-43
TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)
AUTO
YHA376
HA-44
TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)
AUTO
YHA377
HA-45
AUTO
TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d) IGNITION SWITCH ON Refer to EL-POWER. FUSE BLOCK (J/B)
To HA-A/C-07
Next page
INTAKE DOOR MOTOR
THERMISTOR
THERMO CONTROL AMPLIFER To HA-A/C-07
To HA-A/C-09 Next page
To HA-A/C-07
Next page
A/C CONTROL PANEL
AIR MIX DOOR MOTOR
: With diesel engine : With GA engine A/C AUTO AMP.
:With GA engine or diesel engine : With SR engine or QG engine
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
YHA341
HA-46
TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)
AUTO
WITH SR ENGINE or QG ENGINE
Preceding page
FUSE BLOCK (J/B)
AIR CONDITIONER RELAY
REFRIGERANT PRESSURE SENSOR
COMPRESSOR
CVT models ECM
MT models
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) ELECTRICAL UNITS
YHA342
HA-47
AUTO
TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d) WITH GA ENGINE or DIESEL ENGINE
To HA-A/C-05
LOW
HIGH
DUAL-PRESSURE SWITCH
AIR CONDITIONER RELAY
NORMAL
To HA-A/C-09
: With GA engine : With diesel engine
Lotemp
ECM
Hitemp
THERMAL PROTECTOR
IACV-FICD SOLENOID VALVE
COMPRESSOR
REFER TO THE FOLLOWING ELECTRICAL UNITS ELECTRICAL UNITS
: This connector is not shown in “HARNESS LAYOUT” of EL section.
YHA343
HA-48
AUTO
TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d) WITH GASOLINE ENGINE IGNITION SWITCH ON or START
HA-A/C-08
BATTERY
Refer to EL-POWER.
10A 11
M1 SQ
5H
BR
BR
BR
, E127
G
GA
17C
12
40A f
FUSE BLOCK (J/B)
M70 E125 GA SQ BR
G
2
3
1
5
LG/R
G/B
COOLING FAN RELAY-1
E45
G/B LG/R
*
GA
: With GA engine
SQ
: With SR engine or QG engine
*
1
*2
1
LG/R
SQ
: E42
GA
: E65
SQ
:
GA
: F70
F4
G/B 1
1
M
COOLING FAN MOTOR-1
M
E19 2
2
B
B
COOLING FAN MOTOR-2
E28 :
SQ
E94 :
GA
SQ : 7 GA : 4 LG/R
SQ : 13
2 RFRL
*
GA : 9
ECM F101
B
B
E11
E37
REFER TO THE FOLLOWING
M1
3 1 2
1
E19 , E28 , E94 B GY B
1 2 3 4 5 6 7 8 9 10
F4 GY
2 5
1
2 3 4 5 6 7 8 9
E45 B
1 2 3 4 5 6 7 E125 8 9 10 11 12 13 14 15 16 BR
FUSE BLOCK - Junction Box (J/B)
E127 FUSE BLOCK - Junction Box (J/B) F101 ELECTRICAL UNITS
F70 GY
YHA235
HA-49
TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)
AUTO
WITH DIESEL ENGINE IGNITION SWITCH ON or START
BATTERY
Refer to EL-POWER
FUSE BLOCK (J/B)
COOLING FAN MOTOR-1
COOLING FAN RELAY-3
COOLING FAN RELAY-1
COOLING FAN RELAY-2
To HA-A/C-07
NORMAL
HIGH HIGH
LOW
COOLING FAN MOTOR-2
TRIPLEPRESSURE SWITCH
LOW
ECM To HA-A/C-05
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) ELECTRICAL UNITS
YHA344
HA-50
AUTO
TROUBLE DIAGNOSES Main Power Supply and Ground Circuit Check
POWER SUPPLY CIRCUIT CHECK FOR AUTO A/C SYSTEM Check power supply circuit for auto air conditioning system. Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.
A/C CONTROL PANEL Check power supply circuit for A/C control panel unit with ignition switch ON. 1. Disconnect A/C control panel harness connector. 2. Connect voltmeter from harness side. 3. Measure voltage across terminal No. p 1 and body ground.
A/C control panel connector
Voltmeter terminal
! YHA237
@
1 p
Body ground
Voltage Approx. 12V
Check body ground circuit for A/C control panel with ignition switch OFF. 1. Disconnect A/C control panel harness connector. 2. Connect ohmmeter from harness side. 3. Check for continuity between terminal No. p 2 , p 8 , p 14 , p 20 and body ground.
A/C control panel connector
Ohmmeter terminal
!
@
2 p 8 p 14 p 20 p
A/C control panel connector
Body ground
Continuity
Yes
YHA238
AUTO AMP. CHECK Check power supply circuit for auto amp. with ignition switch ON. 1. Disconnect auto amp. harness connector. 2. Connect voltmeter from harness side. 3. Measure voltage across terminal No. p 1 and body ground.
Auto amp. connector
Voltmeter terminal
! 1 p
YHA239
HA-51
@ Body ground
Voltage Approx. 12V
AUTO TROUBLE DIAGNOSES Main Power Supply and Ground Circuit Check (Cont’d) Check body ground circuit for auto amp. with ignition switch OFF. 1. Disconnect auto amp. harness connector. 2. Connect ohmmeter from harness side. 3. Check for continuity between terminal No. p 17 and body ground.
Auto amp. connector
Ohmmeter terminal
! YHA240
Continuity
@
17 p
Body ground
Yes
Diagnostic Procedure 1 SYMPTOM: Blower motor does not rotate at all. (Fan switch “AUTO”, “1”, “2”, “3”, “4”) ● Perform PRELIMINARY CHECK 2 before referring to the following flow chart.
Blower motor connector
KHA118
CHECK POWER SUPPLY FOR BLOWER MOTOR. Disconnect blower motor harness connector. Do approx. 12 volts exist between blower motor harness terminal No. p 1 and body ground?
NG
E
Check 15A fuses (No. , at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)
OK
Blower motor connector
H
Check circuit continuity between blower motor harness terminal No. and body ground.
NG 2 p
E
Reconnect blower motor harness connector.
OK H Continuity should exist.
KHA119
CHECK BLOWER MOTOR. NG H
Replace blower motor. Resistor connector H
KHA120
CHECK BLOWER MOTOR CIRCUIT BETWEEN BLOWER MOTOR AND RESISTOR. Do approx. 12 volts exist between resistor harness terminal No. p 5 and body ground? OK
Blower motor connector
Resistor connector H
NG
E
Disconnect blower motor and resistor harness connectors.
H
Note
Check circuit continuity between blower motor harness terminal No. 2 and resistor harness p terminal No. p 5 .
A p
(Go to next page.)
YHA244
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-52
TROUBLE DIAGNOSES Diagnostic Procedure 1 (Cont’d)
AUTO
A p
A/C Control panel connector
H
CHECK RESISTOR AFTER DISCONNECTING IT.
NG
E
Replace resistor.
OK H
CHECK FAN SWITCH. (Refer to Electrical Components Inspection.) (HA-78)
NG
E
Replace A/C control panel.
OK
NHA447
Note H Check circuit continuity between fan switch harness terminal No. p 2 , 8 , p 14 , p 20 and body ground. p Check body ground circuit for A/C control panel. (Refer to Main Power Supply and Ground Circuit Check, HA-51). OK H
Replace blower motor. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-53
AUTO
TROUBLE DIAGNOSES
Diagnostic Procedure 2: Models with relay type 1 SYMPTOM: Blower motor does not rotate at all when the fan speed is in AUTO. (It operates in 1, 2, 3, or 4-speed only.)
LO relay connector
YHA245
CHECK POWER SUPPLY FOR A/C (LO) RELAY. Disconnect LO relay harness connector. Do approx. 12 volts exist between AUTO relay harness terminal No. p 1 and body ground?
NG
E
Check 10A fuse (No.
26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)
OK
LO relay connector H
Check circuit continuity between LO 2 and relay harness terminal No. p body ground. YHA246
NG
E
OK
CHECK FAN SWITCH (Refer to Electrical Components Inspection.) (HA-78) OK
NG H
Replace A/C control panel.
LO relay connector
H
Check circuit continuity between LO relay harness terminal No. p 2 and A/C control panel harness terminal No. 33 . p
YHA247
LO relay connector
Resistor connector
Note
Note
H
CHECK POWER SUPPLY FOR LO RELAY. Do approx. 12 volts exist between LO relay harness terminal No. p 3 and body ground? YHA248
NG
E
Check circuit continuity between resistor harness terminal No. p 8 and LO relay harness terminal No. p 3 .
OK H
A p
A/C control panel connector
(Go to next page.) LO relay connector
Continuity should exist when test leads are connected as shown; itshould not exist when test leads are reversed.
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
NHA448
HA-54
AUTO TROUBLE DIAGNOSES Diagnostic Procedure 2: Models with relay type 1 (Cont’d) A p
LO relay connector
Note
H
Check circuit continuity between LO relay 5 and body harness terminal No. p ground. OK YHA250
H
CHECK LO RELAY AFTER DISCONNECTING IT.
HA-55
NG
E
Replace LO relay.
AUTO
TROUBLE DIAGNOSES
Diagnostic Procedure 2: Models with relay type 2 SYMPTOM: Blower motor does not rotate at all when the fan speed is in AUTO. (It operates in 1, 2, 3, or 4-speed only.)
YHA379
CHECK POWER SUPPLY FOR A/C (LO) RELAY. Disconnect LO relay harness connector. Do approx. 12 volts exist between AUTO relay harness terminal No. p 1 and body ground?
NG
E
Check 10A fuse (No.
26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)
OK H
Check circuit continuity between LO 2 and relay harness terminal No. p body ground. YHA380
NG
E
OK
CHECK FAN SWITCH (Refer to Electrical Components Inspection.) (HA-78) OK
NG H
Replace A/C control panel.
H
Note
Check circuit continuity between LO relay harness terminal No. p 2 and A/C control panel harness terminal No. 33 . p
YHA381
Note
H
CHECK POWER SUPPLY FOR LO RELAY. Do approx. 12 volts exist between LO relay harness terminal No. p 3 and body ground? YHA382
NG
E
Check circuit continuity between resistor harness terminal No. p 8 and LO relay harness terminal No. p 3 .
OK H
A p
(Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
YHA389
HA-56
AUTO TROUBLE DIAGNOSES Diagnostic Procedure 2: Models with relay type 2 (Cont’d) A p
Note Check circuit continuity between LO relay harness terminal No. p 5 and body ground. H
H
OK NG
CHECK LO RELAY AFTER DISCONNECTING IT.
E
Replace LO relay.
YHA384
Diagnostic Procedure 3: Models with relay type 1 Control panel connector
SYMPTOM: Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in HIGH or MED.)
Auto amp. connector
C/R *1
YHA262
Auto amp. connector
CHECK AUTO AMP. AND PTC. Connect checking resistor. (Refer to HA-51.) Does blower motor fan speed change when you move PTC from 18°C (64°F) to 32°C (90°F)?
Note NG
E
OK
Control panel connector
CHECK PTC CIRCUIT BETWEEN CONTROL PANEL AND AUTO AMP. Disconnect control panel and auto amp. harness connectors. Check circuit continuity between control panel harness terminal No. 21 and auto amp. harp ness terminal No. p 4 . OK
H YHA263
Note
H
Check circuit continuity between control panel harness terminal No. 25 and auto amp. harp 5 . ness terminal No. p
CHECK SENSOR CIRCUIT. How to repair Ambient sensor circuit
Go to Diagnostic Procedure 11.
In-vehicle sensor circuit
Go to Diagnostic Procedure 12.
Reconnect control panel harness connector.
OK
OK F
H
CHECK A/C CONTROL PANEL. (Refer to HA-51.) NG H
Replace A/C Control panel. H
p A
(Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-57
AUTO TROUBLE DIAGNOSES Diagnostic Procedure 3: Models with relay type 1 (Cont’d) A p
Auto amp. connector H
Checking resistor Refer to pageHA-30. NHA301
CHECK AUTO AMP. Connect checking resistor. (Refer to HA-30.) Do approx. 12 volts exist between auto amp. harness terminal No. p 15 , p 16 and body ground?
NG
E
Replace auto amp.
OK H
Blower motor connector
CHECK HIGH OR MED-HIGH, MEDLOW RELAY AFTER DISCONNECTING IT. (Refer to HA-78.)
HIGH relay connector
E
Replace HIGH relay or MED-HIGH, MED-LOW relay.
OK Note
H
NHA449
Does continuity exist between blower motor harness terminal No. p 2 and 3 ? HIGH relay terminal No. p Yes Note
H
Fan resistor connector
NG
MED-HIGH Relay connector
Does continuity exist between resistor harness terminal No. p 6 and MEDHIGH relay harness terminal No. p 3 ? Yes H
Replace auto amp.
YHA253
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-58
AUTO
TROUBLE DIAGNOSES
Diagnostic Procedure 3: Models with relay type 2 Control panel connector
SYMPTOM: Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in HIGH or MED.)
Auto amp. connector
C/R *1
YHA262
Auto amp. connector
CHECK AUTO AMP. AND PTC. Connect checking resistor. (Refer to HA-51.) Does blower motor fan speed change when you move PTC from 18°C (64°F) to 32°C (90°F)?
Note NG
E
OK
Control panel connector
CHECK PTC CIRCUIT BETWEEN CONTROL PANEL AND AUTO AMP. Disconnect control panel and auto amp. harness connectors. Check circuit continuity between control panel harness terminal No. 21 and auto amp. harp 4 . ness terminal No. p OK
H YHA263
Note
H
CHECK SENSOR CIRCUIT.
Check circuit continuity between control panel harness terminal No. 25 and auto amp. harp ness terminal No. p 5 .
How to repair Ambient sensor circuit
Go to Diagnostic Procedure 11.
In-vehicle sensor circuit
Go to Diagnostic Procedure 12.
Reconnect control panel harness connector.
OK
OK F
H
CHECK A/C CONTROL PANEL. (Refer to HA-51.) NG H
Replace A/C Control panel. H
p A
(Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-59
AUTO TROUBLE DIAGNOSES Diagnostic Procedure 3: Models with relay type 2 (Cont’d) A p
Auto amp. connector H
Checking resistor Refer to pageHA-30. NHA301
CHECK AUTO AMP. Connect checking resistor. (Refer to HA-30.) Do approx. 12 volts exist between auto amp. harness terminal No. p 15 , p 16 and body ground?
NG
E
Replace auto amp.
OK H
Blower motor connector
CHECK HIGH OR MED-HIGH, MEDLOW RELAY AFTER DISCONNECTING IT. (Refer to HA-78.)
HIGH relay connector
NG
E
Replace HIGH relay or MED-HIGH, MED-LOW relay.
OK Note
H
NHA449
Does continuity exist between blower motor harness terminal No. p 2 and 3 ? HIGH relay terminal No. p Yes Note
H
Does continuity exist between resistor harness terminal No. p 6 and MEDHIGH relay harness terminal No. p 3 ? Yes H
Replace auto amp.
YHA385
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-60
AUTO
TROUBLE DIAGNOSES
Diagnostic Procedure 4: Models with relay type 1 Auto amp. connector
AUTO amp. connector
YHA254
SYMPTOM: Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in LOW.) CHECK THERMAL TRANSMITTER. Disconnect auto amp. harness connector. Is resistance between auto amplifier terminal No. p 10 and p 5 lower than approx. 940Ω?
OK
E
NG
CHECK POWER SUPPLY FOR LOW RELAY. Disconnect low relay. Do approx. 12 volts exist between low relay harness terminal No. p 1 and body ground? OK
NG
H
CHECK THERMAL TRANSMITTER CIRCUIT. Go to Diagnostic Procedure 14. (HA-77) YHA390 H
H
Reconnect low relay.
Check 10A fuse (No.
26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)
A/C control panel connector
H
NHA450
NG
CHECK A/C CONTROL PANEL Do approx. 0.5V exist between A/C control panel terminal p 35 and body ground when you select AUTO position?
E
Replace A/C control panel.
OK Auto amp. connector
A/C control panel connector
Note
H
Check circuit continuity between A/C control panel harness terminal p 35 and 11 . auto amp. harness terminal p OK H
YHA259
CHECK AUTO AMP. Connect checking resistor. (Refer to HA-30.) Do approx. 0 volts exist between low relay harness terminal No. p 2 and body ground when you move PTC from 18°C (64°F) to 32°C (90°F)? H
NG
E
Replace low relay.
OK
A p
(Go to next page) YHA391
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-61
AUTO TROUBLE DIAGNOSES Diagnostic Procedure 4: Models with relay type 1 (Cont’d) A p
Auto amp. connector H
YHA257
CHECK POWER SUPPLY FOR AUTO AMP. Disconnect auto amp. harness connector. Do approx. 12 volts exist between auto amp. harness terminal No. p 1 and body ground?
NG
E
Check 10A fuse (No.
26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)
OK Note
H
Auto amp. connector
CHECK BODY GROUND CIRCUIT FOR AUTO AMP. Does continuity exist between auto amp. harness terminal No. p 17 and body ground? OK YHA258
H
Replace auto amp. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-62
AUTO
TROUBLE DIAGNOSES
Diagnostic Procedure 4: Models with relay type 2 Auto amp. connector
AUTO amp. connector
YHA254
SYMPTOM: Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in LOW.) CHECK THERMAL TRANSMITTER. Disconnect auto amp. harness connector. Is resistance between auto amplifier terminal No. p 10 and p 5 lower than approx. 940Ω?
OK
E
NG
CHECK POWER SUPPLY FOR LOW RELAY. Disconnect low relay. Do approx. 12 volts exist between low relay harness terminal No. p 1 and body ground? OK
NG
H
CHECK THERMAL TRANSMITTER CIRCUIT. Go to Diagnostic Procedure 14. (HA-77) YHA386 H
H
Reconnect low relay.
Check 10A fuse (No.
26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)
A/C control panel connector
H
NHA450
NG
CHECK A/C CONTROL PANEL Do approx. 0.5V exist between A/C control panel terminal p 35 and body ground when you select AUTO position?
E
Replace A/C control panel.
OK Auto amp. connector
A/C control panel connector
Note
H
Check circuit continuity between A/C control panel harness terminal p 35 and 11 . auto amp. harness terminal p OK H
YHA259
CHECK AUTO AMP. Connect checking resistor. (Refer to HA-30.) Do approx. 0 volts exist between low relay harness terminal No. p 2 and body ground when you move PTC from 18°C (64°F) to 32°C (90°F)? H
NG
E
Replace low relay.
OK
A p
(Go to next page) YHA387
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-63
AUTO TROUBLE DIAGNOSES Diagnostic Procedure 4: Models with relay type 2 (Cont’d) A p
Auto amp. connector H
YHA257
CHECK POWER SUPPLY FOR AUTO AMP. Disconnect auto amp. harness connector. Do approx. 12 volts exist between auto amp. harness terminal No. p 1 and body ground?
NG
E
Check 10A fuse (No.
26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)
OK Note
H
Auto amp. connector
CHECK BODY GROUND CIRCUIT FOR AUTO AMP. Does continuity exist between auto amp. harness terminal No. p 17 and body ground? OK YHA258
H
Replace auto amp. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-64
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 5
SYMPTOM: Starting fan speed control does not operate. A/C control panel connector
CHECK THERMAL TRANSMITTER CIRCUIT. Go to Diagnostic Procedure 14. (HA77)
NG
E
Replace engine thermal transmitter.
E
Replace A/C control panel
OK NHA451
Auto amp. connector
A/C control panel connector
H
CHECK A/C CONTROL PANEL OPERATION Do approx. 12V exist between A/C control panel harness terminal p 22 and body ground when water temp. is below 56°C (133°F)?
NG
NG Note
H
YHA259
Disconnect auto amp. and A/C control panel harness connector. Check circuit continuity between auto amp. harness terminal No. p 11 and A/C control panel harness terminal No. 35 . p OK H
Replace auto amp. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-65
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 6
SYMPTOM: There is too much difference between setting temp. on PTC and in-vehicle temperature. ● Perform PRELIMINARY CHECK 2 before referring to the following flow chart.
Air mix door motor connector
C/R *2
Checking resistor Refer to pageHA-30.
RHA963G
CHECK PBR. Connect checking resistor. (Refer to HA-30.) Do approx. 5 volts exist between air mix door motor harness terminal No. 4 and p 3 when PTC is set at p 25°C (77°F)?
NG
E
CHECK PTC. (Refer to HA-84.) OK H
Replace A/C control panel.
OK H
A p
(Go to next page.)
NG
H
CHECK PBR. Refer to Inspection of Sensor. OK
H
Replace auto amp.
NG
H
CHECK AIR MIX DOOR MECHANISM. Refer to Control Linkage Adjustment. (Refer to HA-83.) OK
NG H
Repair or adjust. H
Replace AIR MIX MOTOR.
HA-66
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 6 (Cont’d) A p
CONNECT
H
Auto amp. connector M421
CHECK IN-VEHICLE SENSOR AND AMBIENT SENSOR. (Refer to Control System Input Components.) (HA-85, 86)
NG
E
Replace in-vehicle sensor or ambient sensor.
E
Replace sunload sensor or auto amp.
OK H
CHECK SUNLOAD SENSOR. Go to Diagnostic Procedure 13. (HA76) Auto amp. connector M421
NG
OK H
RHA037H
CHECK AUTO AMP. OPERATION. Do approx. 0.5 volts exist between auto amp. harness terminal No. p 9 and body ground when A/C switch is ON? Do approx. 0 volts exist between auto amp. harness terminal No. p 9 and body ground when A/C switch is OFF?
NG
E
CHECK A/C CONTROL PANEL OPERATION. Do approx. 0.5 volts exist between A/C control panel connector terminal No. p 29 and body ground when A/C switch is ON? OK
OK
NG H
Replace A/C control panel
H
Replace auto amp.
H
Note
Check circuit continuity between A/C control panel harness terminal 29 and Auto amp. harp ness terminal p 9
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-67
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 7 Control panel connector
SYMPTOM: Air mix door motor does not operate normally. ● Perform PRELIMINARY CHECK 2 before referring to the following flow chart.
Auto amp. connector
C/R *2
YHA262
CHECK AUTO AMP. AND PTC. Connect checking resistor. (Refer to page HA-30.) Does air outlet temperature change when you move PTC from 20°C (68°F) to 30°C (86°F)?
NG
E
OK Auto amp. connector
Control panel connector
Note CHECK PTC CIRCUIT BETWEEN PTC AND AUTO AMP. Disconnect control panel and auto amp. harness connectors. Check circuit continuity between control panel harness terminal No. 21 and auto amp. harp ness terminal No. p 4 . OK
H
Check circuit continuity between control panel harness terminal No. 25 and auto amp. harp ness terminal No. p 5 .
CHECK SENSOR CIRCUIT. How to repair YHA263
Ambient sensor circuit
Go to Diagnostic Procedure 11.
In-vehicle sensor circuit
Go to Diagnostic Procedure 12.
Air mix door motor connector
Note
H
H
OK
NG
CHECK PTC. (Refer to HA-84.)
E
Replace A/C control panel.
OK H
CHECK FOR OUTPUT OF AUTO AMP. Connect checking resistor. Do approx. 10.5 volts exist between air mix door motor harness terminals No. 4 and p 1 when you move PTC p from 18°C (64°F) to 32°C (90°F) or when you move PTC from 32°C (90°F) to 18°C (64°F)? Air mix door operation NHA303
Terminal No. 1 p
4 p
Cold , Hot
!
@
Hot , Cold
@
!
Stop
—
—
Voltage Approx. 10.5V 0V
NG
E
Disconnect auto amp. and air mix door motor harness connectors.
Note
H
Check circuit continuity between auto amp. harness terminal No. p 12 (p 13 ) and air mix door motor harness terminal No. p 1 (p 4 ). OK H
Replace auto amp. H
OK
Replace air mix door motor. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-68
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 9
SYMPTOM: Intake door does not change. ● Perform PRELIMINARY CHECK 1 and Main Power Supply and Ground Circuit Check before referring to the following flow chart.
Intake door motor connector
YHA261
CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR. Disconnect intake door motor harness connector. Do approx. 12 volts exist between intake door motor harness terminal No. 1 and body ground? p
NG
E
Check 10A fuses (No. 20 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)
OK Intake door motor connector
Continuity should exist when test leads are connected as shown; itshould not exist when test leads are reversed.
Intake door motor connector
H
CHECK BODY GROUND CIRCUIT FOR INTAKE DOOR MOTOR. Does continuity exist between intake door motor harness terminal No. p 3 and body ground when REC switch is ON? Does continuity exist between intake door motor harness terminal No. p 4 and body ground when REC switch is OFF? OK
NG
E
Disconnect control panel harness connector.
Note
H
Check circuit continuity between control panel harness terminal No. 4 (p 6 ) and intake p door motor harness terminal No. p 3 (p 4 )? OK
H
Replace intake door motor. NHA452
Control panel connector
Intake door motor connector
H
Replace A/C control panel.
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
YHA265
HA-69
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 10
SYMPTOM: Magnet clutch does not engage when A/C switch and fan switch are ON. Compressure connector
YHA266
Yes Check the following. CHECK POWER SUPPLY FOR E COMPRESSOR. ● Magnet clutch coil Disconnect compressor harness conNG nector. H Do approx. 12 volts exist between Replace magnet clutch. compressor harness terminal No. Refer to HA-111. 1 and body ground? p No
Compressure connector
Note H Check circuit continuity between A/C NG relay harness terminal No. p 3 and compressor harness terminal No. 1 . p Continuity should exist. If OK, check harness for short.
A/C relay connector
E
Check the following. ● Thermal protector (GA, diesel engine)
OK YHA267
H
CHECK POWER SUPPLY FOR A/C RELAY. Do approx. 12 volts exist between A/C relay harness terminal No. p 5 and body ground?
A/C relay connector
No
E
Yes H
YHA268
CHECK POWER SUPPLY FOR A/C RELAY. Do approx. 12 volts exist between A/C relay harness terminal No. p 2 and body ground?
Yes
E
No H
CHECK A/C RELAY AFTER DISCONNECTING IT. Refer to HA-78.
A/C relay connector
NG
E
Check power supply circuit and 10A fuse (No. 20 ), located in the fuse block). (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)
Check power supply circuit and 10A fuse (No. 20 ), located in the fuse block). (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.) Replace A/C relay.
OK H
Reconnect A/C relay. YHA269
For Diesel engine
p
(Go to HA-71)
p
(Go to HA-73)
E A
For SR engine or QG engine
EC
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-70
TROUBLE DIAGNOSES Diagnostic Procedure 10 (Cont’d)
AUTO
A p
H
ECM connector
CHECK COIL SIDE CIRCUIT OF A/C RELAY Do approx. 12 volts exist between ECM harness terminal No. 204 and body ground?
No
E
Disconnect A/C relay. Disconnect ECM harness connector.
Yes Note H CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY HARNESS TERMINAL NO. p 1 AND ECM HARNESS TERMINAL NO. 204 . Continuity should exist. If OK, check harness for short.
NHA454
A/C relay connector
ECM connector
H
p B
NHA455
(Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-71
TROUBLE DIAGNOSES Diagnostic Procedure 10 (Cont’d)
AUTO
B p
ECM connector
H
No
CHECK VOLTAGE FOR ECM. Do approx. 12 volts exist between ECM harness terminal No. 403 and body ground? H
NHA456
E
CHECK ECM. Refer to EC section.
Yes
Disconnect ECM harness connector. Disconnect triple-pressure switch harness connector. Yes H
ECM connector
Triplepressure switch connector
CHECK CIRCUIT CONTINUITY BETWEEN ECM HARNESS TERMINAL NO. 403 AND TRIPLE-PRESSURE SWITCH HARNESS TERMINAL NO. p 4 . Continuity should exist. If OK, check harness for short. H
NHA457
NG E Replace triple-pressure
CHECK TRIPLE-PRESSURE SWITCH. Refer to HA-79. H
switch.
OK
Disconnect thermo control amp. switch harness connector. Triple-pressure switch connector
Thermo control amp.
Note
H
YHA280
CHECK CIRCUIT CONTINUITY BETWEEN TRIPLE-PRESSURE SWITCH HARNESS TERMINAL NO. p 1 AND THERMO CONTROL AMP. SWITCH HARNESS TERMINAL NO. p 3 . Continuity should exist. If OK, check harness for short. H
Thermo control amp.
OK
CHECK THERMO CONTROL AMP. Refer to HA-80.
Control panel connector
YHA275
Note H OK Check circuit continuity between control CHECK FOR A/C CONE 10 and thermo panel harness terminal No. p TROL PANEL OPERATION. control amp. No. p 2 . Does approx. 0.5V exist between A/C control panel harness terminal No. 10 and body ground? p OK Check ECM
A/C control panel connector
F
NG H
Replace A/C control panel
Note: If the result is NG or No after checking circuit continuity, repair harness or connector. NHA453
HA-72
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 10 (Cont’d) C p
ECM connector H
CHECK COIL SIDE CIRCUIT OF A/C RELAY Do approx. 12 volts exist between ECM harness terminal No.p 23 and body ground?
No
E
Disconnect A/C relay. Disconnect ECM harness connector.
Yes YHA281
A/C relay connector
Note CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY HARNESS TERMINAL NO. p 1 AND ECM HARNESS TERMINAL NO. p 23 . Continuity should exist. If OK, check harness for short. H
ECM connector
H YHA282
CHECK VOLTAGE FOR ECM. Do approx. 12 volts exist between ECM harness terminal No. p 44 and body ground?
ECM connector
No
E
CHECK ECM. Refer to EC section.
E
Replace pressure sensor.
Yes H
Disconnect ECM harness connector. Disconnect refrigerant pressure sensor harness connector. Yes Note
H NHA458
ECM connector Refrigerant pressure sensor connector
CHECK CIRCUIT CONTINUITY BETWEEN ECM HARNESS TERMINAL NO. p 74 AND PRESSURE SENSOR HARNESS TERMINAL NO. p 2 . Continuity should exist. If OK, check harness for short. H
NG
CHECK PRESSURE SENSOR. Refer to HA-80. H
YHA273
D p
OK
(Go to next page.)
HA-73
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 10 (Cont’d) D p
H
A/C control panel connector
CHECK FOR A/C CONTROL PANEL OPERATION. Does approx. 0.5V exist between A/C control panel harness terminal No. p 10 and body ground?
NG
E
Replace A/C control panel.
OK NHA453
Thermo control amp.
H Note Check circuit continuity between control panel harness terminal No. p 10 and thermo control amp. No. p 2 .
Control panel connector
H
OK
Check ECM.
Note: If the result is NG or No after checking circuit continuity, repair harness or connector. YHA275
Diagnostic Procedure 11 SYMPTOM: Ambient sensor circuit is open or shorted. Ambient sensor connector
YHA283
CHECK AMBIENT SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP. Disconnect ambient sensor harness connector. Do approx. 5 volts exist between ambient sensor harness terminal No. p 1 and body ground?
NG E
Ambient sensor connector
Check circuit continuity between auto amp. harness terminal No. p 8 and ambient sensor harness terminal No. p 1 , and between auto amp. harness terminal No. 8 and body ground. p
H
H
Disconnect auto amp. harness connector.
Ambient sensor connector
Replace auto amp.
Check circuit continuity between ambient sensor harness terminal No. p 2 and auto amp. harness terminal No. p 5 . H
Auto amp. connector
OK
Note
H
YHA284
Note
H
OK
Auto amp. connector
Disconnect auto amp. harness connector.
OK
CHECK AMBIENT SENSOR. (Refer to HA-86.) H
NG E
Replace ambient sensor.
OK
Replace auto amp.
Note: If the result is NG or No after checking circuit continuity, repair harness or connector. YHA285
HA-74
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 12
SYMPTOM: In-vehicle sensor circuit is open or shorted. In-vehicle sensor connector
YHA286
CHECK IN-VEHICLE SENSOR CIRCUIT BETWEEN IN-VEHICLE SENSOR AND AUTO AMP. Disconnect in-vehicle sensor harness connector. Do approx. 5 volts exist between invehicle sensor harness terminal No. 1 and body ground? p
NG
E
Disconnect auto amp. harness connector.
OK
Auto amp. connector
In-vehicle sensor connector
H
Note
H
Check circuit continuity between auto amp. harness terminal No. p 7 and in-vehicle sensor harness terminal No. 1 , and between auto p amp. harness terminal No. p 7 and body ground.
Disconnect auto amp. harness connector.
YHA287
OK Auto amp. connector
In-vehicle sensor connector
Note
H
H
Check circuit continuity between invehicle sensor harness terminal No. 2 and auto amp. harness terminal p 8 . No. p
Replace auto amp.
OK H YHA288
CHECK IN-VEHICLE SENSOR. (Refer to HA-85.)
NG
E
Replace in-vehicle sensor.
OK H
Replace auto amp. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-75
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 13
SYMPTOM: Sunload sensor circuit is open or shorted. Sunload sensor connector
YHA289
CHECK SUNLOAD SENSOR CIRCUIT BETWEEN SUNLOAD SENSOR AND AUTO AMP. Disconnect sunload sensor harness connector. Do approx. 5 volts exist between sunload sensor harness terminal No. p 1 and body ground?
NG
E
Note
H
Check circuit continuity between auto amp. harness terminal No. p 6 and sunload sensor harness terminal No. p 1 and between auto amp. harness terminal No. 6 and body ground. p
OK Auto amp. connector
Disconnect auto amp. harness connector.
Sunload sensor connector
OK H
H
Disconnect auto amp. harness connector.
Replace auto amp.
YHA290
Note
H
Auto amp. connector
Sunload sensor connector
Check circuit continuity between sunload sensor harness terminal No. p 2 and auto amp. harness terminal No. 5 . p OK H
CHECK SUNLOAD SENSOR. (Refer to HA-86.) YHA291
NG
E
Replace sunload sensor.
OK H
Replace auto amp. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-76
AUTO
TROUBLE DIAGNOSES Diagnostic Procedure 14
SYMPTOM: Thermal transmitter circuit is open or shorted. Note Thermal transmitter connector
YHA292
CHECK THERMAL TRANSMITTER CIRCUIT. Disconnect thermal transmitter harness connector. Do approx. 12 volts exist between thermal transmitter harness terminal No. 1 and body ground? p
NG
E
Check circuit continuity between thermal transmitter harness terminal No. p 1 and control panel harness terminal No. p 24 .
OK H
Replace control panel Control panel connector
Thermal transmitter connector
H
Disconnect control panel harness connector. H
YHA293
CHECK THERMAL TRANSMITTER. (Refer to “THERMAL TRANSMITTER CHECK” in EL section.)
NG
E
Replace thermal transmitter.
OK H
Replace control panel Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-77
AUTO
TROUBLE DIAGNOSES Electrical Components Inspection FAN SWITCH Check voltage terminals at each switch position.
A/C control panel
FUNCTION
NHA291
A/C CONTROL PANEL TERMINAL
SWITCH POSITION LOW OFF
MEDIUM MEDIUM LOW HIGH
I
I
I I
II
HIGH
II
II
OFF
—
—
—
—
—
—
FAN RELAY LO
33
12V
<0.5V
<0.5V
<0.5V
<0.5V
FAN RELAY MLO
32
12V
12V
<0.5V
<0.5V
<0.5V
FAN RELAY MHI
31
12V
12V
12V
<0.5V
<0.5V
FAN RELAY HI
30
12V
12V
12V
12V
<0.5V
A/C SWITCH Check voltage terminals at each switch position. Switch condition
Terminal No. 10 p
A/C
29 p
ON
< 0.5V
< 0.5V
OFF
0
0
A/C control panel
NHA292
A/C, LOW, MED-LOW, MED-HIGH and HIGH RELAYS Check continuity between terminal Nos.
3 p
and
5 . p
Conditions
Continuity
1 p
12V direct current supply between terminal Nos. and p 2
Yes
No current supply
No
If NG, replace relay. YHA389
HA-78
AUTO TROUBLE DIAGNOSES Electrical Components Inspection (Cont’d) .
TRIPLE-PRESSURE SWITCH (WITH DIESEL ENGINE) Triple-pressure switch
Terminals
RHA364G
Lowpressure side
Mediumpressure side*
Highpressure side
1 - p 4 p
2 - p 3 p
1 - p 4 p
High-pressure side line pressure kPa (bar, kg/cm2, psi)
Operation
Continuity
Increasing to 152.0 - 201.0 (1.520 - 2.010, 1.55 - 2.05, 22.0 - 29.2)
ON
Exists.
Decreasing to 152.0 - 201.0 (1.520 - 2.010, 1.55 - 2.05, 22.0 - 29.2)
OFF
Does not exist.
Increasing to 1,422 - 1,618 (14.22 - 16.18, 14.5 - 16.5, 206 - 235)
ON
Exists.
Decreasing to 1,128 - 1,422 (11.28 - 14.22, 11.5 - 14.5, 164 - 206)
OFF
Does not exist.
Decreasing to 2,059 - 2,256 (20.6 - 22.6, 21 - 23, 299 - 327)
ON
Exists.
Increasing to 2,648 - 2,844 (26.5 - 28.4, 27 - 29, 384 - 412)
OFF
Does not exist.
* For cooling fan motor operation
HA-79
AUTO TROUBLE DIAGNOSES Electrical Components Inspection (Cont’d)
PRESSURE SENSOR V out (V) Vcc = 5.0 (VDC)
Dual-pressure switch (3.882) GND V out V cc
Pg
(0.362)
0.278 (1.8)
Kpa (kgf/cm2G) KHA121
2.65 (26)
THERMO CONTROL AMP. Evaporator outlet air temperature °C (°F)
Thermo amp. operation
Tester
Decreasing to 0.1 - 0.9 (32 - 34)
Turn OFF
Approx. 12V
Increasing to 2.5 - 3.5 (37 - 38)
Turn ON
Approx. 0V
RHA329F
Control Panel System This control panel system operates the intake door motor to activate their corresponding doors.
SWITCHES AND THEIR CONTROL FUNCTIONS Knob/Switch position A/C
Compressor
q
ON*1
Air outlet Intake air Knob/Switch A/C
q
VENT
Mode
q
B/L q
FOOT q
F/D q
DEF q
*1: Compressor is operated by thermo control amp. (With diesel engine) Compressor is operated by ECM (with SR engine and QG engine).
HA-80
FRE REC
ON*1
TROUBLE DIAGNOSES Control Panel System (Cont’d)
AUTO
INTAKE DOOR MOTOR The intake door motor is installed on the intake unit. When the door position is determined by pushing the “REC” switch on the control panel, the motor rotates and the air inlet is changed.
NHA293
Ignition switch ON
Intake door motor
To A/C control
YHA294
Removal and Installation Refer to “INSTRUMENT PANEL” in BT section for details. Snap ring
Mode cable
NOTE: When removing the control panel, the Mode control cable should be disconnected from the control panel rather than from the heater. Removal of the mode cable will result in breakage of the ferrule retaining clips. On reassembly, the cable is retained by a snap ring (Part number: 9-22504-1) which is pushed into a slot in the control base plate which aligns with a groove in the cable sleeve.
Control panel KHA125
HA-81
TROUBLE DIAGNOSES
AUTO
Control Linkage Adjustment MODE CONTROL CABLE
.
ZHA176A
1. For RHD models, turn the mode control knob to the VENT position. For LHD models, turn the mode control knob to the DEF position. 2. For RHD models, set the side link in the VENT position by hand. For LHD models, set the side link in the DEF position by hand. 3. Pull on the cable cover in the direction of the arrow, then clamp it. After positioning control cable, check that it operates correctly.
RHA630E
WATER COCK CONTROL ROD When adjusting water cock control rod, first disconnect temperature control cable from air mix door lever and then adjust control rod. Reconnect temperature control cable and readjust it. (Refer to TEMPERATURE CONTROL CABLE.) 1. Push air mix door lever in direction of arrow. 2. Pull control rod of water cock in direction of arrow so as to make clearance of about 2 mm (0.08 in) between ends of rod and link lever and connect the rod to door lever. After connecting control rod, check it operates correctly. ●
SHA522E
HA-82
TROUBLE DIAGNOSES Control Linkage Adjustment (Cont’d)
AUTO
AIR MIX DOOR
Heater unit Air mix door link
Air mix door lever Air mix door motor
KHA127
1. Install air mix door motor on heater unit. Ensure that the air mix door motor lever is fitted into slit portion of air mix door link. 2. Connect the air mix door motor harness connector. 3. Turn ignition switch to “ON” position. 4. Check that air mix door operates properly when PTC is moved from 18 to 32°C (64 to 90°F). After positioning control cable, check that it operates correctly.
FRESH VENT CONTROL CABLE 1. Turn the fresh vent control knob to the shut position. 2. Set the fresh vent door lever in shut position. 3. Adjust the position of the cable cover for proper operation, then secure to the clamps. After positioning control cables, check that it operates correctly.
Clamp
Pull
Clamp
Cable cover KHA126
INTAKE DOOR MOTOR 1. Install intake door motor on intake unit. Ensure that the intake door motor lever is fitted into the slit portion of intake door link. 2. Connect the intake door motor harness connector. 3. Turn ignition switch to “ON” position. 4. Check that intake door operates properly when REC switch is turned ON and OFF. ZHA178A
HA-83
AUTO
SYSTEM DESCRIPTION Overview of Control System
The control system consists of a) input sensors and switches, b) the automatic amplifier (microcomputer), and c) outputs. The relationship of these components is shown in the diagram below.
A/C control panel PTC (Potentio temperature Control) A/C switch Autoswitch Fan switch
Ambient sensor
Automatic amplifier (Micro-computer) Air mix door motor
Air mix door
In-vehicle sensor PBR (Potentio Balance Resistor)built-into air mix door motor
sunload sensor LOW, MED, HIGH and AUTO
Blower motor
Thermal transmitter
YHA295
Control System Input Components POTENTIO TEMPERATURE CONTROL (PTC) The PTC is built into the control panel. It can be set at an interval of 1°C in the 18°C to 32°C temperature range by pushing the temperature button. The set temperature is digitally displayed.
Temperature button NHA294
Measure voltage between auto amp. terminal ground. Auto amp. connector
NHA315
HA-84
4 p
and body
AUTO SYSTEM DESCRIPTION Control System Input Components (Cont’d)
Output voltage
PTC Output voltage
Set temperature
(°C)
KHA128
IN-VEHICLE SENSOR The in-vehicle sensor is attached to the right side of the control unit. It converts variations in the temperature of the compartment air drawn in by the aspirator into a resistance value, which is then input into the auto amplifier. In-vehicle sensor
NHA295
After disconnecting in-vehicle sensor harness connector, measure resistance between terminals p 1 and p 2 at sensor harness side, using the table below. In-vehicle sensor
Temperature °C (°F)
Resistance kΩ
0 (32)
6.0
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
In-vehicle sensor
NHA287
Aspirator Aspirator duct Aspirator
The aspirator is located in front of heater unit. It produces vacuum pressure due to air discharged from the heater unit, continuously taking compartment air in the aspirator.
NHA312
HA-85
AUTO SYSTEM DESCRIPTION Control System Input Components (Cont’d) Aspirator
Aspirator duct
Heater unit case
RHA979G
AMBIENT SENSOR The ambient sensor is located on the hood lock stay. It detects the ambient temperature and converts it into a resistance value, which is then input into the auto amplifier.
Ambient sensor
NHA313
After disconnecting ambient sensor harness connector, measure resistance between terminals p 1 and p 2 at sensor harness side, using the table below.
Ambient sensor harness connector
Temperature °C (°F)
Resistance kΩ
−20 (−4)
9.98
−10 (14)
5.57
0 (32)
3.26
10 (50)
1.98
20 (68)
1.25
25 (77)
1.00
30 (86)
0.81
40 (104)
0.54
Ambient sensor
NHA288
SUNLOAD SENSOR The sunload sensor is located on the center defroster grille. It detects sunload entering through the windshield by means of a photo diode and converts it into a current value which is then input to the auto amplifier.
Sunload sensor
NHA314
HA-86
AUTO SYSTEM DESCRIPTION Control System Input Components (Cont’d) Measure voltage between terminals p 5 and p 6 at auto air conditioner harness side, using the table below.
Auto amplifier
Auto amp. connector Auto amp. connector
●
Input current mA
Output voltage V
0
5.00
0.1
4.09
0.2
3.18
0.3
2.27
0.4
1.36
0.5
0.45
When checking sunload sensor, select a place where sun shines directly on it.
NHA289
A/C RELAY .
The A/C relay is located on the left side of the engine room. When the A/C remain and fan switch are ON, the A/C relay operates and transmits A/C operation signals to ECM.
A/C Relay
NHA298
Control System Auto Amplifier (Auto amp.) The auto amplifier has a built-in microcomputer which processes the information sent from the various sensors needed for air conditioner operation. The air mix door motor and blower motor are then controlled. Signals from the various switches and the Potentio Temperature Control (PTC) are directly entered into the auto amplifier.
Auto amplifier
RHA024H
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
HA-87
AUTO SYSTEM DESCRIPTION Control System Auto Amplifier (Auto amp.) (Cont’d) 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.
SUNLOAD COMPENSATION The auto amplifier compensates for sunload by altering the air mix door position and air flow volume according to the amount of sunload detected by the sunload sensor. When the amount of sunload is great, the air mix door is moved toward the “COLD” side. Along with this air mix door movement, air flow volume will also be changed.
Auto amplifier A/C control panel PTC
In-vehicle sensor
Air mix door position arithmetic circuit
Air mix door motor
Air flow volume arithmetic circuit
LOW, MED, HIGH and AUTO relays
Ambient sensor Sunload compensation Sunload sensor
Air mix door position compensation amount
YHA296
Sunload kW (kcal/h, BTU/h)/m2 [kW (kcal/h,BTU/h)/sq ft]
0.768 (660, 2,619) [0.0713 (61.31, 243.3)]
Sunload compensation specifications SHA493CA
HA-88
AUTO SYSTEM DESCRIPTION Control System Auto Amplifier (Auto amp.) (Cont’d)
A/C SWITCH COMPENSATION The auto amplifier alters the air mix door position and air flow volume according to a signal emitted from the A/C switch. When the A/C switch is “ON”, the auto amplifier compensates for the PBR’s input signal and moves the air mix door toward the “HOT” side. Auto amplifier A/C control panel PTC
In-vehicle sensor Air mix door position arithmetic circuit Ambient sensor Air mix door motor
Output signal process
Sunload sensor
A/C control panel A/C switch
PBR
Sunload compensation
YHA297
Air mix door opening ratio
(%) 100
15
0
0
100
(%)
Air mix door position arithmetic value A/C switchcompensation specifications KHA115
HA-89
SYSTEM DESCRIPTION
AUTO
Control System Output Components AIR MIX DOOR CONTROL (Automatic temperature control) Component parts Air 1) 2) 3) 4) 5) 6)
mix door control system components are: Auto amplifier Ambient sensor In-vehicle sensor Sunload sensor Air mix door motor (PBR) A/C switch
System operation The air mix door is automatically controlled so that in-vehicle temperature is maintained to the set temperature. The temperature set by the PTC (Potentio Temperature Control) and the temperature detected by the in-vehicle sensor and ambient sensor are compensated by the sunload sensor signal. The auto amplifier then determines the air mix door position. The air mix door position detected by the PBR is compensated by the ON-OFF operation of the A/C switch. The air mix door position determined by the auto amplifier is compared with that detected by the PBR. The auto amplifier then transmits the signal to the air mix door motor in order to activate it.
Auto amplifier
Constant voltage transformation PTC In-vehicle sensor
Ambient sensor PBR
Air mix door position arithmetic circuit
Air mix door motor
Sunload compensation
sunload sensor Air mix door position detection
A/C switch
A/C switch compensation
KHA116
HA-90
AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d) Air mix door control specifications
PTC: 25°C (77°F) Condition
Fan switch Auto Withoutsunload
Ambient temperature °C (°F) 2.4
Voltage (V)
2.3
-20 (-4) -10 (-4)
0 (32) 2.2 A/C switch OFF 10(50) 2.1 20 (68) A/C switch ON 25 (77)
2.0
30(86)
1.9 54.5 Air mix door opening angle 0.5
1.0
1.5 2.0 2.5 PBRresistance (kΩ)
40 (104) (59)
(68) (77) (86) In vehicle temperature °C (°F)
(95)
(104)
3.0
SHA497CB
SENSOR INPUT PROCESS Auto amplifier
The auto amplifier detects the voltage produced by each sensor, the PBR and fixed resistor. The fixed resistor is built into the auto amplifier. 12-volt power voltage is first converted to approximately 5 volts by the constant voltage circuit where it is then applied to the ground line of the auto amplifier via the fixed resistor and the sensor. In this manner, the auto amplifier monitors the voltages of the fixed resistor, each sensor and the PBR to determine sensor input.
Constant-voltage circuit Fixed resistor
Detection of sensor voltage Each sensor
RHA790A
HA-91
AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d)
OPERATION OF AIR MIX DOOR MOTOR ●
Auto amp. Comparator (1) Air mix door position arithmetic circuit
Air mix door motor
Example p 1 When the temperature in the vehicle is lower than the set temperature. When the temperature in the vehicle is low, in-vehicle sensor resistance is great and the input voltage to the auto amplifier becomes great. As a result, the voltage from the air mix door position arithmetic circuit also becomes great. When this voltage is greater than the voltage from the PBR, comparator (1), Tr p 1 and Tr p 4 turn ON. 12 becomes ! and terminal No. Accordingly terminal No. p 13 becomes @. The air mix door motor rotates clockwise and p the air mix door moves toward the “HOT” side.
PBR Comparator (2)
RHA514DB
As the air mix door moves toward the “HOT” side, the voltage from the PBR becomes greater and consequently becomes equal to that from the air mix door position arithmetic circuit. As a result, comparator (1) turns OFF and the air mix door motor stops.
Auto amp. Comparator (1) Air mix door position arithmetic circuit
Air mix door motor
PBR Comparator (2)
SHA568CB
HA-92
AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d) ● Example p 2
Auto amp. Comparator (1) Air mix door position arithmetic circuit
Air mix door motor
When the temperature in the vehicle is higher than the set temperature. When the temperature in the vehicle is high, in-vehicle sensor resistance is small and the input voltage to the auto amplifier becomes small. As a result, the voltage from the air mix door position arithmetic circuit also becomes small. When this voltage is smaller than the voltage from the PBR, comparator (2), Tr p 2 and Tr p 3 turn ON. 13 becomes ! and terminal No. Accordingly terminal No. p 12 becomes @. The air mix door motor rotates counterclockp wise and the air mix door moves toward the “COLD” side.
PBR Comparator (2)
SHA569CB
As the air mix door moves toward the “COLD” side, the voltage from the PBR becomes smaller and consequently becomes equal to that from the air mix door position arithmetic circuit. As a result, comparator (2) turns OFF and the air mix door motor stops.
Auto amp. Comparator (1) Air mix door position arithmetic circuit
Air mix door motor
PBR Comparator (2)
SHA570CB
AIR MIX DOOR MOTOR
Heater unit Air mix door link
The air mix door motor is attached to the heater unit. It rotates so that the air mix door is opened to a position set by the auto amplifier. Motor rotation is conveyed through a shaft. The air mix door position is then fed back to the auto amplifier by the PBR built into the air mix door motor.
Air mix door lever Air mix door motor
KHA127
HA-93
AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d) Air mix door motor connector M413
(Cold side)
(HOT side)
2
1
Air mix door operation
Direction of lever movement
!
@
COLD , HOT
Clockwise (Toward passenger compartment)
—
—
STOP
STOP
@
!
HOT , COLD
Counterclockwise (Toward engine compartment)
PBR RHA026H
Characteristic PBR
Resistance of PBR (Ω) 4 andp 3 ) (resistance between terminal p
.
3.0
2.5
2.0
1.5
1.0
0.5
60° COLD
Air mix door opening angle
HOT KHA129
PBR Measure voltage between terminals ness side.
Air mix door motor
and
4 p
at vehicle har-
NHA311
Ignition switch: ON
5.0
●
4.0 Voltage (V)
3 p
Ensure tester pointer deflects smoothly when PTC is moved from 18°C (64°F) to 32°C (90°F) and vice versa.
3.0 2.0 1.0 0 Full cold
Full hot
Air mix door opening angle PBR RHA607AA specification
HA-94
AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d)
FAN SPEED CONTROL Component parts Fan speed control system components are: 1) Auto amplifier 2) In-vehicle sensor 3) Ambient sensor 4) Sunload sensor 5) A/C switch relay 6) A/C switch 7) Fan switch 8) Blower motor 9) Resistance 10) HI, MH, ML and LO relays
System operation Blower fan speed is automatically controlled so that the in-vehicle temperature is maintained to the set temperature. The temperature set by the PTC (Potentio Temperature Control) and the temperature detected by the invehicle sensor and ambient sensor are compensated by the sunload sensor signal. The auto amplifier then determines fan speed from the ON-OFF operation of the A/C switch. The fan speed decision by the auto amplifier activates the fan relay and the blower fan motor rotates. When the A/C switch is ON, fan speed is activated in 4 steps, HI, MH, ML, and LO. When the A/C switch is OFF, fan speed is activated in 3 steps, MH, ML, and LO.
Auto amplifier
HI relay
Constant voltage transformation Air mix door position arithmetic circuit In-vehicle sensor Ambient sensor Sunload sensor
A/C operation signal detection
Blower motor
Resistor MH relay
Sunload compensation Air flow volume arithmetic circuit
ML relay
A/C switch
LO relay
Fan switch (AUTO) KHA130
HA-95
AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d)
SHA573CC
HI relay
Blower motor
Signals from each sensor, PTC, A/C switch etc. are sent to the air flow volume arithmetic circuit in the auto amplifier. Air flow volume is determined by this circuit. (1) When the air flow volume is set to ML The air flow volume arithmetic circuit gives current to Tr p 3 , which turns the ML relay on. Thus, the blower motor rotates in the ML condition.
Resistor MH relay Air flows volume arithmetic circuit
ML relay
Fan switch (AUTO)
A/C (LO) relay
SHA574CA
HA-96
AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d) (2) When set to HI The air flow volume arithmetic circuit gives current to Tr p 1 , which turns the HI relay on. Thus, the blower motor rotates in the HI condition. Also, Tr p 2 and Tr p 3 are receiving current and as a result the ML and MH relays are on. Auto amp.
HI relay
Blower motor Resistor
MH relay Air flows volume arithmetic circuit
ML relay
Fan switch (AUTO)
LO relay
SHA574CA
Auto amp.
(3) When set to LO The air flow volume arithmetic circuit does not give any current to Tr p 1 , p 2 nor p 3 . Only the LO relay turns on and so the blower motor rotates in the LO condition.
HI relay
Blower motor
Resistor MH relay Air flows volume arithmetic circuit
ML relay
Fan switch (AUTO)
LO relay
SHA576CA
HA-97
AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d)
STARTING FAN SPEED CONTROL
Blower speed
The starting fan control system is so designed to prevent excess cold air from being expelled after the engine is started when the engine coolant temperature is low. The component parts related to this system are the water temperature sensor microswitch, HI, MH, ML and LO relays, blower motor, resistance and auto amplifier. When the fan switch is set to AUTO, the mode is selected either B/L, FOOT or FOOT/DEF and the engine coolant temperature is below 56°C (133°F), the speed of the blower motor is fixed in the LO position.
1.0
0 (32)
50 (122)
°C (°F)
Auto amp. . .
Constant voltage transformation
Blower motor
HI relay
.
Sensor voltage
Air mix door position arithmetic circuit
Air flow volume arithmetic circuit
Mode switch
Resistor MH relay
ML relay
LO relay
Water temperature meter
Fan switch (AUTO)
Thermal transmitter
SHA188DA
LO, ML, MH AND HI RELAYS . . .
.
HI relay
ML relay
LO relay
The LO and ML relays are located on the auto amplifier bracket, and the MH and HI relays are installed on the back side of the audio unit. Each fan relay operates according to the air flow volume determined by the auto amplifier. The blower motor then operates accordingly.
MH relay
NHA304
HA-98
AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d) IGN
ACC
Auto amplifier HI relay
Resistor MH relay
Air flows volume arithmetic circuit
ML relay
LO relay
Fan switch (AUTO)
SHA578CA
HA-99
AUTO
SERVICE PROCEDURES HFC-134a (R-134a) Service Procedure
SETTING OF SERVICE TOOLS AND EQUIPMENT DISCHARGING REFRIGERANT WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting requirements of HFC-134a (R-134a) recycling equipment or HFC-134a (R-134a) recovery equipment. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Shut-off valve
A/C service valve
Recovery/Recycling/Recharghing equipment SHA539DC
EVACUATING SYSTEM AND CHARGING REFRIGERANT
Manifold gauge set Shut-off valve
Shut-off valve
A/C service valve
A/C service valve
For charging
Refrigerant container (HFC-134a) Weight scale
Recovery/Recycling/Recharging equipment
For evacuating vacuum pump
SHA540DC
HA-100
SERVICE PROCEDURES HFC-134a (R-134a) Service Procedure (Cont’d) Set the recovery/recycling equipment.
Recovered lubricant. HA-100.
H
Discharge refrigerant into recovery/ recycling equipment. H
Repair or replace parts. H
Evacuate the unwanted air in charging hoses. H
Evacuating (over 25 minutes). H E
Check airtightness H
E
Repair.
E
Repair.
E
Repair.
*-1
Partial charging [approx. 200 g (7.05 oz)]. H
Preliminary refrigerant leak check. H
*-1
Complete charging [specified amount -200 g (7.05 oz)] H
*-2
Check for refrigerant leaks. H
Check for A/C operation and A/C cooling performance H
Remove service couplers from A/C service valves. H
Recover refrigerant in charging hoses. H
Remove service tools.
Note: *-1 Before charging refrigerant, ensure engine is OFF. *-2 Before checking for leaks, start engine to activate air conditioner system then turn it OFF. Service valve caps must be attached to valves (to prevent leakage).
HA-101
AUTO
AUTO
SERVICE PROCEDURES Maintenance of Lubricant Quantity in Compressor
The lubricant used to lubricate the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large gas 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)
LUBRICANT CR-14 Name: Nissan A/C System Oil Type R Part number: KLH00-PAGR0 CSV613 Name: Nissan A/C System Oil Type S Part number: KLH00-PAGS0
CHECKING AND ADJUSTING Adjust the lubricant quantity according to the flowchart shown below.
START H
Yes
Can lubricant return operation be performed? ● A/C system works properly. ● There is no evidence of a large amount of lubricant leakage.
E
No
H
Should the compressor be replaced? No
F
Yes
H
A p
(Go to next page.)
H
Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large amount of lubricant leakage.)
Yes
E
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
No
H
Carry out the A/C performance test.
Perform lubricant return operation, proceeding as follows: -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------1. Start engine, and set the following conditions: ● Test condition Engine speed: Idling to 1,200 rpm A/C or AUTO switch: ON Blower speed: Max. position Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).] 2. Next item is for CSV613 compressor. Connect the manifold gauge, and check that the high pressure side pressure is 588 kPa (5.9 bar, 6 kg/cm2, 85 psi) or higher. If less than the reference level, attach a cover to the front face of the condenser to raise the pressure. 3. Perform lubricant return operation for about 10 minutes. 4. Stop engine. CAUTION: If excessive lubricant leakage is noted, do not perform the lubricant return operation.
F
Amount of lubricant m (Imp fl oz)
Remarks
Evaporator
75 (2.6)
—
Condenser
75 (2.6)
—
Liquid tank
5 (0.2)
Add if compressor is not replaced. *1
In case of refrigerant leak
30 (1.1)
Large leak
—
Small leak*2
*1: If compressor is replaced, addition of lubricant is included in the flow chart. *2: If refrigerant leak is small, no addition of lubricant is needed.
HA-102
SERVICE PROCEDURES Maintenance of Lubricant Quantity in Compressor (Cont’d)
AUTO
A p
H
1.Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/ recycling equipment. 2. Remove the drain plug of the “old”(removed) compressor (applicable only to V-5, V-6, DKS-16H or DKS-17CH compressor). Drain the lubricant into a graduated container and recordthe amount of drained lubricant. 3. Remove the drain plugand drain the lubricant from the “new” compressor into aseparate, clean container. 4. Measure an amount of newlubricant installed equal to amount drained from “old” compressor. Add this lubricant to “new” compressor through thesuction port opening. 5. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to “new” compressor through the suction port opening. 6.Torque the drain plug. CWV618 or CSV613compressor: 18 - 19 (1.8 - 1.9 kg-m, 13 - 14 ft-lb) DKS-16Hcompressor: 14 - 16 (1.4 - 1.6 kg-m, 10 - 12 ft-lb) DKS-17CHcompressor: 14 - 16 (1.4 - 1.6 kg-m, 10 - 12ft-lb) 7. If the liquid tank also needs tobe replaced, add an additional 5 m (0.2 Imp fl oz) of lubricant atthis time. Do not add this 5 m (0.2 Imp fl oz) of lubricantif only replacing thecompressor.
Recovery/ Recycling equipment
New compressor
Old compressor
Record amount Drain lubricant from new compressor into clean container
Record amount
Reinstall “X” m + “Y” m of newlubricant
New lubricant
New compressor Add an additional 5 m (0.2 US fl oz, 0.2 Imp fl oz) ofnew lubricant when replacing liquid tank.
RHA065DD
HA-103
AUTO
SERVICE PROCEDURES Refrigerant Lines ●
Refer to page HA-4 regarding “Precautions for RefrigerantConnection”.
LHD MODELS SEC. 271 ⋅ 274 ⋅ 276 Hexagonal socket screw Expansion valve
2.9 - 4.4N·m (0.3 - 0.45 kg-m, 26.0 - 39.1 in-lb)
KHA051
SEC. 271 ⋅ 274 ⋅ 276
G p
E p
B p
17 19 A p
F p
p
Pressure switch H p
D p
l ll l
: Refrigerant leak checking order : (Tightening torque) : (Wrench size) : (O-ring size) : N·m (kg-m, ft-lb)
p C
: 25 - 34 (2.5 - 3.5, 18 - 25) : N·m (kg-m, in-lb) : 10 - 20 (1.0 - 2.0, 87 - 174) : 3 - 4 (0.3 - 0.4, 26 - 35) : 8 - 11 (0.8 - 1.1, 69 - 95) KHA052
HA-104
AUTO
SERVICE PROCEDURES Refrigerant Lines (Cont’d) RHD MODELS Hexagonal socket screw
SEC. 271 ⋅ 274 ⋅ 276
2.9 - 5.3N·m (0.3 - 0.54 kg-m, 26.0 - 46.9 in-lb) Expansion valve
KHA053
SEC. 271 ⋅ 274 ⋅ 276 Cooling unit
F p
p B
E p
Compressor Pressure D switch p
G p
p
p C
p A
l ll l
: Refrigerant leak checking order : (Tightening torque) : (Wrench size) : (O-ring size) : N·m (kg-m, ft-lb) : 25 - 34 (2.5 - 3.5, 18 - 25) : N·m (kg-m, in-lb)
Condenser
: 10 - 20 (1.0 - 2.0, 87 - 174) : 3 - 4 (0.3 - 0.4, 26 - 35) : 8 - 11 (0.8 - 1.1, 69 - 95) KHA054
HA-105
SERVICE PROCEDURES
AUTO
Checking Refrigerant Leaks PRELIMINARY CHECK Perform a visual inspection of all refrigeration parts, fittings, hoses, and components for signs of A/C lubricant leakage, damage and corrosion.
PRECAUTIONS FOR HANDLING LEAK DETECTOR
A/C leak detector
SHA705EB
When performing a refrigerant leak check, use an A/C leak detector 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. Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and cleaners, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Do not allow the sensor tip of the detector to come into contact with any substance. This can also cause false readings and may damage the detector.
1. Position probe approximately 5 mm (3/16 in) away from point to be checked.
SHA707E
2. When testing, circle each fitting completely with probe.
SHA706E
HA-106
SERVICE PROCEDURES Checking Refrigerant Leaks (Cont’d)
AUTO
3. Move probe along component approximately 25 to 50 mm (1 to 2 in)/sec.
SHA708E
CHECKING PROCEDURE To prevent inaccurate or false readings, make sure there is no refrigerant vapor or tobacco 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. Charge the system with the specified amount of refrigerant. 2. Run the engine with the A/C compressor On for at least 2 minutes. 3. Stop engine.
Pressure
Pressure in high pressure line
Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector on the high pressure line. The pressure in the high pressure line will gradually drop after refrigerant circulation stops and pressure in the low pressure line will gradually rise, as shown in the graph. Leaks are more easily detected when pressure is high.
Pressure in low pressure line Time Compressor stops
RHA604B
4. Conduct the leak test from the high side to the low side at points p A through p H . Refer to HA-104, LHD models); p A through p G (Refer to HA-105, RHD models). Perform a leak check for the following areas carefully. Clean the component to be checked and move the leak detector probe completely around the connection/component. ● Compressor Check the fitting of high and low pressure hoses, relief valve and shaft seal. ● Liquid tank Check the pressure switch, tube fitting and the fusible plug mounts. ● Service valves Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks). ● Cooling unit (Evaporator) Turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the cooling unit. Insert the leak detector probe into the drain hose immediately after stopping the engine. (Keep the probe inserted for at least ten seconds.) 5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat check.
HA-107
SERVICE PROCEDURES Checking Refrigerant Leaks (Cont’d)
AUTO
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components. 7. Start engine.
HA-108
AUTO
SERVICE PROCEDURES Compressor Mounting CD engine models SEC. 274⋅275
37 - 50 (3.8 - 5.1, 27 - 37)
45 - 60 (4.6 - 6.1, 33 - 44)
Bracket
27 - 35 (2.8 - 3.6, 20 - 26)
Idler pulley
Compressor
37 - 50 (3.8 - 5.1, 27 - 37) .
: N·m (kg-m, ft-lb) KHA056
HA-109
AUTO
SERVICE PROCEDURES Compressor Mounting (Cont’d) SR engine models SEC. 274⋅275
16 - 19 (1.6 - 1.9, 12 - 14)
45 - 60 (4.6 - 6.1, 33 - 44)
45 - 60 (4.6 - 6.1, 33 - 44)
16 - 19 (1.6 - 1.9, 12 - 14)
16 - 19 (1.6 - 1.9, 12 - 14) : N·m (kg-m, ft-lb)
45 - 60 (4.6 - 6.1, 33 - 44) KHA057
QG engine models SEC.274⋅275
45 - 60 (4.6 - 6.1, 33 - 44)
31 - 40 (3.1 - 4.1, 23 - 29) 25 - 31 (2.4 - 3.2, 18 - 23)
34 - 46 (3.4 - 4.6, 25 - 33)
31 - 40 (3.1 - 4.1, 23 - 29) : N·m (kg-m, ft-lb) NHA316
HA-110
SERVICE PROCEDURES Compressor Mounting (Cont’d)
AUTO
Belt tension ●
Refer to MA section.
Fast Idle Control Device (FICD) ●
refer to EC section.
Compressor — Model CR-14 (Calsonic make) SEC. 274
Magnet clutch assembly
Field coil
Compressor
Snap ring
Pulley assembly Shim Snap ring Clutch disc Center bolt
12 - 15 N·m (1.2 - 1.5 kg-m, 9 - 11ft-lb) RHA314E
Compressor Clutch REMOVAL ● ●
When removing center bolt, hold clutch disc with clutch disc wrench. Take off clutch disc.
RHA315EA
●
Remove snap ring (which secures rotor pulley) by using external snap ring pliers.
Snap ring pliers
RHA316E
HA-111
SERVICE PROCEDURES Compressor Clutch (Cont’d) Gear puller
●
Pulley removal Position the center pulley puller on the end of the drive shaft, and remove the pulley assembly using any commercially available pulley puller. To prevent the pulley groove from being deformed, the puller claws should be positioned onto the edge of the pulley assembly.
●
Remove snap ring (which secures field coil) by using external snap ring pliers.
Rotor pulley
Pulley puller claws
Pulley assembly
AUTO
RHA317E
External snap ring pliers
.
Clutch disc Snap ring
RHA318E
Field coil Snap ring
INSPECTION Clutch disc If the contact surface shows signs of damage due to excessive heat, the clutch disc and pulley should be replaced.
Pulley Pulley assembly Center bolt
Shim
RHA319E
Check the appearance of the pulley assembly. If the contact surface of the pulley shows signs of excessive grooving due to slippage, both the pulley and clutch disc should be replaced. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.
Coil Check coil for loose connection or cracked insulation.
INSTALLATION ● Position the field coil. Be sure to align the coil’s pin with the hole in compressor’s front head. ● Install snap ring (which secures field coil) by using external snap ring pliers.
RHA320E
HA-112
SERVICE PROCEDURES Compressor Clutch (Cont’d) ● ●
Snap ring
Position and install pulley assembly securely by using plastic hammer. Install snap ring (which secures rotor pulley) by using external snap ring pliers.
RHA321EA
●
Shim
AUTO
Install the clutch disc on the drive shaft, together with the original shim(s). Press the disc down by hand.
Clutch disc
RHA322E
Using the clutch wrench disc to prevent clutch disc rotation, tighten the bolt to 12 to 15 N·m (1.2 to 1.5 kg-m, 9 to 11 ft-lb) torque. After tightening the bolt, check that the pulley rotates smoothly. ●
Torque wrench
RHA323E
●
Clutch disc Pulley assembly
Check clearance around the entire periphery of clutch disc. Disc-to-pulley clearance: 0.3 - 0.6 mm (0.012 - 0.024 in) If the specified clearance is not obtained, replace adjusting spacer and readjust.
BREAK-IN OPERATION 0.3 - 0.6 mm (0.012 - 0.024 in)
Feeler gauge
RHA087E
When replacing compressor clutch assembly, do not forget break-in operation, accomplished by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.
Thermal Protector INSPECTION ● Thermal protector
●
When servicing, do not allow foreign matter to get into compressor. Check continuity between two terminals.
SHA055B
HA-113
SERVICE PROCEDURES
AUTO
CSV613 Compressor
Center bolt 14 N·m (1.4 kg-m, 10 ft-lb) Clutch disc Snap ring
Compressor unit
Field coil Snap ring Pulley assembly Shim KHA114
KV99106100
Compressor Clutch REMOVAL ●
When removing center bolt, hold clutch disc with clutch disc wrench.
RHA136E KV99232340
RHA399FA
HA-114
SERVICE PROCEDURES Compressor Clutch (Cont’d)
AUTO
●
Remove the clutch disc using the clutch disc puller. Insert the holder’s three pins into the holes in the clutch disc. Rotate the holder clockwise to hook it onto the plate. Then, tighten the center bolt to remove the clutch disc. After removing the clutch disc, remove the shims from either the drive shaft or the clutch disc.
●
Remove the snap ring using external snap ring pliers.
●
Pulley removal Position the center pulley puller on the end of the drive shaft, and remove the pulley assembly using any commercially available pulley puller. To prevent the pulley groove from being deformed, the puller claws should be positioned onto the edge of the pulley assembly.
●
Remove the field coil harness clip. Remove the snap ring using external snap ring pliers.
KV99106100
RHA124FA
External snap ring pliers
Snap ring RHA138E
Pulley puller
Pulley assembly RHA139E
●
Snap ring
RHA145E
INSPECTION Clutch disc If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley.
Pulley Coil Pulley Clutch disc RHA126F
Check the appearance of the pulley assembly. Check if the contact surface of the pulley shows sign of excessive grooving, replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.
HA-115
SERVICE PROCEDURES Compressor Clutch (Cont’d) Field coil
AUTO
Coil Check coil for loose connection or cracked insulation.
INSTALLATION ● Install the field coil. Be sure to align the coil’s pin with the hole in the compressor’s front head. ● Install the field coil harness clip using a screwdriver.
Pin
RHA142E
●
Install the pulley assembly using the installer and a hand press, and then install the snap ring using snap ring pliers.
●
Install the clutch disc on the drive shaft, together with the original shim(s). Press the clutch disc down by hand.
KV99106200
Snap ring Pulley assembly
RHA143E
Shim
RHA127F
Using the holder to prevent clutch disc rotation, tighten the bolt to 14 N·m (1.4 kg-m, 10 ft-lb) torque. After tightening the bolt, check that the pulley rotates smoothly. ●
Torque wrench
RHA086E
●
Clutch disc Pulley assembly
Check clearance around the entire periphery of clutch disc. Disc-to-pulley clearance: 0.3 - 0.6 mm (0.012 - 0.024 in) If the specified clearance is not obtained, replace adjusting spacer and readjust.
0.3 - 0.6 mm (0.012 - 0.024 in)
Feeler gauge
NHA310
HA-116
SERVICE PROCEDURES
AUTO
BREAK-IN OPERATION When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.
Ventilation Air Filter Ventilation air filter
Fresh air Recirculation air
Evaporator
FUNCTION Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing ventilation air filter into cooling unit.
Intake unit RHA336F
REPLACEMENT TIMING Replace ventilation air filter every 2 years or 30,000 km (15,000 miles). Caution label is fixed inside the glove box.
SHA868E
REPLACEMENT PROCEDURES ●
Ventilation air filter
● ●
Remove instrument lower cover with glove box. Refer to BT section. Take out ventilation air filter which is secured with one clip, from cooling unit. Replace with new one and reinstall instrument lower cover and glove box.
KHA058
HA-117
AUTO
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications COMPRESSOR CD20T engine
SR20DE, QG16⋅18DE engine
CALSONIC make CR-14
CALSONIC make CSV613
Vane rotary
Variable displacement
144 (8.79)
6 to 125 (0.37 to 7.63)
Model Type 3
Displacement
cm (cu in)/Rev
Clockwise (Viewed from drive end)
Direction of rotation Drive belt
CD engine model: Type A
Poly V
LUBRICANT Model
CALSONIC make CR-14
CALSONIC make CSV613
Name
Nissan A/C System Oil Type R
Nissan A/C system Oil Type S
KLH00-PAGR0
KLH00-PAGS0
Total in system
180 (6.3)
200 (7.04)
Compressor (Service parts) charging amount
180 (6.3)
200 (7.04)
Part number Capacity
m (Imp fl oz)
REFRIGERANT Type Capacity
HFC-134a kg (lb)
0.60 ± 0.05 (1.32 ± 0.11)
Inspection and Adjustment ENGINE IDLING SPEED When A/C is ON Refer to EC section.
BELT TENSION
COMPRESSOR Model
CR-14/CSV613
Clutch disc-to-pulley clearance mm (in)
0.3 - 0.6 (0.012 - 0.024)
Refer to Checking Drive Belts (MA section).
HA-118
ELECTRICAL SYSTEM SECTION
EL
When you read wiring diagrams: ● Read GI section, “HOW TO READ WIRING DIAGRAMS”. When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.
CONTENTS PRECAUTIONS AND PREPARATION.......................... 5 Precautions ................................................................ 5 HARNESS CONNECTOR.............................................. 6 Description ................................................................. 6 STANDARDIZED RELAY .............................................. 8 Description ................................................................. 8 POWER SUPPLY ROUTING ....................................... 10 Schematic ................................................................ 10 Wiring Diagram - POWER - .................................... 12 Fuse ......................................................................... 22 Fusible Link.............................................................. 22 Circuit Breaker Inspection ....................................... 22 GROUND DISTRIBUTION........................................... 23 BATTERY ..................................................................... 29 How to Handle Battery ............................................ 29 Battery Test and Charging Chart............................. 32 Service Data and Specifications (SDS)................... 36 STARTING SYSTEM ................................................... 37 Wiring Diagram - START -....................................... 37 Trouble Diagnoses................................................... 40 Construction............................................................. 41 Removal and Installation ......................................... 47 Inspection................................................................. 47 Assembly ................................................................. 51 Service Data and Specifications (SDS)................... 52 CHARGING SYSTEM .................................................. 53 Wiring Diagram - CHARGE -................................... 53 Trouble Diagnoses................................................... 55 Construction............................................................. 56 Removal and Installation ......................................... 60
Disassembly............................................................. 60 Inspection................................................................. 60 Assembly ................................................................. 62 Service Data and Specifications (SDS)................... 63 COMBINATION SWITCH............................................. 64 Combination Switch/Check...................................... 64 STEERING SWITCH.................................................... 65 Check....................................................................... 65 Replacement............................................................ 66 HEADLAMP (WITHOUT DAYTIME LIGHT SYSTEM) - CONVENTIONAL TYPE - ........................ 67 Wiring Diagram - H/LAMP -..................................... 67 Trouble Diagnoses................................................... 69 Bulb Replacement ................................................... 70 Aiming Adjustment ................................................... 70 HEADLAMP (WITHOUT DAYTIME LIGHT SYSTEM) - XENON TYPE - ........................................ 72 System Description.................................................. 72 Wiring Diagram - H/LAMP -..................................... 73 Trouble Diagnoses................................................... 75 Bulb Replacement ................................................... 76 HEADLAMP - DAYTIME LIGHT SYSTEM - ............... 78 Schematic ................................................................ 78 Wiring Diagram - DTRL -......................................... 79 HEADLAMP - DAYTIME LIGHT SYSTEM WITH XENON TYPE - ............................................................ 82 Schematic ................................................................ 82 Wiring Diagram - DTRL -......................................... 83 HEADLAMP - DAYTIME LIGHT SYSTEM - ............... 86 Trouble Diagnoses................................................... 86
EL
HEADLAMP - HEADLAMP AIMING CONTROL (MANUAL) - ................................................................. 87 Wiring Diagram - H/AIM - ........................................ 87 HEADLAMP - HEADLAMP AIMING CONTROL (AUTO) -....................................................................... 91 System Description.................................................. 91 Initialisation .............................................................. 91 Component Parts and Harness ............................... 92 Wiring Diagram - H/AIM - ........................................ 93 Trouble Diagnosis .................................................... 95 Removal and Installation ......................................... 99 PARKING, LICENSE AND TAIL LAMPS.................. 100 Wiring Diagram - TAIL/L -...................................... 100 STOP LAMP .............................................................. 104 Wiring Diagram - STOP - ...................................... 104 BACK-UP LAMP........................................................ 107 Wiring Diagram - BACK/L - ................................... 107 FRONT FOG LAMP....................................................110 Wiring Diagram - F/FOG - ......................................110 Aiming Adjustment .................................................. 111 Bulb Specifications ................................................. 111 REAR FOG LAMP ......................................................112 Wiring Diagram - R/FOG -......................................112 TURN SIGNAL AND HAZARD WARNING LAMPS ..117 Schematic ...............................................................117 Wiring Diagram - TURN - .......................................118 Trouble Diagnoses................................................. 123 ILLUMINATION .......................................................... 124 Schematic .............................................................. 124 Wiring Diagram - ILL - ........................................... 125 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS ....................................... 130 System Description................................................ 130 Schematic .............................................................. 131 Wiring Diagram - INT/L - ....................................... 132 BULB SPECIFICATIONS .......................................... 137 Headlamp............................................................... 137 Exterior Lamp ........................................................ 137 Interior Lamp.......................................................... 137 METER AND GAUGES ............................................. 138 System Description................................................ 138 Combination Meter ................................................ 139 Wiring Diagram - METER -/MODELS BEFORE VIN - P11U0548750............................................... 141 Schematic .............................................................. 144 Wiring Diagram - METER -/M/T MODELS AFTER VIN - P11U0548750.................................. 146 Wiring Diagram - METER -/CVT MODELS AFTER VIN - P11U0548750.................................. 149 Combination Meter Self-Diagnosis ........................ 152 Trouble Diagnoses (Models before VIN P11U0548750) ....................................................... 155 Trouble Diagnoses (Models after VIN P11U0548750) ....................................................... 159 Fuel Level Sensor Unit Check............................... 164 QG & SR Engine Models ...................................... 164
CD20T Engine Models .......................................... 164 Thermal Transmitter Check ................................... 164 WARNING LAMPS .................................................... 165 Warning Lamps/Schematic .................................... 165 Wiring Diagram - WARN - ..................................... 167 Electrical Components Inspection ......................... 179 WARNING CHIME ..................................................... 180 System Description................................................ 180 Wiring Diagram - CHIME - .................................... 181 Trouble Diagnoses................................................. 183 Electrical Components Inspection ......................... 185 FRONT WIPER AND WASHER ................................ 186 System Description................................................ 186 Wiring Diagram - WIPER - .................................... 188 Removal and Installation ....................................... 190 Front Washer Nozzle Adjustment .......................... 192 Front Washer Tube Layout .................................... 192 REAR WIPER AND WASHER .................................. 193 System Description................................................ 193 Wiring Diagram - WIP/R -...................................... 195 Removal and Installation ....................................... 197 Washer Nozzle Adjustment ................................... 197 Washer Tube Layout ............................................. 199 Check Valve........................................................... 199 HEADLAMP WASHER .............................................. 200 Wiring Diagram - HLC -......................................... 200 Washer Tube Layout ............................................. 202 Check Valve........................................................... 202 HORN, CIGARETTE LIGHTER AND CLOCK .......... 203 Wiring Diagram - HORN - ..................................... 203 REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER ............................................... 207 System Description................................................ 207 Schematic .............................................................. 208 Wiring Diagram - DEF -......................................... 209 Trouble Diagnoses................................................. 212 Electrical Components Inspection ......................... 213 Filament Check...................................................... 213 Filament Repair ..................................................... 214 AUDIO ........................................................................ 216 Anti-theft System ................................................... 216 Speed Dependent Volume Control........................ 217 Personal Audio Settings ........................................ 217 Schematic .............................................................. 218 Wiring Diagram - AUDIO -..................................... 219 Trouble Diagnoses................................................. 226 Inspection............................................................... 228 AUDIO ANTENNA ..................................................... 229 Location of Antenna............................................... 229 ELECTRIC SUNROOF .............................................. 230 Wiring Diagram - SROOF - ................................... 230 POWER DOOR MIRROR .......................................... 231 Wiring Diagram - MIRROR - ................................. 231 POWER SEAT ........................................................... 233 Power Seat/Wiring Diagram - SEAT - ................... 233 HEATED SEAT .......................................................... 234
EL-2
Heated Seat/Wiring Diagram - HSEAT - ............... 234 POWER WINDOW ..................................................... 236 System Description................................................ 236 Schematic .............................................................. 239 Wiring Diagram - WINDOW - ................................ 240 Trouble Diagnoses................................................. 243 POWER DOOR LOCK............................................... 245 System Description/Door Lock for LHD Models.... 245 Schematic .............................................................. 246 Wiring Diagram - D/LOCK -................................... 248 Trouble Diagnoses................................................. 256 POWER DOOR LOCK - SUPER LOCK -................. 265 Component Parts Location .................................... 265 System Description/Super Lock for RHD Models . 266 Schematic .............................................................. 268 Wiring Diagram - S/LOCK -................................... 270 Trouble Diagnoses................................................. 283 MULTI-REMOTE CONTROL SYSTEM ..................... 296 System Description................................................ 296 Schematic .............................................................. 297 Wiring Diagram - MULTI - ..................................... 298 Trouble Diagnoses................................................. 303 ID Code Entry Procedure ...................................... 305 TIME CONTROL UNIT (TCU) ................................... 306 System Description................................................ 306 Trouble Diagnosis .................................................. 309 THEFT WARNING SYSTEM ......................................311 Components Parts and Harness Connector Location ..................................................................311
System Description................................................ 312 Schematic .............................................................. 315 Wiring Diagram - THEFT -..................................... 316 Trouble Diagnoses................................................. 328 NATS (NISSAN ANTI-THEFT SYSTEM)................... 342 Component Parts Location .................................... 342 Wiring Diagram - NATS -....................................... 343 NATS (NISSAN ANTI-THEFT SYSTEM)................... 345 System Description................................................ 345 System Composition.............................................. 346 CONSULT-II ........................................................... 347 Trouble Diagnoses................................................. 349 How to Replace NATS IMMU................................ 363 LOCATION OF ELECTRICAL UNITS....................... 365 Engine Compartment............................................. 365 Passenger Compartment....................................... 366 HARNESS LAYOUT .................................................. 368 Outline.................................................................... 368 How to Read Harness Layout ............................... 369 Engine Control Harness ........................................ 370 Engine Room Harness .......................................... 376 Main Harness......................................................... 382 Body Harness ........................................................ 386 Air Conditioner Harness ........................................ 402 Room Lamp Harness............................................. 403 Back Door Harness ............................................... 404 Front Door Harness (LH side) ............................... 406 Front Door Harness (RH side) .............................. 407 Rear Door Harness................................................ 408
WIRING DIAGRAM REFERENCE CHART ECCS (Ignition system) .......................................................................................................................... AUTOMATIC TRANSAXLE CONTROL SYSTEM ................................................................................... ANTI-LOCK BRAKE SYSTEM ................................................................................................................ SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” ........................................................................ HEATER AND AIR CONDITIONER .........................................................................................................
EL-3
EC SECTION AT SECTION BR SECTION RS SECTION HA SECTION
NOTE
EL-4
PRECAUTIONS AND PREPARATION Precautions SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System “Air Bag” and “Seat Belt Pre-tensioner”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of an air bag module (located in the center of the steering wheel and on the instrument panel on the passenger side, where fitted), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along with the seat belt help to reduce the risk or severity of injury to the driver and front passenger in a side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information necessary to service the system safely is included in the RS 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 dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT-TENSIONER” connector) can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors). Not use electrical test equipment on any circuit related to the SRS.
EL-5
HARNESS CONNECTOR Description 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 illustration below. Refer to the next page for description of the slide-locking type connector. CAUTION: Do not pull the harness or wires when disconnecting the connector. [Example] ● ●
PUSH
Terminal retainer PUSH
Packing (Water-proof type) Connector housing
LIFT
PUSH PUSH
PUSH PUSH
PUSH (For combination meter)
(For relay)
SEL769D
EL-6
HARNESS CONNECTOR Description (Cont’d) 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 lifting the slider. Refer to the illustration 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. [Example] ●
Waterproof type
쑗1
Firmly grasp shell of connector housing at A.
쑗2
Push slider until connector pops or snaps apart.
쑗3
Disconnect harness connector.
Non-waterproof type
쑗1
Firmly grasp shell of connector housing at A.
쑗2
Pull back on the slider while pulling apart male and female halves of connector.
쑗3
Disconnect harness connector.
SEL769V
EL-7
STANDARDIZED RELAY Description NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.
NORMAL OPEN RELAY
NORMAL CLOSED RELAY
MIXED TYPE RELAY
SW 1 “OFF”
Flows
Flows
Does not flow
Does not flow
SW 1
SW 1
BATTERY
SW 1
BATTERY
BATTERY
Flows Does not flow
SW 1 “ON”
Does not flow
Flows
SW 1
SW 1
BATTERY
SW 1
BATTERY
BATTERY SEL881H
TYPE OF STANDARDIZED RELAYS 1M
.......... 1 Make
2M
1T
.......... 1 Transfer
1M⋅1B .......... 1 Make 1 Break
1M
.......... 2 Make
2M 1M
2M
1T
1M⋅1B
1T 1B
1M
SEL882H
EL-8
STANDARDIZED RELAY Description (Cont’d) Type
Outer view
Circuit
Connector symbol and connection
Case color
BLACK
BROWN
GRAY
BLUE
The arrangement of terminal numbers on the actual relays may differ from those shown above.
EL-9
SEL188W
POWER SUPPLY ROUTING Schematic BATTERY
COMBINATION SWITCH LIGHTING SWITCH
R/FOG SWITCH
IGNITION SWITCH
ACCESSORY RELAY
POWER FUSE IGNITION RELAY
POWER WINDOW RELAY
REAR WINDOW DEFFOGGER RELAY
TIME CONTROL UNIT
YEL218C
EL-10
POWER SUPPLY ROUTING Schematic (Cont’d)
YEL948C
EL-11
POWER SUPPLY ROUTING Wiring Diagram — POWER — BATTERY POWER SUPPLY — IGNITION SWITCH IN ANY POSITION Gasoline engine models
YEL949C
EL-12
POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) Diesel engine models
YEL950C
EL-13
POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)
To ELPOWER-01
To ELPOWER-05 FUSE AND FUSIBLE LINK BOX
To ELPOWER-02
To EL-H/LAMP EL-DTRL EL-HLC EL-H/AIM
To EL-HORN To EL-H/LAMP EL-DTRL EL-HLC
To EL-DTRL
To EL-H/LAMP EL-DTRL EL-H/AIM
To EC-MAIN EC-EGR EC-EGVC/V EC-AAC/V EC-TP/SW EC-IGN/SG AT-MAIN
To EC-MAIN EC-CMPS EC-MAFS EC-EGR EC-EGVC/V EC-AAC/V EC-TP/SW EC-IGN/SG EC-POS EC-PHASE AT-MAIN
LIGHTING SWITCH OFF
1ST
2ND
OFF
1ST
2ND
ON OFF REAR FOG LAMP SWITCH
COMBINATION SWITCH
FRONT AND REAR OFF
OFF FRONT
FRONT AND REAR
FRONT
FRONT AND REAR FOG LAMP SWITCH
: With gasoline engine : With diesel engine
To ELPOWER-06
Next page
: With daytime light system : Without daytime light system
To EL-R/FOG
: With front fog lamp : Without front fog lamp
To EL-HLC EL-DTRL EL-H/AIM EL-ILL
YEL222C
EL-14
POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)
YEL951C
EL-15
POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)
YEL952C
EL-16
POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) To EL-POWER-03 : With daytime light system : Without daytime light system : With glove box lamp
DAYTIME LIGHT CONTROL UNIT To EL-TAIL/L EL-H/AIM
FUSE BLOCK (J/B)
TIME CONTROL UNIT
To EL-ILL
To EL-ILL
To EL-ILL
To EL-TAIL/L EL-H/AIM EL-ILL
To EL-ILL EL-AUDIO
To EL-ILL
To EL-ILL
To EL-ILL
To EL-ILL
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) : This connector is not shown in “HARNESS LAYOUT” of EL section.
YEL225C
EL-17
POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) ACCESSORY POWER SUPPLY — IGNITION SWITCH IN “ACC” OR “ON” BATTERY : With gasoline engine
Refer to EL-POWER-01, EL-POWER-02, EL-POWER-03, EL-POWER-04 EL-POWER-05
: With diesel engine : With gasoline engine and with XENON headlamp : Except
OFF
ACC
ST
IGNITION SWITCH
POWER FUSE 15A
ON
ACCESSORY RELAY
FUSE BLOCK (J/B)
To EL-AUDIO EL-MIRROR
To EL-HORN
To EL-HORN
REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)
YEL226C
EL-18
POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) IGNITION POWER SUPPLY — IGNITION SWITCH IN “ON” AND/OR “START” BATTERY Refer to EL-POWER-01, EL-POWER-02, EL-POWER-03, EL-POWER-05
To EL-POWER-10 ST
OFF
: With gasoline engine : With diesel engine
IGNITION SWITCH
ACC ON
Next page
To EC-MAIN EC-IGN/SG FUSE BLOCK (J/B)
Next page IGNITION RELAY To EL-POWER-10
Next page
To BR-ABS
To EL-WIP/R
To EC-VSS EC-MIL/DL EC-GLOW BR-ABS RS-SRS EL-HORN EL-WARN EL-METER EL-CHARGE EL-ILL EL-H/AIM AT-NONDTC To EL-WIP/R
To EL-NATS EL-HLC
To RS-SRS
To EC-VSS AT-PNP/SW AT-NONDTC EL-BACK/L EL-METER
To EC-INJECT EC-MIL/DL EC-FUEL EC-MAIN
To EL-DTRL HA-A/C EC-COOL/F
To EC-O2S1B1 EC-O2H1B1 EC-O2S2B1 EC-O2H2B1 EC-FUEL EC-PGC/V EC-SWL/V EC-IVC EC-EGRC/V EC-HO2S EC-AAC/V EC-MAIN EL-START EL-DTRL HA-A/C EC-COOL/F
REFER TO THE FOLLOWING
FUSE BLOCK Junction Box (J/B)
YEL227C
EL-19
POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)
Preceding page
FUSE BLOCK (J/B)
Preceding page Next page REAR WINDOW DEFOGGER RELAY
FUEL PUMP RELAY
TIME CONTROL UNIT
To EL-WIPER
To EL-WIP/R EL-WIPER
To EC-F/PUMP
To HA-HEATER HA-A/C
To EL-HSEAT
To EL-DEF
To EL-DEF
To EC-F/PUMP
REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)
: This connector is not shown in “HARNESS LAYOUT” of EL section.
YEL228C
EL-20
POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) : CVT models To EL-POWER-08 OFF
IGNITION SWITCH
ST
: M/T models : With gasoline engine : With diesel engine
ON ACC
To EL-START
FUSE BLOCK (J/B)
To EL-POWER-08 Preceding page BLOWER RELAY
To EL-POWER-01 POWER WINDOW RELAY
To EL-POWER-02 To EL-POWER-08
To EL-SROOF
To EL-WINDOW
To HA-HEATER HA-A/C
To HA-A/C EC-FICD EC-A/CCUT
To HA-HEATER HA-A/C EC-FICD EC-A/CCUT
To EL-DTRL EC-S/SIG EC-MAIN
REFER TO THE FOLLOWING
FUSE BLOCK Junction Box (J/B)
YEL250B
EL-21
POWER SUPPLY ROUTING Fuse
OK
a. If fuse is blown, be sure to eliminate cause of problem before installing new fuse. b. Use fuse of specified rating. Never use fuse of more than specified rating. c. Do not partially install fuse; always insert it into fuse holder properly. d. Remove fuse for “ELECTRICAL PARTS (BAT)” if vehicle is not used for a long period of time.
Blown CEL083
Fusible Link Fusible link
Fuse
NEL545
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 problem. ● Never wrap outside of fusible link with vinyl tape. Important: Never let fusible link touch any other wiring harness or vinyl or rubber parts.
Circuit Breaker Inspection
Time (sec.)
For example, when current is 30A, the circuit is broken within 8 to 20 seconds.
Break point
Current (A) SBF284E
Circuit Breaker (PTC Thermistor Type) The PTC thermister generates heat in response to current flow. The temperature (and resistance) of the thermister 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. SEL109W
EL-22
GROUND DISTRIBUTION GROUND M6/M26/M28
E10
CONNECT TO A/C AUTO AMP. A/C CONTROL PANEL A/C HIGH RELAY A/C LOW RELAY (Type-1) A/C LOW RELAY (Type-2) A/C MH RELAY (Type-1) A/C MED-HIGH RELAY (Type-2) A/C MED-LOW RELAY AUDIO CIGARETTE LIGHTER SOCKET COMBINATION METER (ILLUMINATION) (Without illumination control switch) (Models before VIN P11U0548750) COMBINATION METER (ABS WARNING LAMP) (Models before VIN - P11U0548750) COMBINATION METER (AIR BAG WARNING LAMP) (Models before VIN - P11U0548750) COMBINATION METER (AIR BAG WARNING LAMP) (Models after VIN - P11U0548750) COMBINATION METER (HIGH BEAM INDICATOR) (Models before VIN - P11U0548750) COMBINATION METER (Hyper CVT M6 models) (Models before VIN - P11U0548750) COMBINATION METER (Hyper CVT M6 models) (Models after VIN - P11U0548750) COMBINATION METER (SPEEDOMETER) (Models before VIN P11U0548750) COMBINATION METER (SPEEDOMETER) (Models after VIN P11U0548750) COMBINATION METER (Models before VIN - P11U0548750) COMBINATION METER (Models after VIN - P11U0548750) COMBINATION METER (Models after VIN - P11U0548750) CONTROL DEVICE (Hyper CVT M6 models) CONTROL DEVICE (Hyper CVT models) DATA LINK CONNECTOR DATA LINK CONNECTOR (TERMINAL NO. 13) AIRBAG DIAGNOSIS SENSOR UNIT DONGLE CONTROL UNIT (RHD) DOOR MIRROR REMOTE CONTROL SWITCH FAN SWITCH FAN SWITCH (Gasoline engine) (without A/C) FUSE BLOCK (J/B) (IGNITION RELAY, BLOWER RELAY) FUSE BLOCK (J/B) (FRONT FOG LAMP RELAY)
CONN. M115 M44, M47 M119 M120 M123 M118 M122 M121 M42 M39 E124
EL-ILL
M38
BR-ABS
M38
RS-SRS
M89
RS-SRS
E124
EL-H/LAMP, EL-DTRL
M38
AT-NONDTC
M89
AT-NONDTC
M38
EC-VSS
M89
EC-VSS
M38 M89 E131 M79 M49 M59 M59 M87 M85 M5 M46 M46 M1 M1
EL-METER, EL-WARN, EL-HORN EL-METER, EL-WARN, EL-HORN AT-NONDTC, EL-ILL AT-NONDTC, EL-ILL AT-NONDTC, EL-ILL EC-MIL/DL RS-SRS RS-SRS EL-NATS, EL-AUDIO EL-MIRROR HA-HEATER EC-LOAD EL-POWER EL-F/FOG, EL-POWER EL-WINDOW, EL-SROOF, EL-POWER EL-ILL EL-TURN, EL-ILL EL-ILL AT-NONDTC EC-BRK/SW EL-ILL, EL-DEF HA-HEATER, EL-ILL EL-SLOOF EL-ILL EL-BUZZER, EL-S/LOCK, EL-D/LOCK, EL-THEFT, EL-DEF, EL-MULTI, EL-INT/L, EL-TURN EL-INT/L EL-INT/L EL-METER, EC-VSS BR-ABS
FUSE BLOCK (J/B) (POWER WINDOW RELAY)
M1
GLOVE BOX LAMP (ILLUMINATION) HAZARD SWITCH HEATER (ILLUMINATION) INDICATOR CONTROL UNIT (Hyper CVT M6 models) RDNT BRAKE SWITCH (RHD) (CD20 engine) A/C CONTROL PANEL (REAR WINDOW DEFOGGER SWITCH) A/C CONTROL PANEL (RECIRCULATION SWITCH) SUNROOF SWITCH SPOT LAMP
M24 M58 M45 M72 M64 M44 M47 R4 R5
TIME CONTROL UNIT
B96
VANITY MIRROR LAMP (LHD) VANITY MIRROR LAMP (RHD) VEHICLE SPEED SENSOR ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
R9 R2 F25 E78
EL-23
CELL CODE HA-A/C HA-A/C HA-A/C HA-A/C HA-A/C HA-A/C HA-A/C HA-A/C EL-ILL, EL-AUDIO EL-HORN
GROUND DISTRIBUTION GROUND E11/E37
E68 E88 F9
CONNECT TO ACCESSORY RELAY BRAKE FLUID LEVEL SWITCH CLEARANCE LAMP LH CLEARANCE LAMP RH COMBINATION METER (FRONT FOG LAMP INDICATOR) (Models before VIN - P11U0548750) COMBINATION METER (FRONT FOG LAMP INDICATOR) (Models after VIN - P11U0548750) COMBINATION METER (REAR FOG LAMP INDICATOR) (Models before VIN - P11U0548750) COMBINATION METER (REAR FOG LAMP INDICATOR) (Models after VIN - P11U0548750) COMBINATION METER (HIGH BEAM INDICATOR) (Models after VIN - P11U0548750) COMBINATION METER (ILLUMINATION) (Models after VIN P11U0548750) COMBINATION METER (TURN) (Models before VIN P11U0548750) COMBINATION METER (TURN) (Models after VIN P11U0548750) COMBINATION SWITCH (FRONT WIPER SWITCH) COMBINATION SWITCH (TRIP COMPUTER SWITCH) COMBINATION SWITCH (TURN SIGNAL SWITCH) COOLING FAN MOTOR-1 (Gasoline engine) COOLING FAN MOTOR-2 (CD20 engine) COOLING FAN MOTOR-2 (QG18, SR20 engine) COOLING FAN MOTOR-2 (With A/C) (GA16 engine) COOLING FAN RELAY-2 (CD engine) DAYTIME LIGHT CONTROL UNIT FRONT FOG LAMP LH (Type-1) FRONT FOG LAMP LH (Type-2) FRONT FOG LAMP RH (Type-1) FRONT FOG LAMP RH (Type-2) FRONT TURN SIGNAL LAMP LH FRONT TURN SIGNAL LAMP RH FRONT WIPER MOTOR FRONT WIPER RELAY HEAD LAMP RELAY LH HEAD LAMP RELAY RH HEAD LAMP WASHER MOTOR HEAD LAMP WASHER SWITCH HEADLAMP AIMING MOTOR LH HEADLAMP AIMING MOTOR RH HEADLAMP LH HEADLAMP RH HOOD SWITCH NATS IMMU POWER STEERING OIL PRESSURE SWITCH (Gasoline) RDNT BRAKE SWITCH (LHD) (CD20 engine) REAR WIPER RELAY SEDIMENTER SENSOR SIDE TURN SIGNAL LAMP LH (Type-1) SIDE TURN SIGNAL LAMP LH (Type-2) SIDE TURN SIGNAL LAMP RH (Type-1) SIDE TURN SIGNAL LAMP RH (Type-2) TRIPLE-PRESSURE SWITCH (CD engine) WASHER LEVEL SWITCH ALTERNATOR (GA engine) ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) ALTERNATOR (QG16, QG18, SR20, CD engine)
EL-24
CONN. E95 E14 E85 E87
CELL CODE EL-POWER, EL-HORN EL-WARN EL-TAIL/L EL-TAIL/L
E124
EL-F/FOG
E131
EL-F/FOG
E124
EL-R/FOG
E131
EL-R/FOG
E131
EL-H/LAMP, EL-DTRL
E131
EL-ILL
E124
EL-TURN
E131
EL-TURN
E114 E114 E111 E19 E18 E28 E94 E54 E117 E6 E146 E34 E147 E8 E36 E62 E70 E74 E75 E38 E128 E4 E33 E5 E32 E12 E121 E60 E122 E52 E13 E9 E148 E59 E149 E20 E39 E71 E78 F10
EL-WIPER, EL-WIP/R EL-METER EL-TURN HA-A/C, EC-COOL/F HA-A/C, EC-COOL/F HA-A/C, EC-COOL/F HA-A/C, EC-COOL/F HA-A/C, EL-COOL/F EL-DTRL EL-F/FOG EL-F/FOG EL-F/FOG EL-F/FOG EL-TURN, EL-THEFT EL-TURN, EL-THEFT EL-WIPER EL-WIPER EL-H/LAMP, EL-DTRL EL-HLC, EL-H/LAMP, EL-DTRL EL-HLC EL-HLC, EL-ILL EL-H/AIM EL-H/AIM EL-H/LAMP, EL-DTRL EL-H/LAMP, EL-DTRL EL-THEFT EL-NATS EC-PST/SW EC-BRK/SW EL-WIP/R EL-WARN EL-TURN, EL-THEFT EL-TURN, EL-THEFT EL-TURN, EL-THEFT EL-TURN, EL-THEFT HA-A/C, EC-COOL/F EL-WARN EL-CHARGE BR-ABS EL-CHARGE
GROUND DISTRIBUTION GROUND F15/F18
CONNECT TO CAMSHAFT POSITION SENSOR (QG16, QG18 engine) CONDENSER (QG16, QG18 engine) CRANKSHAFT POSITION SENSOR (QG16, QG18 engine) DATA LINK CONNECTOR DISTRIBUTOR (CAMSHAFT POSITION SENSOR) (GA16, SR20 engine) DISTRIBUTOR (GA16, SR20 engine) ECM (CD20 engine) ECM (Gasoline engine) HEATED OXYGEN SENSOR 2 (REAR) (QG18, SR20 engine) (Type-1) HEATED OXYGEN SENSOR 2 (REAR) (QG16, QG18 engine) (Type-2) HEATED OXYGEN SENSOR 2 (REAR) (SR20 engine) (Type-2) IACV-FICD SOLENOID VALVE (GA16 engine) IGNITION COIL NO. 1 (QG16, QG18 engine) IGNITION COIL NO. 2 (QG16, QG18 engine) IGNITION COIL NO. 3 (QG16, QG18 engine) IGNITION COIL NO. 4 (QG16, QG18 engine) PARK/NEUTRAL POSITION (PNP) SWITCH (M/T models) PARK/NEUTRAL POSITION (PNP) SWITCH (CVT models) SHIELD WIRE (CAMSHAFT POSITION SENSOR) (QG18 engine) (If so equipped) SHIELD WIRE (CRANKSHAFT POSITION SENSOR) (QG18 engine) (If so equipped) SHIELD WIRE (CRANKSHAFT POSITION SENSOR) (SR20 engine) SHIELD WIRE (DISTRIBUTOR) (GA16, SR20 engine) (If so equipped) SHIELD WIRE (HEATED OXYGEN SENSOR) (GA16 engine) SHIELD WIRE (HEATED OXYGEN SENSOR 1 (FRONT)) (QG18, SR20 engine) (If so equipped) SHIELD WIRE (HEATED OXYGEN SENSOR 2 (REAR) (QG18, SR20 engine) (If so equipped) SHIELD WIRE (MASS AIR FLOW SENSOR) (Gasoline engine) (If so equipped) SHIELD WIRE (THROTTLE POSITION SENSOR) (Gasoline engine) (If so equipped) TCM (TRANSMISSION CONTROL MODULE)
EL-25
CONN. F95 F94 F88 M59
CELL CODE EC-PHASE EC-IGN/SG EC-POS EC-MIL/DL
F33
EC-CMPS
F33 F116 F101
EC-IGN/SG EC-MAIN EC-MAIN
F76
EC-O2S2B1, EC-02HSB1
F123
EC-O2S2B1, EC-02HSB1
F117 F40 F89 F90 F91 F92 F28 F72
EC-O2S2B1, EC-02HSB1 EC-FICD, HA-A/C EC-IGN/SG EC-IGN/SG EC-IGN/SG EC-IGN/SG EC-PNP/SW EC-PNP/SW, EL-START
F95
EC-PHASE
F88
EC-POS
F83
EC-CKPS
F33
EC-CMPS
F34
EC-HO2S EC-O2S1B1, EC-O2H1B1, EC-FUEL
F34 F76
EC-O2S2B1, EC-O2H2B1
F38
EC-MAFS
F16
EC-TPS, AT-TPS
M78
AT-MAIN, AT-TPS
GROUND DISTRIBUTION GROUND B18/B27
CONNECT TO AUTO LEVEL CONTROL UNIT BACK-UP LAMP (Sedan) (LHD) BACK-UP LAMP (Sedan) (RHD) CD AUTO CHANGER CENTRAL UNLOCK/TRUNK OR BACK DOOR RELEASE SWITCH DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE) (UNLOCK SENSOR) (With super lock) DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE) (UNLOCK SENSOR) (With power door lock) DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE) (UNLOCK SENSOR) (With super lock) DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE) (UNLOCK SENSOR) (With power door lock) DOOR LOCK ACTUATOR ASSEMBLY REAR LH (UNLOCK SENSOR) (With super lock) DOOR LOCK ACTUATOR ASSEMBLY REAR LH (UNLOCK SENSOR) (With power door lock) DOOR LOCK ACTUATOR ASSEMBLY REAR RH (UNLOCK SENSOR) (With super lock) DOOR LOCK ACTUATOR ASSEMBLY REAR RH (UNLOCK SENSOR) (With power door lock) DOOR MIRROR HEATER (DRIVER’S SIDE) (Type-1) DOOR MIRROR HEATER (DRIVER’S SIDE) (Type-2) DOOR MIRROR HEATER (PASSENGER SIDE) (Type-1) DOOR MIRROR HEATER (PASSENGER SIDE) (Type-2) EXTERNAL TRUNK RELEASE SWITCH (Sedan) FUEL PUMP (GA16, QG18, SR20 engine) FUEL LEVEL SENSOR UNIT HEADLAMP AIMING SWITCH (Type-1) HEADLAMP AIMING SWITCH (Type-2) HEATED SEAT LH HEATED SEAT RH HEATED SEAT SWITCH LH HEATED SEAT SWITCH RH KEY CYLINDER SWITCH (DRIVER’S SIDE) KEY CYLINDER SWITCH (PASSENGER SIDE) POWER SEAT POWER SOCKET (Wagon) POWER WINDOW MAIN SWITCH REAR FOG LAMP (LHD) (Sedan with type-1) REAR FOG LAMP (RHD) (Sedan with type-1) REAR WIPER MOTOR (Sedan) SIDE AIR BAG MODULE LH SIDE AIR BAG MODULE RH TRUNK ROOM LAMP SWITCH (Sedan)
CONN. B123 T13 T8 B47 B121
EL-S/LOCK, EL-MULTI, EL-THEFT
D26
EL-D/LOCK, EL-MULTI, EL-THEFT
D16
EL-S/LOCK, EL-MULTI, EL-THEFT
D27
EL-D/LOCK, EL-MULTI, EL-THEFT
D21
EL-THEFT, EL-MULTI
D28
EL-MULTI, EL-THEFT
D25
EL-THEFT, EL-MULTI
D29
EL-MULTI, EL-THEFT
D4 D31 D13 D30 T20 B30 B31 B106 E129 B21 B61 B104 B105 D9 D17 B22 B86 D5 T8 T13 B52 B142 B143
EL-DEF EL-DEF EL-DEF EL-DEF EL-S/LOCK, EL-D/LOCK EC-F/PUMP EL-METER, EL-WARN EL-H/AIM, EL-ILL EL-H/AIM, EL-ILL EL-HSEAT EL-HSEAT EL-HSEAT EL-HSEAT EL-S/LOCK, EL-THEFT, EL-D/LOCK EL-S/LOCK, EL-D/LOCK EL-SEAT EL-HORN EL-WINDOW EL-R/FOG EL-R/FOG EL-WIP/R RS-SRS RS-SRS EL-INT/L, EL-WARN, EL-THEFT, ELMULTI EL-THEFT
B102
EL-26
EL-S/LOCK, EL-D/LOCK
D7
T10
ULTRA SONIC CANCEL SWITCH
CELL CODE EL-H/AIM EL-BACK/L EL-BACK/L EL-AUDIO
GROUND DISTRIBUTION GROUND B48/D110
CONNECT TO BACK-UP LAMP (Hatchback) (LHD) BACK-UP LAMP (Hatchback) (RHD) EXTERNAL BACK DOOR RELEASE SWITCH (Hatchback) HIGH-MOUNTED STOP LAMP (Hatchback) HIGH-MOUNTED STOP LAMP (Wagon) LICENSE PLATE LAMP LH (Hatchback with type-1) LICENSE PLATE LAMP LH (Hatchback with type-2) LICENSE PLATE LAMP LH (Wagon) LICENSE PLATE LAMP RH (Hatchback with type-1) LICENSE PLATE LAMP RH (Hatchback with type-2) LICENSE PLATE LAMP RH (Wagon) LUGGAGE ROOM LAMP SWITCH (Hatchback) (Wagon)
B65 B72 B119 B150/B151
REAR COMBINATION LAMP LH (BACK-UP LAMP) (Wagon for LHD) REAR COMBINATION LAMP LH (REAR FOG LAMP LH) (with type-1) REAR COMBINATION LAMP LH (STOP LAMP) (Hatchback) (Wagon) REAR COMBINATION LAMP LH (TAIL LAMP) (Hatchback) (Wagon) REAR COMBINATION LAMP LH (TURN SIGNAL) (Hatchback) (Wagon) REAR COMBINATION LAMP RH (BACK-UP LAMP) (Wagon for RHD) REAR COMBINATION LAMP RH (REAR FOG LAMP RH) (with type-1) REAR COMBINATION LAMP RH (STOP LAMP) (Hatchback) (Wagon) REAR COMBINATION LAMP RH (TAIL LAMP) (Hatchback) (Wagon) REAR COMBINATION LAMP RH (TURN SIGNAL) (Hatchback) (Wagon) REAR FOG LAMP (LHD) (Hatchback) REAR FOG LAMP (RHD) (Hatchback) REAR WINDOW DEFOGGER (Hatchback) REAR WINDOW DEFOGGER (Wagon) REAR WIPER MOTOR (Hatchback) (Wagon) SHIELD WIRE (SATELLITE SENSOR LH) (with type-1) SHIELD WIRE (SATELLITE SENSOR LH) (with type-2) SHIELD WIRE (SATELLITE SENSOR RH) REAR WINDOW DEFOGGER (Sedan) LICENSE PLATE LAMP LH (Sedan with type-2) LICENSE PLATE LAMP RH (Sedan with type-2) REAR COMBINATION LAMP LH (STOP LAMP) (Sedan with type-2) REAR COMBINATION LAMP LH (TAIL LAMP) (Sedan with type-2) REAR COMBINATION LAMP LH (TURN SIGNAL) (Sedan with type-2) REAR COMBINATION LAMP RH (STOP LAMP) (Sedan with type-2) REAR COMBINATION LAMP RH (TAIL LAMP) (Sedan with type-2) REAR COMBINATION LAMP RH (TURN SIGNAL) (Sedan with type-2)
EL-27
CONN. D108 B134 D117 D114 B85 B127 B149 D106 B128 B148 D116 D105
CELL CODE EL-BACK/L EL-BACK/L EL-S/LOCK, EL-D/LOCK EL-STOP EL-STOP EL-TAIL/L EL-TAIL/L EL-TAIL/L EL-TAIL/L EL-TAIL/L EL-TAIL/L EL-INT/L, EL-WARN, EL-THEFT, ELMULTI
D104
EL-BACK
D104
EL-R/FOG
B46
EL-STOP
B46
EL-TAIL/L
B46
EL-TURN, EL-THEFT
D108
EL-BACK/L
D108
EL-R/FOG
B49
EL-STOP
B49
EL-TAIL/L
B49
EL-TURN, EL-THEFT
B135 D119 B41 D113 D107 B70 B137 B71 B120 B149 B148
EL-R/FOG EL-R/FOG EL-DEF EL-DEF EL-WIP/R RS-SRS RS-SRS RS-SRS EL-DEF EL-TAIL/L EL-TAIL/L
B145
EL-STOP
B145
EL-TAIL/L
B145
EL-TURN, EL-THEFT
B152
EL-STOP
B152
EL-TAIL/L
B152
EL-TURN, EL-THEFT
GROUND DISTRIBUTION GROUND T3/T4
CONNECT TO LICENSE PLATE LAMP LH (Sedan with type-1) LICENSE PLATE LAMP RH (Sedan with type-1) REAR COMBINATION LAMP LH (STOP LAMP) (Sedan with type-1) REAR COMBINATION LAMP LH (TAIL LAMP) (Sedan with type-1) REAR COMBINATION LAMP LH (TURN SIGNAL) (Sedan with type-1) REAR COMBINATION LAMP RH (STOP LAMP) (Sedan with type-1) REAR COMBINATION LAMP RH (TAIL LAMP) (Sedan with type-1) REAR COMBINATION LAMP RH (TURN SIGNAL) (Sedan with type-1)
EL-28
CONN. T9 T19
EL-TAIL/L EL-TAIL/L
CELL CODE
T2
EL-STOP
T2
EL-TAIL/L
T2
EL-TURN, EL-THEFT
T5
EL-STOP
T5
EL-TAIL/L
T5
EL-TURN, EL-THEFT
BATTERY 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.
How to Handle Battery
Keep clean and dry.
METHODS OF PREVENTING OVER-DISCHARGE 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. SEL711E Remove negative terminal.
●
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.)
●
Check the charge condition of the battery. Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent overdischarge.
SEL712E Hydrometer
Thermometer
SEL459R
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 the acid contacts the eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.
EL-29
BATTERY How to Handle Battery (Cont’d) ● ●
Remove the cell plug using a suitable tool. Add distilled water up to the MAX level.
Cell plug
“MAX” level “MIN” level
SEL001K
SULPHATION Normal battery Sulphated battery Charging voltage Charging voltage
Charging current Charging current
A battery will be completely discharged if it is left unattended for a long time and the specific gravity becomes less than 1.100. This may result in sulphation on the cell plates. To find if a discharged battery has been “sulphated”, pay attention to its voltage and current when charging it. As shown in the figure at left, if the battery has been “sulphated”, less current and higher voltage may be observed in the initial stage of charging.
Duration of charge SEL005Z
Read top level with scale
Hydrometer
SPECIFIC GRAVITY CHECK 1. Read hydrometer and thermometer indications at eye level.
Thermometer
SEL442D
● Hydrometer
When electrolyte level is low, tilt battery case for easy measurement.
Thermal gauge
SEL006Z
EL-30
BATTERY How to Handle Battery (Cont’d) 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.
Specific gravity at electrolyte temperature
Converted specific gravity
.
Freezing zone
(−22)
(−4)
(14) (32) (50) (68) Electrolyte temperature °C (°F)
EL-31
(86)
(104)
(122) SEL007Z
BATTERY Battery Test and Charging Chart Chart I
VISUAL INSPECTION ● Check battery case for cracks or bends. ● Check battery terminals for damage. ● If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in), it is OK. OK
왔
왔
Replace battery.
CHECKING SPECIFIC GRAVITY Refer to “Specific Gravity Check”.
왔
왔
Below 1.100
왔
SLOW CHARGE Refer to “A: Slow Charge”.
왔
1.100 - 1.220
*
Above 1.220
QUICK CHARGE Refer to “C: Quick Charge”.
STANDARD CHARGE Refer to “B: Standard Charge”.
Ready for use ● Mount battery again and check loose terminals. Also check other related circuits.
CAPACITY TEST Refer to “Chart II”.
CAPACITY TEST Refer to “Chart II”. NG
OK
Ready for Replace use battery.
Ready for use
왔
왔
NG 왔
왔
CHECKING SPECIFIC GRAVITY Refer to “Specific Gravity Check”.
QUICK CHARGE Refer to “C: Quick Charge”. ● Time required: 45 min.
왔
왔
RECHARGE Refer to “C: Quick Charge”. ● If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F).
Ready for use
OK
Ready for use
CAPACITY TEST Refer to “Chart II”. OK
CAPACITY TEST Refer to “Chart II”.
왔
왔
왔
왔
NG
왔
왔
OK
CAPACITY TEST Refer to “Chart II”. OK
왔
왔
왔
왔 왔
NG
NG
Replace battery.
* “STANDARD CHARGE” is recommended if the vehicle is in storage after charging.
EL-32
NG
왔
Replace battery.
BATTERY Battery Test and Charging Chart (Cont’d) Check battery type and determine the specified current using the following table. Fig. 1 DISCHARGING CURRENT (Load Tester) ●
Chart II
CAPACITY TEST
왔
왔
Test using battery checker.
Test using load tester.
왔
왔
Follow manufacturer’s instructions to check and determine if battery is serviceable. OK 왔
Ready for use
NG
Type (YUASA type code)
Current (A)
025
240
027
285
096
375
063
210
065
255
075
300
Read load tester voltage when specified discharging current (Refer to Fig. 1.) flows through battery for 15 seconds.
왔
Go to next step.
왔
Above 9.6 volts
왔
Below 9.6 volts
OK 왔
Ready for use
NG 왔 SEL008Z
Go to next step.
EL-33
BATTERY Battery Test and Charging Chart (Cont’d) A: SLOW CHARGE
Determine initial charging current from specific gravity referring to Fig. 2. Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)
왔 ● ●
Charge battery. Check charging voltage 30 minutes after starting the battery charge.
CONVERTED SPECIFIC GRAVITY Below 1.100 ●
왔
왔
●
Below 12 volts or above 15 volts
12 to 15 volts OK
BATTERY TYPE (YUASA type code) 025
027
096
063
065
075
7.0 (A)
7.0 (A)
8.5 (A)
8.0 (A)
10.0 (A)
10.0 (A)
Check battery type and determine the specified current using the table shown above. After starting charging, adjustment of charging current is not necessary.
NG 왔
왔
Fig. 3 ADDITIONAL CHARGE (Slow charge)
Replace battery.
Continue to charge for 12 hours.
Below 1.150
왔
왔
CHECKING SPECIFIC GRAVITY Refer to “Specific Gravity Check”.
왔
Charge for 5 hours at initial charging current setting.
1.150 - 1.200
1.200 - 1.240
왔
Above 1.240
왔
Charge for 4 hours at initial charging current setting.
Charge for 2 hours at initial charging current setting.
Conduct additional charge as per Fig. 3, if necessary. 왔
왔
왔
왔
왔
Go to “CAPACITY TEST”.
왔
Go to “CAPACITY TEST”.
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). ● Remove cell caps during charging.
EL-34
BATTERY Battery Test and Charging Chart (Cont’d) B: STANDARD CHARGE
Determine initial charging current from specific gravity, referring to Fig. 4.
왔
Charge battery for 8 hours.
Fig. 4 INITIAL CHARGING CURRENT SETTING (Standard charge)
025
027
096
063
065, 075
1.100 - 1.130
6.0 (A)
6.0 (A)
7.5 (A)
7.0 (A)
9.0 (A)
1.130 - 1.160
5.0 (A)
5.0 (A)
6.0 (A)
6.0 (A)
8.0 (A)
1.160 - 1.190
4.0 (A)
4.0 (A)
5.0 (A)
5.0 (A)
7.0 (A)
1.190 - 1.220
3.0 (A)
3.0 (A)
4.0 (A)
4.5 (A)
5.0 (A)
● ●
왔
CHECKING SPECIFIC GRAVITY Refer to “Specific Gravity Check”.
왔
Conduct additional charge as per Fig. 5, if necessary.
왔
Go to “CAPACITY TEST”.
BATTERY TYPE (YUASA type code)
CONVERTED SPECIFIC GRAVITY
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) Below 1.150
왔
1.150 - 1.200
1.200 - 1.240
왔
Charge for 3.5 hours at initial charging current setting. 왔
Above 1.240
왔
Charge for 2.5 hours at initial charging current setting.
Charge for 1.5 hours at initial charging current setting.
왔
왔
왔
왔
Go to “CAPACITY TEST”.
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). ● Remove cell caps during charging.
EL-35
BATTERY Battery Test and Charging Chart (Cont’d) C: QUICK CHARGE Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick charge) BATTERY TYPE (YUASA type code)
Determine initial charging current setting and charging time from specific gravity, referring to Fig. 6.
025, 027, 063
096, 065, 075
20 (A)
25 (A)
CONVERTED SPECIFIC GRAVITY
CURRENT [A]
왔
Charge battery.
왔
Go to “CAPACITY TEST”.
● ●
1.100 - 1.130
2.5 hours
1.130 - 1.160
2.0 hours
1.160 - 1.190
1.5 hours
1.190 - 1.220
1.0 hours
Above 1.220
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). ● Do not exceed the charging time specified in Fig. 6, because charging battery over the charging time can cause deterioration of the battery.
Service Data and Specifications (SDS)
Applied model
Type (YUASA type code) Capacity
V-AH
CCA
EL-36
SR engine SR with CVT engine (cold with CVT area) (stanCD dard) engine (standard)
QG engine (standard)
QG engine (cold area) SR engine with MT (standard)
SR engine with MT (cold area
CD engine (cold area)
025
027
063
065
075
096
12 - 61
12 - 61
12 - 47
12 - 55
12 - 50
12 - 75
480
570
420
510
600
750
STARTING SYSTEM Wiring Diagram — START — GASOLINE ENGINE MODELS WITH M/T BATTERY Refer to EL-POWER.
: With GA engine and QG engine for Nordic : Except : With GA engine ST
OFF
IGNITION SWITCH
ON
: With QG engine : With SR engine or QG engine
ACC
STARTER MOTOR
BATTERY
YEL128C
EL-37
STARTING SYSTEM Wiring Diagram — START — (Cont’d) GASOLINE ENGINE MODELS WITH CVT
YEL999C
EL-38
STARTING SYSTEM Wiring Diagram — START — (Cont’d) DIESEL ENGINE MODELS BATTERY
Refer to EL-POWER.
ST
OFF
IGNITION SWITCH
ON ACC
STARTER MOTOR BATTERY
YEL130C
EL-39
STARTING SYSTEM Trouble Diagnoses If any abnormality is found, immediately disconnect battery negative terminal. Starter does not stop.
왘
Replace magnetic switch.
왘
Does engine turn normally?
Engine does not start. 왔
Does engine turn by cranking?
Yes
Yes
왘
Check ignition/fuel system.
왘
Repair starter motor.
왘
Check pinion clutch.
왘
Replace magnetic switch.
왘
Repair starter motor.
No (Turns slowly.)
No 왔
OK
Check battery as follows: ● Charging condition ● Terminal connections ● Terminal corrosion 왔
NG
A 쑗
왔
Does starter motor turn?
Yes
왘
Yes
Does gear shaft turn?
No
No 왔
Check reduction gear, armature and gear shaft. 왔
Check fuse and fusible link.
NG
왘
Replace.
OK 왔
Check battery as follows: ● Charging condition ● Terminal connections ● Terminal corrosion
A 쑗
NG
왔 왘
OK 왔
Check starting system wiring.
NG
● ●
Charge battery. Repair connections and corrosion of battery terminals.
왘
Repair.
왘
Replace magnetic switch
왘
Does starter turn under no load by connecting wires as follows?
OK 왔
Does magnetic switch operation sound occur?
No
Yes 왔
Check condition of pinion and ring gear mesh.
OK
Yes
NG 왔 ● ● ●
No
Adjust pinion movement. Check pinion moving mechanism. Check ring gear. SEL009Z
EL-40
STARTING SYSTEM Construction Internal gear
SEC. 233 S114-806A
Through-bolts Packing
4.9 - 6.4 (0.50 - 0.65, 43.4 - 56.40)
7.4 - 9.8 (0.75 - 1.00, 65.1 - 86.8) Magnetic switch assembly Center bracket (P) Dust cover kit
Planetary gear
Shift lever set
Pinion shaft
Gear case assembly
Thrust washer
E-ring
Rear cover assembly Thrust washer Brush spring
Pinion assembly Pinion stopper
. .
Brush
Brush
(-)
Brush assembly
(+)
Armature assembly 6.4 - 7.8 (0.65 - 0.80, 56.4 - 69.4)
Yoke assembly
N·m (kg-m, in-lb) High-temperature grease point
Center bracket (A) MEL675EB
SEC. 233 S114-871
Internal gear Through-bolts Packing 7.4 - 9.8 (0.75 - 1.00, 65.1 - 86.8) Magnetic switch assembly
4.9 - 6.4 (0.50 - 0.65, 43.4 - 56.40)
Center bracket (P) Dust cover kit Shift lever set
Planetary gear
Pinion shaft Gear case assembly
E-ring
Thrust washer
Rear cover assembly Thrust washer
Pinion assembly Pinion stopper
Brush spring Brush (-) Brush (+)
Brush assembly
Armature assembly 6.4 - 7.8 (0.65 - 0.80, 56.4 - 69.4)
Yoke assembly
: N·m (kg-m, in-lb) : High-temperature grease point
Center bracket (A)
EL-41
YEL420B
STARTING SYSTEM Construction (Cont’d) SEC. 233 S114-800B
쑗4
쑗3
4.9 - 6.4 (0.50 - 0.65, 43.4 - 56.4)
쑗2 쑗1 쑗5 쑗6
쑗8 13 쑗 10 쑗
쑗7
1.7 - 2.4 (0.17 - 0.24, 14.8 - 20.8)
쑗9
11 쑗
14 쑗 12 쑗
6.4 - 8.3 (0.65 - 0.85, 56.4 - 73.8)
: N·m (kg-m, in-lb) : High-temperature grease point YEL421B
1 쑗 2 쑗 3 쑗 4 쑗 5 쑗
Shift lever Adjusting plate Magnetic switch assembly Internal gear Planetary gear
6 쑗 7 쑗 8 쑗 9 쑗 10 쑗
Pinion shaft Rear cover Brush spring Brush (−) Brush (+)
EL-42
11 쑗 12 쑗 13 쑗 14 쑗
Armature Yoke Pinion assembly Gear case
STARTING SYSTEM Construction (Cont’d) SEC. 233 M70R
8 (0.8, 69)
: N·m (kg-m, in-lb) YEL422B
1 쑗 2 쑗 3 쑗 4 쑗 5 쑗
Magnetic switch assembly Shift lever assembly Gear case Pinion assembly Pinion shaft assembly
6 쑗 7 쑗 8 쑗 9 쑗 10 쑗
Planetary gear assembly Centre bracket Armature Pinion stopper Yoke assembly
EL-43
11 쑗 12 쑗 13 쑗 14 쑗
Brush holder Rear cover Drain hose Through-bolts
STARTING SYSTEM Construction (Cont’d) SEC. 233 S13 - 305
6.4 - 7.8 (0.65 - 0.80, 56.4 - 69.4)
7.4 - 9.8 (0.75 - 1.00, 65.1 - 86.8)
N·m (kg-m, in-lb) High-temperature grease point
NEL299
1 쑗 2 쑗 3 쑗 4 쑗 5 쑗 6 쑗 7 쑗
Bearing retainer Pinion shaft Clutch assembly Return spring Pinion stopper Stopper clip Gear case
8 쑗 9 쑗 10 쑗 11 쑗 12 쑗 13 쑗 14 쑗
Adjusting plates Torsion spring Shift lever Magnetic switch assembly Armature assembly Field coil Yoke
EL-44
15 쑗 16 쑗 17 쑗 18 쑗 19 쑗 20 쑗
Brush (+) Brush spring Brush (−) Brush holder Rear cover Through-bolt
STARTING SYSTEM Construction (Cont’d) SEC. 233 M2M62071
4.9 - 6.9 (0.50 - 0.70, 43.4 - 60.8)
3.9 - 7.8 (0.40 - 0.80, 34.7 - 69.4)
2.5 - 4.4 (0.25 - 0.45, 21.7 - 39.1) N·m (kg-m, in-lb) MEL780DB 1 쑗 2 쑗 3 쑗 4 쑗 5 쑗 6 쑗
Pinion stopper Pinion assembly Gear case Pinion shaft assembly Shift lever Spring
7 쑗 8 쑗 9 쑗 10 쑗 11 쑗 12 쑗
Holder Reduction gear Washer Center bracket Magnetic switch assembly Armature
13 쑗 14 쑗 15 쑗 16 쑗 17 쑗 18 쑗
Yoke Brush (+) Brush spring Brush (-) Brush holder Rear cover
MEL232M
EL-45
STARTING SYSTEM Construction (Cont’d) SEC. 233 S13-531
6.4 - 7.8 (0.65 - 0.80, 56.4 - 69.4)
7.4 - 9.8 (0.75 - 1.00, 65.1 - 86.8)
N·m (kg-m, in-lb) High temperature grease point
MEL233FB
1 쑗 2 쑗 3 쑗 4 쑗 5 쑗 6 쑗 7 쑗
Bearing retainer Pinion shaft Clutch assembly Return spring Pinion stopper Stopper clip Gear case
8 쑗 9 쑗 10 쑗 11 쑗 12 쑗 13 쑗 14 쑗
Dust cover Torsion spring Shift lever Magnetic switch assembly Armature assembly Field coil Yoke
EL-46
15 쑗 16 쑗 17 쑗 18 쑗 19 쑗 20 쑗
Brush (+) Brush spring Brush (−) Brush holder Rear cover Through-bolt
STARTING SYSTEM : N·m (kg-m, ft-lb)
Removal and Installation Removal 1. 2. 3. 4. 5. 6. 7.
36 - 48 (3.7 - 4.9, 26.6 - 35.4)
NEL301
Remove battery negative cable from battery. Remove intake air duct. Remove starter motor mounting bolts. Remove battery cable from starter motor. Disconnect harness connector from starter motor harness. Remove intake manifold support bracket. Remove starter motor from under the vehicle.
Installation ●
Installation is reverse order of removal.
YEL947C
Inspection Type 1
MAGNETIC SWITCH CHECK “M” terminal
Before starting to check, disconnect battery ground cable. Disconnect “M” terminal of starter motor. 1. Continuity test (between “S” terminal and switch body). ● No continuity ... Replace. 2. Continuity test (between “S” terminal and “M” terminal). ● No continuity ... Replace. ● ●
Type 2
“M” terminal
NEL302
EL-47
STARTING SYSTEM Inspection (Cont’d) PINION/CLUTCH CHECK 1. Inspect pinion teeth. ● Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.) 2. Inspect reduction gear teeth. ● Replace reduction gear if teeth are worn or damaged. (Also check condition of armature shaft gear teeth.) 3. 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.
Type 1
Type 2
NEL303
BRUSH CHECK Brush cap and lever Check wear of brush. Wear limit length: Refer to SDS (EL-52). ● Excessive wear ... Replace.
Vernier caliper Brush
SEL014Z
Brush Spring Pressure
Brush spring
Check brush spring pressure with brush spring detached from brush. Spring pressure (with new brush): Refer to SDS (EL-52). ● Not within the specified values ... Replace.
Brush
SEL015Z
Brush Holder
Type 1
1. Perform insulation test between brush holder (positive side) and its base (negative side). ● Continuity exists. ... Replace. 2. Check brush to see if it moves smoothly. ● If brush holder is damaged or deformed, replace it; clear sliding surface if dirty.
NEL304
EL-48
STARTING SYSTEM Inspection (Cont’d) Type 1
YOKE CHECK Magnet Holder
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. Holder may move slightly as it is only inserted and not bonded. CAUTION: Do not clamp yoke in a vice or strike it with a hammer.
Type 2 Magnet
SEL018Z
ARMATURE CHECK 1. Continuity test (between two segments side by side). ● No continuity ... Replace. 2. Insulation test (between each commutator bar and shaft). ● Continuity exists. ... Replace.
SEL019Z
3. Check commutator surface. ● Rough ... Sand lightly with No. 500 - 600 emery paper.
Emery paper SEL020Z
4. Check diameter of commutator. Commutator minimum diameter: Refer to SDS (EL-52). ● Less than specified value ... Replace. Vernier caliper
Commutator SEL021Z
EL-49
STARTING SYSTEM Inspection (Cont’d) M70R 5. Check depth of insulating mica from commutator surface. ● Less than 0.3 mm (0.012 in) ... Replace.
0,3 mm (0,012 in)
SEL207P
S13-305, S13-531, S114-800B, S114-806A, S114-871, M2M62071, 0 001 116 006 6. Check depth of insulating mold from commutator surface. ● Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm (0.020 to 0.031 in) Round
0.5 - 0.8 mm (0.020 - 0.031 in)
Correct
File
Commutator
Segment Mold
Incorrect SEL022Z
EL-50
STARTING SYSTEM Assembly 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 Pinion stopper
Clearance “l” With pinion driven out by magnetic switch, push pinion back to remove slack and measure clearance “l” between the front edge of the pinion and the pinion stopper. Clearance “l”: Refer to SDS (EL-52).
Clearance “l” SEL026Z
Movement “” Compare movement “” in height of pinion when it is pushed out with magnetic switch energized and when it is pulled out by hand until it touches stopper. Movement “” Refer to SDS (EL-52).
SEL497D
●
Not in the specified value ... Adjust by selecting the correct adjusting plate.
Adjusting plate
NEL305
EL-51
STARTING SYSTEM Service Data and Specifications (SDS) STARTER
Type
M70R
M2T62071
0 001 116 006
MAGNETI MARELLI
MITSUBISHI
BOSCH
Reduction gear type
Reduction gear type
Non-Reduction
SR20
CD20T
QG18 QG16
Applied model System voltage
V
12
No load Terminal voltage
V
11.5
11.0
11.5
Current
A
115
Less than 105
Less than 48
rev/min
More than 4500
More than 4,030
More than 5,800
Min. commutator dia.
mm (in)
28.8 (1.134)
31.4 (1.236)
33.5 (1.319)
Min. brush of length
mm (in)
5.0 (0.197)
11.5 (0.453)
3.5 (0.138)
14.3 - 25.2 (1.46 - 2.57, 3.22 - 5.69)
13.7 - 25.5 (1.4 - 2.6, 3.1 - 5.7)
5.2 (0.53, 1.17) at 7.5 mm (0.295 in) brush length
Movement “” in height of pinion assembly mm (in)
—
—
—
Clearance “I” between pinion front edge & pinion stopper mm (in)
0 - 3.0 (0 - 0.118)
—
0.0 - 3.9 (0 - 0.154)
Revolution
Brush spring tension
N (kg, lb)
S114-806A
S114-871
Type
S13-305
S13-531
S114-800B
CD20T cold area
QG18⋅QG16 cold area
HITACHI Reduction gear type
Applied model System voltage
SR20 with CVT models
SR20
CD20T
V
12
V
11.0
No load Terminal voltage Current Revolution
A rev/min
Less than 90 More than 2,700
More than 2,300
Less than 140
Less than 90
More than 3900
More than 2750
Min. commutator dia.
mm (in)
28.0 (1.102)
35.5 (1.398)
28.0 (1.102)
Min. brush length
mm (in)
10.5 (0.413)
11.0 (0.433)
10.5 (0.413)
28.4 - 34.3 (2.90 - 3.50, 6.39 - 7.72)
12.7 - 17.7 (1.29 - 1.80, 2.84 - 3.97)
Brush spring tension
N (kg, lb)
16.2 (1.65, 3.64)
12.7 - 17.7 (1.29 1.80, 2.84, 3.97)
Clearance between bearing & armature shaft mm (in) Clearance “I” between pinion front edge & pinion stopper mm (in)
Less than 0.2 (0.008) 0.3 - 2.5 (0.012 - 0.098)
0.3 - 2.0 (0.012 - 0.079)
EL-52
0.3 - 0.8 (0.012 - 0.031)
0.3 - 2.5 (0.012 - 0.098)
CHARGING SYSTEM Wiring Diagram — CHARGE — GASOLINE ENGINE MODELS
YEL001D
EL-53
CHARGING SYSTEM Wiring Diagram — CHARGE — (Cont’d) DIESEL ENGINE MODELS
YEL002D
EL-54
CHARGING SYSTEM Trouble Diagnoses Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suitable test probes are necessary for the test. The alternator can be checked easily by referring to the Inspection Table. ● Before starting, inspect the fusible link. ● Use fully charged battery.
WITH IC REGULATOR
Ignition switch “ON”
Warning lamp “OFF”
Disconnect connector (S, L) and ground L harness side.
Check the following: ⋅ Warning lamp bulb ⋅ Fuse for warning lamp
Warning lamp “OFF”
Warning lamp “ON”
Damaged IC regulator. Replace.
Warning lamp “ON” Engine start. Engine speed: 1,500 rpm
Warning lamp “ON”
Warning lamp “OFF”
OK
Check the following: ⋅ Drive belt ⋅ Fuse for S terminal ⋅ Connector (S, L terminal) connection
Engine idling
Warning lamp “OFF”
OK
More than 15.5V
Damaged IC regulator. Replace.
No generation
Field circuit is open.
Warning lamp “ON” Engine speed: 1,500 rpm (Measured B terminal voltage)
Warning lamp: “CHARGE” warning lamp in combination meter
Note: ● If the inspection result is OK even though the charging system is malfunctioning, check the B terminal connection. (Check the tightening torque.) ● When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary, replace faulty parts with new ones.
MALFUNCTION INDICATOR The IC regulator warning function activates to illuminate “CHARGE” warning lamp, if any of the following symptoms occur while alternator is operating: ● Excessive voltage is produced. ● No voltage is produced.
EL-55
CHARGING SYSTEM Construction SEC. 231 LR190-734E
쑗7
쑗5
3.14 - 3.9 (0.320 - 0.398, 27.8 - 34.5)
쑗6 7.8 - 10.8 (0.80 - 1.10, 69.4 - 95.5)
3.14 - 3.9 (0.320 - 0.398, 27.8 - 34.5)
쑗2
쑗3
10 쑗
쑗4
쑗1 3.14 - 3.9 (0.320 - 0.398, 27.8 - 34.5)
쑗9 63.7 - 83.3 (6.50 - 8.50, 46.99 - 61.44)
: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb)
쑗8
NEL320
1 쑗 2 쑗 3 쑗 4 쑗
Pulley assembly Front cover Front bearing Retainer
5 쑗 6 쑗 7 쑗
8 쑗 9 쑗 10 쑗
Rotor Slip ring Stator
EL-56
IC voltage regulator assembly Diode assembly Rear cover
CHARGING SYSTEM Construction (Cont’d) SEC. 231 A2TB3691 A2TB3891 12.8 - 18.6 (1.3 - 1.9, 10 - 13) 3.5 - 5.3 (0.36 - 0.54, 31.0 - 46.9) 2.0 - 5.3 (0.20 - 0.54, 17.7 - 46.9)
99 - 137 (10.1 - 12.9, 73 - 101)
2.0 - 5.3 (0.20 - 0.54, 17.7 - 46.9) : N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) YEL427B
1 쑗 2 쑗 3 쑗 4 쑗
Pulley assembly Front cover Front bearing Bearing retainer
5 쑗 6 쑗 7 쑗
Rotor Rear bearing Stator
EL-57
8 쑗 9 쑗 10 쑗
IC voltage regulator assembly Diode assembly Rear cover
CHARGING SYSTEM Construction (Cont’d)
MEL141LA
EL-58
CHARGING SYSTEM Construction (Cont’d) SEC. 231 A115I-80A 8 쑗
70 - 90 (7.1 - 9.2, 51.6 - 66.4)
3.5 - 5.5 (0.36 - 0.56, 31 - 49) 9 쑗 10 쑗
7 쑗
쑗1
4 쑗
6-8 (0.6 - 0.8, 53 - 71)
3 쑗
5 쑗
11 쑗
6 쑗
2 쑗
3-4 (0.3 - 0.4, 27 - 35) : N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) YEL429B
1 쑗 2 쑗 3 쑗 4 쑗
Pulley assembly Front cover Front bearing Bearing retainer
5 쑗 6 쑗 7 쑗 8 쑗
Stator Rotor Special bolt Rear cover
EL-59
9 쑗 10 쑗 11 쑗
Diode assembly Brush holder Dust cover
CHARGING SYSTEM Removal and Installation Loosen
1. 2. 3. 4. 5. 6. 7.
Adjusting bolt
Tighten
Lock bolt
.
NEL327
: N·m (kg-m, ft-lb)
16 - 21 (1.6 - 2.1, 12 - 15)
Loosen lock bolt. Remove RH undertray. Loosen alternator mounting bolt and remove drive belt. Remove lock bolt and adjust. Remove harness connectors. Remove alternator mounting bolt. Support engine with jack, and remove front engine mounting bolt. 8. Remove alternator.
Disassembly REAR COVER 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 bearing box section with a 200W soldering iron. Do not use a heat gun, as it can damage diode assembly.
37 - 50 (3.8 - 5.1, 27 - 37)
37 - 50 (3.8 - 5.1, 27 - 37) SEL910T
REAR BEARING CAUTION: ● Do not reuse rear bearing after removal. Replace with a new one. ● Do not lubricate rear bearing outer race. Soldering iron (200W capacity) Bearing box
SEL032Z
Inspection ROTOR CHECK
Slip rings SEL033Z
1. Resistance test Resistance: Refer to SDS (EL-63). ● Not within the specified values ... Replace rotor. 2. Insulator test ● Continuity exists ... Replace rotor. 3. Check slip ring for wear. Slip ring minimum outer diameter: Refer to SDS (EL-63). ● Not within the specified values ... Replace rotor.
EL-60
CHARGING SYSTEM Inspection (Cont’d) BRUSH CHECK
Type 1
1. Check smooth movement of brush. ● Not smooth ... Check brush holder and clean. 2. Check brush for wear. ● Replace brush if it is worn down to the limit line.
Brush wear limit line
Type 2 Brush wear limit line
SEL034Z
STATOR CHECK
Type 1
1. Continuity test ● No continuity ... Replace stator. 2. Ground test ● Continuity exists ... Replace stator.
Lead wire
Type 2
SEL037Z
EL-61
CHARGING SYSTEM Amount of protrusion: Fix ring at the position of minimum protrusion. Ring
Assembly 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. ●
Eccentric groove
Rear bearing SEL044Z
REAR COVER INSTALLATION (1) Fit brush assembly, diode assembly, regulator assembly and stator. (2) Push brushes up with fingers and install them to rotor. Take care not to damage slip ring sliding surface.
SEL048Z
SEL049Z
EL-62
CHARGING SYSTEM Service Data and Specifications (SDS) ALTERNATOR Type
A2TB3691
A2TB3891
LR180-762
LR190-734E
MITSUBISHI Applied model Nominal rating
V-A
HITACHI
SR20, MT
SR20, CVT
QG18, QG16
CD20T
12-80
12-90
12-80
12-90
Ground polarity
Negative
Minimum revs under noload (When 13.5V is applied) rev/min
Less than 1,300
Hot output current More than 23/1,300 (when 13.5V is applied) More than 64/2,500 A/rev/min More than 82/5,000
Less then 1,000
More than 22/1,300 More than 64/2,500 More than 85/5,000
Regulated output voltage
More than 23/1,300 More than 65/2,500 More than 87/5,000
More than 32/1,300 More than 54/2,500 More than 87/5,000
14.1 - 14.7 V
Brush minimum length mm (in)
5.0 (0.197)
6.0 (0.236)
Brush spring pressure N (g, oz)
4.8 - 6.0 (490 - 610, 17.28 - 21.51)
1.0 - 3.43 (102 - 350, 3.60 - 12.34)
Slip ring minimum diameter mm (in)
22.1 (0.870)
26.0 (1.024)
Rotor coil resistance at 20°C (68°F)
2.2 - 2.6
1.8 - 2.1
EL-63
2.67
2.60
COMBINATION SWITCH Combination Switch/Check FOG
TURN
FRONT WIPER AND WASHER
INT
MIST
WASH (Rear)
FR and RR
LIGHT
REAR WIPER AND WASHER
FR or RR
2ND
TRIP COMPUTER
OFF
OFF
OFF ON
OFF 1ST
VOLUME
WASH (Front)
OFF
INT
LO
HI
(Light)
(Wiper)
LIGHTING SWITCH (With rear fog lamp) OFF 2ND 1ST
(Wiper)
WIPER AND WASHER SWITCH FOG LAMP SWITCH OFF REAR
FRONT MIST OFF INT LO
HI
FR/WASH
WASH OFF RR/WASH
OFF
REAR INT ON
TRIP INT ON
LIGHTING SWITCH (With front and rear fog lamp) OFF
1ST
2ND WIPER AMP.
FOG LAMP SWITCH FR AND RR OFF FR
TURN SIGNAL SWITCH
INTERMITTENT WIPER VOLUME
YEL230C
EL-64
STEERING SWITCH Check
YEL954C
EL-65
STEERING SWITCH Replacement Wiper and washer switch Switch base Lighting switch
For removal and installation of spiral cable, refer to RS section [“Installation — Air Bag Module and Spiral Cable”, “SUPPLEMENTAL RESTRAINT SYSTEM (SRS)”]. ● Each switch can be replaced without removing combination switch base.
YEL903
●
To remove combination switch base, remove base attaching screw.
●
Before installing the steering wheel, align the steering wheel guide pins with the screws which secure the combination switch as shown in the left figure.
YEL904
Screw Combination switch
Steering wheel guide pin
SEL151V
EL-66
HEADLAMP (without Daytime Light System) — Conventional Type — Wiring Diagram — H/LAMP —
EL-H/LAMP-01
BATTERY
Refer to EL-POWER.
15A 31 : 32 :
GS
15A 32 :
GS
DI
33 :
DI
R/W
: With gasoline engine
DI
: With diesel engine
R
R/W
R
8
5
2ND
OFF
GS
2ND
OFF
1ST
COMBINATION SWITCH (LIGHTING SWITCH)
1ST PASS
PASS
PASS
LOW
PASS
PASS
PASS
LOW LOW HIGH
LOW
HIGH
HIGH
HIGH
10
9
7
6
R/Y
R/B
P/L
R/G
HIGH
HIGH
R/B
R/Y
R/B
P/L
R/G
3
1
3
1
HEADLAMP LH LOW
HIGH
E5
HIGH
2
2
B
B
B
B
B
E37
1 2 3
LOW
E5 GY
E111
LOW
LOW
A
Next page
HEADLAMP RH
E32
B
E11
, E32 GY
1 3 13 2 12 14 11 E111 9 6 5 7 8 10 W
YEL257B
EL-67
HEADLAMP (without Daytime Light System) — Conventional Type — Wiring Diagram — H/LAMP — (Cont’d)
YEL003D
EL-68
HEADLAMP (without Daytime Light System) — Conventional Type — Trouble Diagnoses Symptom LH headlamps do not operate.
Possible cause 1. Bulb 2. Grounds 3. 15A fuse
E11
and
E37
4. Lighting switch RH headlamps do not operate.
1. Bulb 2. Grounds 3. 15A fuse
E11
and
E37
4. Lighting switch
Repair order 1. Check bulb. 2. Check grounds E11 and E37 3. Check 15A fuse [No. 31 (gasoline engine), 32 (diesel engine) located in fuse and fusible link box]. Verify battery positive voltage is present at terminal 쑗 8 of lighting switch. 4. Check lighting switch. 1. Check bulb. 2. Check grounds E11 and E37 3. Check 15A fuse [No. 32 (gasoline engine), 33 (diesel engine) located in fuse and fusible link box]. Verify battery positive voltage is present at terminal 쑗 5 of lighting switch. 4. Check lighting switch.
LH high beams do not operate, but LH low beam operates.
1. Bulbs 1. Check bulbs. 2. Open in LH high beams circuit 2. Check R/B wire between lighting switch and LH headlamps for an open circuit. 3. Check lighting switch. 3. Lighting switch
LH low beam does not operate, but LH high beam operates.
1. Bulb 2. Open in LH low beam circuit 3. Lighting switch
1. Check bulb. 2. Check R/Y wire between lighting switch and LH headlamp for an open circuit. 3. Check lighting switch.
RH high beams do not operate, but RH low beam operates.
1. Bulbs 2. Open in RH high beams circuit 3. Lighting switch.
1. Check bulbs. 2. Check R/G wire between lighting switch and RH headlamps for an open circuit. 3. Check lighting switch.
RH low beam does not operate, but RH high beam operates.
1. Bulb 2. Open in RH low beam circuit
1. Check bulb. 2. Check P/L wire between lighting switch and RH headlamp for an open circuit. 3. Check lighting switch.
3. Lighting switch High beam indicator does not work.
1. Bulb 2. Grounds M6 , M26 and M28 or E11 and E39 3. Open in high beam circuit
EL-69
1. Check bulb in combination meter. 2. Check grounds M6 , M26 and M28 or E11 and E39 . 3. Check R/B wire between lighting switch and combination meter for an open circuit.
HEADLAMP (without Daytime Light System) — Conventional Type — Bulb cover Open Rubber cap
Lock
Push to remove
Bulb Replacement The headlamp is a semi-sealed beam type which uses a replaceable halogen bulb. The bulb can be replaced from the engine compartment side without removing the headlamp body. ● Grasp only the plastic base when handling the bulb. Never touch the glass envelope. 1. Disconnect the battery cable. 2. Turn the bulb retaining ring counterclockwise until it is free from the headlamp reflector, and then remove it. 3. Disconnect the harness connector from the back side of the bulb. 4. Remove the headlamp bulb carefully. Do not shake or rotate the bulb when removing it. 5. Install in the reverse order of removal. CAUTION: Do not leave headlamp reflector without bulb for a long period of time. Dust, moisture, smoke, etc. entering headlamp body may affect the performance of the headlamp. Remove headlamp bulb from the headlamp reflector just before a replacement bulb is installed.
SEL995K
Aiming Adjustment When performing headlamp aiming adjustment, use an aiming machine, aiming wall screen or headlamp tester. Aimers should be in good repair, calibrated and operated in accordance with respective operation manuals. If any aimer is not available, aiming adjustment can be done as follows: For details, refer to the regulations in your own country. a. Keep all tires inflated to correct pressures. b. Place vehicle and tester on one and same flat surface. c. See that there is no-load in vehicle (coolant, engine oil filled up to correct level and full fuel tank) other than the driver (or equivalent weight placed in driver’s position).
CAUTION: Be sure aiming switch is set to “0” when performing aiming adjustment on vehicles equipped with headlamp aiming control.
SEL466V
EL-70
HEADLAMP (without Daytime Light System) — Conventional Type — Aiming Adjustment (Cont’d) LOW BEAM 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.
Left and right adjusting screw
Up and down adjusting screw
NEL548
Screen Vertical center line ahead of head lamps
Center of low beam bulb
300 (11.81) Basic illuminating area for adjustment
Horizontal center line of head lamps
Unit: mm (in)
33.5 (1.319)
Cut off line
Aiming allowable area
Screen
27.5 (1.083)
Cut off line
25,000 (984.25) NEL563
●
●
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 to the above shows headlamp aiming pattern for driving on left side of road; for driving on right side of road, aiming pattern is reversed.
EL-71
HEADLAMP (without Daytime Light System) — Xenon Type — System Description Xenon type headlamp is adopted to the low beam headlamps. Xenon bulbs do not use a filament. Instead, they produce light when a high voltage current is passed between two tungsten electrodes through a mixture of xenon (an insert gas) and certain other metal hallides. In addition to added lighting power, electronic control of the power supply gives the headlamps stable quality and tone color. Following are some of the many advantage of the xenon type headlamp. ● The light produced by the headlamps is white color approximating sunlight that is easy on the eyes. ● Light output is nearly double that of halogen headlamps, affording increased area of illumination. ● The light features a high relative spectral distribution at wavelengths to the human eye is most sensitive, which means that even in the rain, more light is reflected back from the road surface toward the vehicle, for added visibility. ● Power consumption is approximately 25 percent less than halogen headlamps, reducing battery load.
Provide an optimum illumination pattern designed to prevent dazzling effect on drivers of oncoming vehicles Cut-line Shade
Reflector Bulb Bulb socket Booster Provides initial voltage amplification
Battery connector (DC12V) HID control unit
Xenon
Transforms battery voltage into illumination Structure of the new xenon lamp
Conventional
Comparison of xenon headlamp and conventional halogen headlamp lighting performance (example)
HID: High Intensity Discharge
SEL440V
EL-72
HEADLAMP (without Daytime Light System) — Xenon Type — Wiring Diagram — H/LAMP — BATTERY : With gasoline engine Refer to EL-POWER.
2ND
OFF
2ND
OFF
1ST
: With diesel engine
COMBINATION SWITCH (LIGHTING SWITCH)
1ST
LOW
PASS
PASS
PASS
PASS
PASS
PASS
LOW LOW HIGH
HIGH
LOW HIGH
HIGH
LOW
LOW HIGH
HIGH
Next page
YEL133C
EL-73
HEADLAMP (without Daytime Light System) — Xenon Type — Wiring Diagram — H/LAMP — (Cont’d)
YEL004D
EL-74
HEADLAMP (without Daytime Light System) — Xenon Type — WARNING: ● The xenon headlamp has a high-tension current generating area. Be extremely careful when removing and installing. Be certain to disconnect the battery negative cable prior to removing or installing. ● When the xenon headlamp is lit, do not touch the harness (covered with red or amber insulation), bulb itself or the bulb socket with your bare hands. ● Never service a xenon headlamp with wet hands. ● When checking body side harness with a circuit tester, be certain to disconnect the harness connector from the xenon headlamp. ● When the xenon headlamp is lit, the xenon bulb must be installed in the headlamp housing. (Never turn on xenon headlamp, if the bulb is out of the headlamp housing.) CAUTION: Make sure to install the bulb securely; if the xenon bulb is improperly installed in its socket, hightension current leaks occur. This may lead to a melted bulb and/or bulb socket.
Trouble Diagnoses Symptom LH or RH xenon headlamp (low beam) blinks, lacks brightness or does not illuminate.
Possible cause
Repair order
1. Check 20A fuse [No. 30 (gasoline engine), 43 (diesel engine) : LH, No. 38 (gasoline engine), 39 (diesel engine), : RH, located in fuse and fusible link box]. Relay 2. Check Headlamp relay. Power supply circuit to headlamp 3. Verify battery positive voltage is present at terminal low beam 3 of headlamp harness with lighting switch in 쑗 “2nd” and “Low” positions. (Before inspecting headlamp terminal, disconnect headlamp connector with lighting switch in “OFF” position.) Xenon bulb 4. Replace the xenon bulb with the other side bulb or new one. (If headlamps illuminate correctly, replace the bulb.) HID control unit and booster 5. Replace the HID control unit and booster as a headlamp assembly.
1. 15A fuse
2. 3.
4.
5.
1. Check 15A fuse [No. 30 (Gasoline engine), No. 43 (diesel engine), : LH, No. 38 (gasoline engine), No. 39 (diesel engine) located in fuse and fusible link box]. 2. Check continuity between headlamp harness terminal 쑗 2 and body ground. (Before inspecting headlamp terminal, disconnect headlamp connector with lighting switch in “OFF” position.)
1. 15A fuse LH or RH [both headlamp high and xenon (low) beam] do not illuminate. 2. Ground circuit
LH or RH headlamp high beam does not illuminate.
1. Check bulb. 1. Bulb 2. Power supply circuit to headlamp 2. Verify battery positive voltage is present at terminal high beam 1 of headlamp harness with lighting switch in 쑗 “2nd” and “HIGH” position. (Before inspecting headlamp terminal, disconnect headlamp connector with lighting switch in “OFF” position.)
HID: High Intensity Discharge
EL-75
HEADLAMP (without Daytime Light System) — Xenon Type — Bulb Replacement CAUTION: ● After replacing a new xenon bulb, be sure to make aiming adjustments. ● Hold only the plastic base when handling the bulb. Never touch the glass envelope. ● Do not leave headlamp reflector without bulb for a long period of time. Dust, moisture, smoke, etc. entering headlamp body may affect the performance of the headlamp. Remove headlamp bulb from the headlamp reflector just before a replacement bulb is installed. 1. Disconnect negative battery cable. 2. Remove side combination lamp and radiator grille. 3. Disconnect headlamp connector. 4. Remove headlamp assembly. WARNING: Never service a xenon headlamp with wet hands.
XENON BULB (LOW BEAM) 1. Remove headlamp seal cover.
.
2. Turn bulb socket counterclockwise with keep pushing, then remove it.
Bulb Socket
NEL765
3. Release retaining pin. 4. Remove the xenon bulb. 5. Install in the reverse order of removal. CAUTION: ● When disposing of the xenon bulb, do not break it; always dispose of it as is. ● Make sure to install the bulb securely; if the xenon bulb is improperly installed in its socket, high-tension current leaks occur. This may lead to a melted bulb and/or bulb socket.
Retaining pin
NEL551
EL-76
HEADLAMP (without Daytime Light System) — Xenon Type — Bulb Replacement (Cont’d) HIGH BEAM .
1. 2. 3. 4. 5.
Seal cover
Pull off headlamp seal cover. Disconnect bulb connector. Release retaining pin. Remove the bulb. Install in the reverse order of removal.
Retaining pin
NEL564
EL-77
COMBINATION SWITCH (LIGHTING SWITCH) OFF
1ST
IGNITION SWITCH ON or START
IGNITION SWITCH START
FUSE
2ND
Schematic
DAYTIME LIGHT CONTROL UNIT
EL-78 LOW
HIGH HEADLAMP LH
LOW
HIGH
To tail lamp
HEADLAMP RH
ALTERNATOR
HEADLAMP — Daytime Light System —
HEADLAMP RELAY RH
HEADLAMP RELAY LH
COMBINATION METER (HI BEAM INDICATOR)
CONVENTIONAL TYPE
BATTERY
YEL273C
HEADLAMP — Daytime Light System — Wiring Diagram — DTRL — CONVENTIONAL TYPE
EL-DTRL-01
BATTERY
Refer to EL-POWER.
15A 31 : 32 :
GS
15A 32 :
GS
DI
33 :
DI
R/W
F
R
To EL-DTRL-03
R/W
R
8
5
2ND
DI
: With diesel engine
G
To EL-DTRL-03
2ND
OFF
1ST
1ST PASS
LOW
: With gasoline engine
R
R/W
OFF
GS
PASS LOW
PASS
LOW
LOW
HIGH
HIGH
HIGH
HIGH
10
9
7
6
G
R/B
P
R/G
PASS
PASS
PASS
COMBINATION SWITCH (LIGHTING SWITCH)
E111
LOW
LOW HIGH
HIGH
R/G
H
P
I
R/B
J
G
K
Next page
1 3 13 2 12 14 11 E111 9 6 5 7 8 10 W
YEL262B
EL-79
HEADLAMP — Daytime Light System — Wiring Diagram — DTRL — (Cont’d) CONVENTIONAL TYPE
YEL005D
EL-80
HEADLAMP — Daytime Light System — Wiring Diagram — DTRL — (Cont’d) CONVENTIONAL TYPE IGNITION SWITCH ON or START
IGNITION SWITCH START
BATTERY
Refer to EL-POWER. FUSE BLOCK (J/B)
2ND
COMBINATION SWITCH (LIGHTING SWITCH)
1ST OFF
To EL-TAIL/L Preceding page
DAYTIME LIGHT CONTROL UNIT
Preceding page
To EL-DTRL-01
Preceding page
: With GA engine or diesel engine : With GA engine : With SR engine or QG engine
ALTERNATOR
ALTERNATOR
ALTERNATOR
: With diesel engine
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
YEL137C
EL-81
OFF
1.a
FUSE
2.a
HEADLAMP RELAY LH
Schematic
HEADLAMP RELAY RH
DAYTIME LIGHT CONTROL UNIT
EL-82 COMBINATION METER (HI BEAM INDICATOR)
HEADLAMP LH LOW
HIGH
HEADLAMP RH LOW
To tail lamp
HIGH
ALTERNATOR
HEADLAMP — Daytime Light System With Xenon Type —
COMBINATION SWITCH (LIGHTING SWITCH)
IGNITION SWITCH START
XENON TYPE
IGNITION SWITCH ON or START
BATTERY
YEL274C
HEADLAMP — Daytime Light System With Xenon Type — Wiring Diagram — DTRL — XENON TYPE BATTERY : With gasoline engine : With diesel engine
Refer to EL-POWER.
To EL-DTRL-06
2ND
OFF
To EL-DTRL-06
2ND
OFF
1ST
COMBINATION SWITCH (LIGHTING SWITCH)
1ST PASS
LOW
PASS
LOW
PASS
LOW HIGH HIGH
LOW HIGH
HIGH
PASS
PASS
PASS LOW
LOW HIGH
HIGH
DIODE Next page
YEL138C
EL-83
HEADLAMP — Daytime Light System With Xenon Type — Wiring Diagram — DTRL — (Cont’d) XENON TYPE
YEL006D
EL-84
HEADLAMP — Daytime Light System With Xenon Type — Wiring Diagram — DTRL — (Cont’d) XENON TYPE IGNITION SWITCH ON or START
IGNITION SWITCH START
BATTERY
Refer to EL-POWER. FUSE BLOCK (J/B)
.
2ND
.
COMBINATION SWITCH (LIGHTING SWITCH)
1ST .
OFF
To EL-TAIL/L
DAYTIME LIGHT CONTROL UNIT
Preceding page
To EL-DTRL-04
Preceding page
: With GA engine or diesel engine : With GA engine : With SR engine or QG engine
ALTERNATOR
ALTERNATOR
ALTERNATOR
: With diesel engine
.
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
YEL140C
EL-85
HEADLAMP — Daytime Light System — Trouble Diagnoses DAYTIME LIGHT CONTROL UNIT INSPECTION TABLE Terminal No.
Connections
INPUT (I)/ OUTPUT (O)
Operated condition
Voltage (V) (Approximate values)
1
Power source for illumination & tail lamp
—
—
12
2
Alternator “L” terminal
I
3
Lighting switch
I
5
Power source for headlamp RH
—
6
Illumination & tail lamp
O
7
Power source for headlamp LH
—
8
Start signal
I
9
Headlamp LH (conventional type), Headlamp relay LH (xenon type)
O
10
Ground
—
11
Headlamp RH (conventional type), Headlamp relay RH (xenon type)
O
12
Power source
—
Engine
Running
12
Stopped
0
1ST⋅2ND position
12
OFF
0
—
12
ON (daytime light operating*)
12
OFF
0
—
12 START
12
ON, ACC or OFF
0
ON (daytime light operating*)
12
OFF
0
Ignition switch
—
—
ON (daytime light operating*)
12
OFF
0
Ignition switch
ON or START
12
ACC or OFF
0
*: Daytime light operating: Lighting switch in “OFF” position with engine running.
Bulb Replacement/Conventional Type For bulb replacement refer to EL-70.
Bulb specifications/Conventional Type For bulb specifications, refer to EL-137.
Aiming Adjustment/Conventional Type For aiming adjustment, refer to EL-70.
Bulb replacement/Xenon Type For bulb replacement, refer to EL-76.
Aiming Adjustment/Xenon Type For aiming adjustment, refer to EL-91.
EL-86
HEADLAMP — Headlamp Aiming Control (Manual) — Wiring Diagram — H/AIM — MODELS BEFORE VIN - P11U0548750 BATTERY : With daytime light system
Refer to EL-POWER.
: Without daytime light system
Next page
2ND
OFF
COMBINATION SWITCH (LIGHTING SWITCH)
FUSE BLOCK (J/B)
1ST
Next page
DAYTIME LIGHT CONTROL UNIT
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
YEL141C
EL-87
HEADLAMP — Headlamp Aiming Control (Manual) — Wiring Diagram — H/AIM — (Cont’d) Preceding page
HEADLAMP AIMING SWITCH
Preceding page
HEADLAMP AIMING MOTOR RH
HEADLAMP AIMING MOTOR LH
YEL142C
EL-88
HEADLAMP — Headlamp Aiming Control (Manual) — Wiring Diagram — H/AIM — (Cont’d) MODELS AFTER VIN - P11U0548750
YEL834C
EL-89
HEADLAMP — Headlamp Aiming Control (Manual) — Wiring Diagram — H/AIM — (Cont’d)
YEL835C
EL-90
HEADLAMP — Headlamp Aiming Control (Auto) — System Description The auto level control unit is designed to adjust the beam angle of the headlamp in response to the loading conditions of the vehicle. It is not designed to compensate for the dynamic handling of the vehicle. The vehicle’s front and rear height is measured by sensors attached to the front stabilizer bar and the rear suspension lateral link arm. The sensors provide a signal to the auto level control unit, which calculates the correct headlamp aiming position and sends a signal to the aiming motors.
Initialisation After the replacement or adjustment of any suspension sensor, the system must be self calibrated. This is achieved as follows. The vehicle must be empty, since any load will result in an invalid calibration. From outside of the vehicle turn ignition on and then within 7 seconds the light switch must be turned from off to side lights on position, 5 times, finishing with the lamps in the on position. The headlamps will then move to the highest, then the lowest then the normal position to indicate that the calibration is successful, as can be seen by the moving beam pattern. After successful calibration the headlamps must then be aimed in the conventional manner. Refer to EL-70.
EL-91
HEADLAMP — Headlamp Aiming Control (Auto) — Component Parts and Harness Connector Location
Rear sensor
Auto level control unit
Headlamp aiming motor RH
Front sensor
Headlamp aiming motor LH
Rear sensor Headlamp aiming motor
Front sensor
Auto level control unit
NEL528
EL-92
HEADLAMP — Headlamp Aiming Control (Auto) — Wiring Diagram — H/AIM — AUTO
YEL836C
EL-93
HEADLAMP — Headlamp Aiming Control (Auto) — Wiring Diagram — H/AIM — (Cont’d)
YEL837C
EL-94
HEADLAMP — Headlamp Aiming Control (Auto) — Bulb (1.2 W or 2 W only)
Trouble Diagnosis PERFORMING SELF-DIAGNOSIS
Auto level control unit NEL530
Check headlamp aiming control (auto) system using a bulb as follows: 1. Connect a bulb 1.2W or 2W between auto level control unit 1 and 쑗 5 . connector terminal 쑗 NOTE: Do not use another bulb. This will damage the auto level control unit. Use a 1.2W or 2W bulb only. 2. After turning the ignition switch from “OFF” to “ON”, the bulb operates. 3. Compare the bulb operation to the chart below.
EL-95
HEADLAMP — Headlamp Aiming Control (Auto) — Trouble Diagnosis (Cont’d) Lighting condition of the bulb
System condition
Reference item
No malfunction is detected. No further action is necessary.
IGN ON ON 1 sec.
—
OFF
NEL531 IGN ON ON
2 sec.
1 sec. OFF
Front sensor or front sensor circuit is malfunctioning. (When rear sensor OK)
Go to DIAGNOSTIC PROCEDURE 1 (EL-97).
Rear sensor or rear sensor circuit is malfunctioning. (Whatever the state of front sensor)
Go to DIAGNOSTIC PROCEDURE 2 (EL-97).
2 sec.
0.5 sec.
NEL532 IGN ON ON
2 sec.
1 sec. OFF
2 sec.
0.5 sec.
0.5 sec.
NEL533
Sensor supply is malfunction- Go to DIAGNOSTIC ing. PROCEDURE 1 and 2 (EL-97).
IGN ON ON
2 sec.
1 sec. OFF
2 sec.
0.5 sec.
0.5 sec.
NEL534
Aiming motor or aiming motor Go to DIAGNOSTIC circuit is malfunctioning. PROCEDURE 3 (EL-98).
IGN ON ON 1 sec. OFF
2 sec.
0.5 sec.
2 sec.
0.5 sec. NEL535
Auto level control unit is malfunctioning.
IGN ON ON
OFF
NEL536
EL-96
Replace auto level control unit.
HEADLAMP — Headlamp Aiming Control (Auto) — Trouble Diagnosis (Cont’d) DIAGNOSTIC PROCEDURE 1 (Front sensor check) Auto leveling control unit B123
Front sensor B131
1) Disconnect control unit and front sensor connector. 2) Check harness continuity between control unit and front sensor. Continuity should exist.
NG
왘
Check harness between control unit and front sensor.
OK 왔 NEL537
1) Remove sensor. 2) Check front sensor linkage operation.
NG
왘
Replace sensor linkage.
OK 왔
Replace front sensor.
DIAGNOSTIC PROCEDURE 2 (Rear sensor check) Auto leveling control unit B123
Rear sensor B133
1) Disconnect control unit and rear sensor connector. 2) Check harness continuity between control unit and rear sensor. Continuity should exist.
NG
왘
Check harness between control unit and rear sensor.
OK 왔 NEL538
1) Remove the sensor. 2) Check rear sensor linkage operation. OK 왔
Replace rear sensor.
EL-97
NG
왘
Replace sensor linkage.
HEADLAMP — Headlamp Aiming Control (Auto) — Trouble Diagnosis (Cont’d) DIAGNOSTIC PROCEDURE 3 (Aiming motor check)
Headlamp aiming motor
Lighting switch “2nd”
CHECK POWER SUPPLY 1) Turn lighting switch to 2nd position. 2) Check voltage between aiming motor terminal 쑗 3 and ground. Battery voltage should exist.
NG
왘
Check harness between combination switch and aiming motor.
OK YEL618B
왔
CHECK GROUND CIRCUIT 1) Turn lighting switch to OFF position. 2) Check continuity between aiming motor terminal 쑗 1 and ground. Continuity should exist.
Headlamp aiming motor LH: E4 RH: E33
왘
Check harness between aiming motor and ground.
OK 왔
NEL540
1) Disconnect control unit and aiming motor connector. 2) Check harness continuity between control unit terminal 쑗 4 and aiming motor terminal 쑗 2 . Continuity should exist. OK 왔
Auto leveling control unit B123
NG
Headlamp aiming motor LH: E4
Replace aiming motor.
RH: E33
NEL541
EL-98
NG
왘
Check harness between control unit and aiming motor.
HEADLAMP — Headlamp Aiming Control (Auto) — Removal and Installation
Front sensor 4.0 - 5.0 (0.4 - 0.51, 35 - 44)
Front linkage to be clamped onto stabilizer bar with wheels down and suspension settled. Rotation to be fixed with link arm in horizontal plane.
18 mm (0.71 in) 3.3 - 7.7 (0.33 - 0.79, 29 - 68)
3.3 - 7.7 (0.33 - 0.79, 29 - 68) Rear sensor The rear sensor linkage does not require setting, but with the wheel on the ground and the suspension settled, ensure that the link arm in the same plane as the connector wire.
: N·m (kg-m, in-lb)
3.3 - 7.7 (0.33 - 0.79, 29 - 68) YEL621B
EL-99
PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L —
YEL838C
EL-100
PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L — (Cont’d) 4-DOOR MODELS
YEL839C
EL-101
PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L — (Cont’d) 5-DOOR HATCH-BACK MODELS
YEL840C
EL-102
PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L — (Cont’d) WAGON MODELS
YEL841C
EL-103
STOP LAMP Wiring Diagram — STOP —
YEL842C
EL-104
STOP LAMP Wiring Diagram — STOP — (Cont’d) 4-DOOR MODELS AND 5-DOOR HATCH-BACK MODELS
YEL843C
EL-105
STOP LAMP Wiring Diagram — STOP — (Cont’d) WAGON MODELS
YEL844C
EL-106
BACK-UP LAMP Wiring Diagram — BACK/L — IGNITION SWITCH ON or START : With CVT FUSE BLOCK (J/B)
: With M/T
Refer to EL-POWER.
: With GA engine or diesel engine : With SR engine or QG engine : Wagon models : 4 door models and 5 door hatchback models
P L
R N
D
BACK-UP LAMP SWITCH
PARK/NEUTRAL POSITION SWTICH OTHERS
Next page
To EL-BACK/L-03
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YEL149C
EL-107
BACK-UP LAMP Wiring Diagram — BACK/L — (Cont’d) 4-DOOR MODELS AND 5-DOOR HATCH-BACK MODELS Preceding page : LHD models : RHD models : 4 doors models : 5 door hatchback models
BACK-UP LAMP
BACK-UP LAMP
BACK-UP LAMP
BACK-UP LAMP
YEL150C
EL-108
BACK-UP LAMP Wiring Diagram — BACK/L — (Cont’d) WAGON MODELS To EL-BACK/L-01
: LHD models : RHD models
REAR COMBINATION LAMP LH (BACK-UP LAMP)
REAR COMBINATION LAMP RH (BACK-UP LAMP)
YEL270C
EL-109
FRONT FOG LAMP Wiring Diagram — F/FOG —
YEL845C
EL-110
FRONT FOG LAMP Aiming Adjustment Before performing aiming adjustment, make sure of the following. a. Keep all tires inflated to correct pressure. b. Place vehicle on level ground. c. Check that vehicle is unloaded (except for full levels of coolant, engine oil and fuel, and spare tire, jack, and tools). Have the driver or equivalent weight placed in driver’s seat. Aiming adjusting screw NEL553
1. Set the distance between the screen and the center of the fog lamp lens as shown at left. 2. Turn front fog lamps ON.
Screen Main axis of light
7.6 m (25 ft)
MEL327G
Vertical centerline ahead of left fog lamp
Top edge of high intensity zone
Vertical centerline ahead of right fog lamp
Car axis
.
100 (4)
Unit: mm (in)
3. Adjust front fog lamps so that the top edge of the high intensity zone is 100 mm (4 in) below the height of the fog lamp centers as shown at left. ● When performing adjustment, if necessary, cover the headlamps and opposite fog lamp.
Floor to center of foglamp lens (height of fog lamp centers)
.
100 (4)
High-intensity areas MEL328G
Bulb Specifications Item Front fog lamp
EL-111
Wattage (W) 55
REAR FOG LAMP Wiring Diagram — R/FOG — MODELS BEFORE VIN - P11U0548750
YEL846C
EL-112
REAR FOG LAMP Wiring Diagram — R/FOG — (Cont’d) 4-door models and 5-door Hatch-back models Preceding page : LHD models : RHD models : 4 door models : 5 doors hatchback models
REAR FOG LAMP
REAR FOG LAMP
REAR FOG LAMP
REAR FOG LAMP
YEL153C
EL-113
REAR FOG LAMP Wiring Diagram — R/FOG — (Cont’d) MODELS AFTER VIN - P11U0548750
YEL847C
EL-114
REAR FOG LAMP Wiring Diagram — R/FOG — (Cont’d) 4-door models and 5-door Hatch-back models
YEL848C
EL-115
REAR FOG LAMP Wiring Diagram — R/FOG — (Cont’d) WAGON MODELS
YEL849C
EL-116
TURN SIGNAL AND HAZARD WARNING LAMPS Schematic
YEL289B
EL-117
TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN —
YEL850C
EL-118
TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — (Cont’d) MODELS BEFORE VIN - P11U0548750
YEL851C
EL-119
TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — (Cont’d)
YEL852C
EL-120
TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — (Cont’d) MODELS AFTER VIN - P11U0548750
YEL854C
EL-121
TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — (Cont’d)
YEL855C
EL-122
TURN SIGNAL AND HAZARD WARNING LAMPS Trouble Diagnoses Symptom Turn signal and hazard warning lamps do not operate.
Possible cause 1. Hazard switch 2. Turn signal switch 3. Harness connector
E104
Turn signal lamps do not operate 1. Turn signal switch but hazard warning lamps oper2. Open in turn signal switch cirate. cuit
Repair order 1. Check hazard switch. 2. Check turn signal switch. 3. Check harness connector
E104
.
1. Check turn signal switch. 2. Check L/G and G/Y wires between time control unit and turn signal switch for open circuit. 3. Check B wire between turn signal switch and ground for open circuit.
Hazard warning lamps do not operate but turn signal lamps operate.
1. Hazard switch 2. Open in hazard switch circuit
1. Check hazard switch. 2. Check G/R wire between time control unit and hazard switch for open circuit. Check B wire between hazard switch unit and ground for open circuit.
Front turn signal lamp LH or RH does not operate.
1. Bulb 2. Grounds
1. Check bulb. 2. Check grounds
E11
and
E37
Rear turn signal lamp LH or RH does not operate.
1. Bulb 2. Grounds
1. Check bulb. 2. Check grounds T3 or B150 and B151 .
and
T4
LH and RH turn indicators do not 1. Grounds operate.
1. Check grounds
and
E37
LH or RH turn indicator does not operate.
1. Check bulb in combination meter.
1. Bulb
EL-123
E11
. or .
B48
and
D110
ILLUMINATION Schematic
YEL856C
EL-124
ILLUMINATION Wiring Diagram — ILL — MODELS BEFORE VIN - P11U0548750 BATTERY
IGNITION SWITCH ON or START
FUSE BLOCK (J/B)
Refer to EL-POWER.
Next page
2ND 1ST OFF
COMBINATION SWITCH (LIGHTING SWITCH)
COMBINATION METER (ILLUMINATION)
HEAD LAMP WASHER SWITCH (ILLUMINATION)
DAYTIME LIGHT CONTROL UNIT
: With daytime light system : Without daytime light system
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
YEL157C
EL-125
ILLUMINATION Wiring Diagram — ILL — (Cont’d)
YEL857C
EL-126
ILLUMINATION Wiring Diagram — ILL — (Cont’d) MODELS AFTER VIN - P11U0548750
YEL858C
EL-127
ILLUMINATION Wiring Diagram — ILL — (Cont’d)
YEL859C
EL-128
ILLUMINATION Wiring Diagram — ILL — (Cont’d)
YEL860C
EL-129
INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS System Description INTERIOR LAMP TIMER OPERATION The time control unit keeps the interior lamp illuminated for about 30 seconds when: ● the ignition key is turned from “ON” to “Acc” to “LOCK” ● the driver’s door is unlocked ● a door is opened and then closed while the ignition switch is in the “OFF” position. (Interior lamp switch in the “DOOR” position). The timer is canceled when: ● driver’s door is locked, or ● ignition switch is turned “ON”.
EL-130
INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Schematic
YEL861C
EL-131
INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — MODELS BEFORE VIN - P11U0548750
YEL862C
EL-132
INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d)
YEL865C
EL-133
INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d) MODELS AFTER VIN - P11U0548750
YEL863C
EL-134
INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d)
YEL866C
EL-135
INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d)
YEL864C
EL-136
BULB SPECIFICATIONS Headlamp Wattage (12 volt) High/low (without xenon headlamp) High/low (with xenon headlamp)
55/55 55/Discharge D2S type
Exterior Lamp Wattage (12 volt) Front combination lamp
Parking
5
Turn signal
21
Front fog lamp
55 (H1) Turn signal
21
Rear combination lamp Stop/Tail
21/5
Back-up
21
Side turn signal lamp
5
License plate lamp
5
High-mounted stop lamp
21
Interior Lamp Wattage (12 volt) Interior lamp
10
Map lamp
3
Step lamp
3.4
Trunk room lamp
3.4
Luggage room lamp
EL-137
5
METER AND GAUGES System Description UNIFIED CONTROL METER ● ●
● ●
Speedometer, odo/trip meter, tachometer, fuel gauge and water temperature gauge are controlled totally by control unit combined with speedometer. Digital meter is adopted for odo/trip meter.* *The record of the odometer is kept even if the battery cable is disconnected. The record of the trip meter is erased when the battery cable is disconnected. Odo/trip meter segment can be checked in diagnosis mode. Meter/gauge can be checked in diagnosis mode.
EL-138
METER AND GAUGES Combination Meter MODELS BEFORE VIN - P11U0548750
YEL229C
EL-139
METER AND GAUGES Combination Meter (Cont’d) MODELS AFTER VIN - P11U0548750
YEL956C
EL-140
METER AND GAUGES Wiring Diagram — METER —/MODELS BEFORE VIN - P11U0548750 BATTERY
IGNITION SWITCH ON or START : With CVT FUSE BLOCK (J/B)
Refer to EL-POWER.
: With M/T : With trip computer : With outside air temperature gauge
.
ELECTRIC SPEEDOMETER TACHOMETER WATER TEMPERATURE GAUGE FUEL GAUGE FUEL WARNING LAMP TRIP COMPUTER: TC OUTSIDE AIR TEMPERATURE GAUGE:
COMBINATION METER
OG
VEHICLE SPEED SENSOR
ON
COMBINATION SWITCH (TRIP COMPUTER SWITCH)
OFF
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YEL164C
EL-141
METER AND GAUGES Wiring Diagram — METER —/MODELS BEFORE VIN - P11U0548750 (Cont’d) .
ELECTRIC SPEEDOMETER TACHOMETER WATER TEMPERATURE GAUGE FUEL GAUGE FUEL WARNING LAMP TRIP COMPUTER: TC OUTSIDE AIR TEMPERATURE GAUGE:
COMBINATION METER
OG
: With CVT : With M/T : With gasoline engine : With diesel engine : With SR engine or QG engine : With trip computer : With outside air temperature gauge : With GA engine
ECM
OUTSIDE AIR TEMPERATURE SENSOR
REFER TO THE FOLLOWING ELECTRICAL UNITS ELECTRICAL UNITS
YEL165C
EL-142
METER AND GAUGES Wiring Diagram — METER —/MODELS BEFORE VIN - P11U0548750 (Cont’d)
.
ELECTRIC SPEEDOMETER TACHOMETER WATER TEMPERATURE GAUGE FUEL GAUGE FUEL WARNING LAMP TRIP COMPUTER: TC OUTSIDE AIR TEMPERATURE GAUGE:
A/C CONTROL PANEL
COMBINATION METER
OG
HEATER ILLUMINATION
: With CVT : With M/T : With air conditioner : Without air conditioner : With GA engine : With SR engine or QG engine
FUEL LEVEL SENSOR UNIT
: With gasoline engine : With diesel engine : With trip computer : With outside air temperature gauge THERMAL TRANSMITTER
REFER TO THE FOLLOWING ELECTRICAL UNITS ELECTRICAL UNITS
YEL166C
EL-143
METER AND GAUGES Schematic M/T MODELS AFTER VIN - P11U0548750
YEL867C
EL-144
METER AND GAUGES Schematic (Cont’d) CVT MODELS AFTER VIN - P11U0548750
YEL937C
EL-145
METER AND GAUGES Wiring Diagram — METER —/M/T MODELS AFTER VIN - P11U0548750
YEL868C
EL-146
METER AND GAUGES Wiring Diagram — METER —/M/T MODELS AFTER VIN - P11U0548750 (Cont’d)
YEL869C
EL-147
METER AND GAUGES Wiring Diagram — METER —/M/T MODELS AFTER VIN - P11U0548750 (Cont’d)
YEL870C
EL-148
METER AND GAUGES Wiring Diagram — METER —/CVT MODELS AFTER VIN - P11U0548750
YEL871C
EL-149
METER AND GAUGES Wiring Diagram — METER —/CVT MODELS AFTER VIN - P11U0548750 (Cont’d)
YEL872C
EL-150
METER AND GAUGES Wiring Diagram — METER —/CVT MODELS AFTER VIN - P11U0548750 (Cont’d)
YEL873C
EL-151
METER AND GAUGES Combination Meter Self-Diagnosis PERFORMING SELF-DIAGNOSIS MODE 1. Turn the ignition switch to the “LOCK” position. 2. Press both reset buttons on the combination meter and keep them depressed. 3. Turn the ignition switch to the “ON” position, while keeping the reset buttons pressed. 4. Release both reset buttons then self-diagnosis will start. The sequence (A to L) is activated by press the either reset buttons. NOTE: If either reset button is not pressed for 20 seconds at each step or if the ignition switch is turned OFF, the self-diagnosis mode is exited.
A)
Check items Odometer segment test
B)
Work instruction code
Display
Remarks All odo trip meter segments are ON.
This information is not used for service. Please skip this step. SEL435X
C)
This information is not used for service. Please skip this step.
Software code
NEL735
D)
This information is not used for service. Please skip this step.
EEPROM code
NEL736
E)
This information is not used for service. Please skip this step.
Hardware code
NEL737
F)
This information is not used for service. Please skip this step.
PCB code
NEL738
G)
Meter/gauge test (Sweeping movement) SEL440X
Tachometer, speedometer, fuel level gauge and water temperature gauge have sweeping movement test. (The meter/gauges operate MIN. , MAX., MAX. , MIN. for 2 times) The odo trip meter segment flashes during the sweep movement.
EL-152
METER AND GAUGES Combination Meter Self-Diagnosis (Cont’d) Check items
H)
Display
Remarks
Error 1 (Bit 0 - Bit 3) SEL441X
I)
Error E (Bit 4 - Bit 7)
The segment of each bit displays “0”, meaning no failure. If the bit(s) displays figures other than “0”, the item of the bit has failed. For details, refer to “Failure chart for Error 1 and Error E” below.
SEL442X
J)
Fuel warning lamp is on and odo trip meter segment “FUEL” flashes.
Fuel warning lamp test
SEL443X
K)
Fuel gauge calibration (CAL)
This information is not used for service. Please skip this step. SEL444X
L)
Fuel gauge calibration (OLD)
This information is not used for service. Please skip this step. SEL445X
Failure Chart for “Error 1” and “Error E” Bit
Detectable items
Description of the failure
Speedometer input signal
No input signal When no signal is detected for 30 minutes continuously with the ignition ON, it should be judged as signal failure. (If input signal is detected later, then the judgement will be canceled immediately.) Abnormal input signal When any signal of frequency which would not exist in normal conditions is detected, it should be judged as signal failure. No input signal When no signal is detected for 30 minutes continuously with the ignition ON, it should be judged as signal failure. (If input signal is detected later, then the judgement will be canceled immediately.) Abnormal input signal When any signal of frequency which would not exist in normal conditions is detected, it should be judged as signal failure.
0
Tachometer input signal
1
EL-153
Displayed figure on the bit Failure No failure
1 0 2
1 0 2
METER AND GAUGES Combination Meter Self-Diagnosis (Cont’d) Bit
2
3
4
5
6 7
Detectable items
Description of the failure
Fuel level input sig- Short circuit nal When short circuit of the signal line is detected for 5 seconds or more, it should be judged as short-circuit failure. Open circuit When open circuit of the signal line is detected for 5 seconds or more, it should be judged as open-circuit failure. Water temperature Short circuit input signal When short circuit of the signal line is detected for 5 seconds or more, it should be judged as short-circuit failure. Open circuit When open circuit of the signal line is detected for 5 seconds or more, it should be judged as open-circuit failure. Short circuit Outside air temperature input sig- When short circuit of the signal line is detected for 5 seconds or more, it should be judged as short-circuit failure. nal Open circuit When open circuit of the signal line is detected for 5 seconds or more, it should be judged as open-circuit failure. Right side reset button Reset buttons Short circuit for reset buttons has failed. When the short circuit is continuously detected for 5 minLeft side reset button has utes or more, it should be failed. judged as short-circuit failure. Both reset buttons have failed. — — CPU EEPROM failure CPU RAM failure
EL-154
Displayed figure on the bit Failure No failure 1 0 2
1 0 2
1 0 2
1 2
0
3 0 1 2
0 0
METER AND GAUGES Trouble Diagnoses (Models before VIN P11U0548750) Combination meter connector
POWER SUPPLY AND GROUND CIRCUIT CHECK Power supply circuit check Terminals 䊝
YEL489B
Ignition switch position 䊞
OFF
ACC
ON
2 쑗
Ground
Battery voltage
Battery voltage
Battery voltage
5 쑗
Ground
0V
0V
Battery voltage
If NG, check the following, ● 10A fuse [No. 16 , located in fuse block (J/B)] ● 10A fuse [No. 12 , located in fuse block (J/B)] ● Harness for open or short between fuse and combination meter
Ground circuit check Terminals 1 쑗
Combination meter connector
- Ground
YEL490B
EL-155
Continuity Yes
METER AND GAUGES Trouble Diagnoses (Models before VIN P11U0548750) (Cont’d) Combination meter connector
INSPECTION/VEHICLE SPEED SENSOR CHECK VEHICLE SPEED SENSOR OUTPUT. 1) Remove vehicle speed sensor from transmission. 2) Check voltage between combination 3 and 쑗 1 while meter terminals 쑗 quickly turning speed sensor pinion.
왘
Vehicle speed sensor is OK.
왘
Check harness for open or short between speedometer and vehicle speed sensor.
왘
Repair harness or connector
왘
Repair harness and connector.
OK
Vehicle speed sensor 왔
CHECK POWER SOURCE. ● Re-install vehicle speed sensor. ● Turn ignition switch to “ON” position. Check voltage between vehicle speed sen3 and ground. sor connector terminal 쑗 Battery voltage should exist.
This connector should remain connected.
NG
NG
OK Vehicle speed sensor pinion
왔 YEL491B
Combination meter connector
CHECK GROUND CIRCUIT OF VEHICLE SPEED SENSOR ● Turn ignition switch to the “LOCK” position. Disconnect vehicle speed sensor connector. Check continuity between vehicle speed 1 and sensor harness connector terminal 쑗 body ground. Continuity should exist.
NG
OK 왔
YEL493B
Check continuity between speedometer harness connector terminal 쑗 3 and vehicle 2 . speed sensor connector terminal 쑗 Continuity should exist. OK 왔
Replace vehicle speed sensor. Vehicle speed sensor connectors
YEL494B
Vehicle speed sensor connectors
Combination meter connector
YEL495B
EL-156
NG
METER AND GAUGES Trouble Diagnoses (Models before VIN P11U0548750) (Cont’d) INSPECTION/ENGINE REVOLUTION SIGNAL Combination meter connector
YEL492B
CHECK ECM OUTPUT. 1. Start engine. 2. Check voltage between combination 1 and 쑗 11 at idle and meter terminals 쑗 2,000 rpm. Higher rpm = Higher voltage Lower rpm = Lower voltage Voltage should change with rpm. 왔
OK 왘
Engine revolution signal is OK.
NG
Check the following ● Combination meter terminal 쑗 1 ground circuit ● Harness for open or short between ECM and combination meter
INSPECTION/FUEL LEVEL SENSOR CHECK GROUND CIRCUIT FOR FUEL LEVEL SENSOR UNIT. Check harness continuity between fuel level sensor unit terminal 쑗 3 and ground. Continuity should exist.
Fuel level sensor unit connector
왔 NEL764
NG
왘
Repair harness or connector.
OK
CHECK GAUGE UNITS. Refer to “FUEL LEVEL SENSOR UNIT CHECK” (EL-164).
NG
왘
Repair or replace. Refer to FE section in Service Manual.
OK Combination meter connector
Fuel level sensor unit connector
NEL763
왔
CHECK HARNESS FOR OPEN OR SHORT 1. Disconnect combination connector and fuel level sensor unit connector. 2. Check continuity between combination meter terminal 쑗 20 and fuel level sensor unit terminal 쑗 1 . Continuity should exist. 3. Check continuity between combination meter 쑗 20 and ground. Continuity should exist. 왔
OK
Fuel level sensor is OK.
EL-157
NG
왘
Repair harness or connector.
METER AND GAUGES Trouble Diagnoses (Models before VIN P11U0548750) (Cont’d) INSPECTION/THERMAL TRANSMITTER Combination meter connector
Thermal transmitter connector
CHECK THERMAL TRANSMITTER. Refer to “THERMAL TRANSMITTER CHECK ” (EL-164).
NG 왘
Repair or replace.
OK 왔
YEL498B
CHECK HARNESS FOR OPEN OR SHORT 1. Disconnect combination connector and thermal transmitter connector. 2. Check continuity between combination 10 and thermal transmitmeter terminal 쑗 ter terminal 쑗 1 . Continuity should exist. 3. Check continuity between combination 10 and ground. meter terminal 쑗 Continuity should exist. 왔
OK
Thermal transmitter is OK.
EL-158
NG 왘
Repair harness or connector.
METER AND GAUGES Trouble Diagnoses (Models after VIN P11U0548750) POWER SUPPLY AND GROUND CIRCUIT CHECK Power supply circuit check Terminals 䊝 YEL007D
Ignition switch position 䊞
OFF
ACC
ON
23 쑗
Ground
Battery voltage
Battery voltage
Battery voltage
쑗1
Ground
0V
0V
Battery voltage
If NG, check the following, ● 10A fuse [No. 16 , located in fuse block (J/B)] ● 10A fuse [No. 12 , located in fuse block (J/B)] ● Harness for open or short between fuse and combination meter
Ground circuit check Terminals 10 쑗
- Ground
YEL008D
EL-159
Continuity Yes
METER AND GAUGES Trouble Diagnoses (Models after VIN P11U0548750) (Cont’d) INSPECTION/VEHICLE SPEED SENSOR (MT models without ABS, and CVT models)
CHECK VEHICLE SPEED SENSOR OUTPUT. 1) Remove vehicle speed sensor from transmission. 2) Check voltage between combination meter terminals 쑗 10 and 쑗 31 while quickly turning speed sensor pinion.
NG
왘
Vehicle speed sensor is OK.
OK 왔
YEL009D
CHECK POWER SOURCE. ● Re-install vehicle speed sensor. ● Turn ignition switch to “ON” position. Check voltage between vehicle speed sensor connector terminal 쑗 3 and ground. Battery voltage should exist.
NG
왘
Check harness for open or short between speedometer and vehicle speed sensor.
OK 왔
Combination meter connector
YEL493B
CHECK GROUND CIRCUIT OF VEHICLE SPEED SENSOR ● Turn ignition switch to the “LOCK” position. Disconnect vehicle speed sensor connector. Check continuity between vehicle speed sensor harness connector terminal 쑗 1 and body ground. Continuity should exist.
NG
왘
Repair harness or connector
왘
Repair harness and connector.
OK 왔
Check continuity between speedometer harness connector terminal 쑗 31 and vehicle speed sensor connector terminal 쑗 2 . Continuity should exist.
Vehicle speed sensor connectors
OK 왔 YEL494B
Replace vehicle speed sensor.
YEL011D
EL-160
NG
METER AND GAUGES Trouble Diagnoses (Models after VIN P11U0548750) (Cont’d) INSPECTION/VEHICLE SPEED SENSOR (MT models with ABS)
CHECK VEHICLE SPEED SENSOR OUTPUT. 1) Jack up the front wheels. 2) Turn ignition switch “ON”. 3) Check voltage between combination meter terminals 쑗 3 and 쑗 1 while turning front wheels.
NG
왘
Vehicle speed sensor is OK.
왘
Repair harness and connector.
OK 왔
Check continuity between speedometer harness connector terminal 쑗 31 and ABS actuator and electric unit connector terminal 쑗 6 . Continuity should exist. OK YEL010D
왔
Replace vehicle speed sensor.
YEL012D
EL-161
NG
METER AND GAUGES Trouble Diagnoses (Models after VIN P11U0548750) (Cont’d) INSPECTION/ENGINE REVOLUTION SIGNAL
YEL013D
CHECK ECM OUTPUT. 1. Start engine. 2. Check voltage between combination meter terminals 쑗 10 and 쑗 22 at idle and 2,000 rpm. Higher rpm = Higher voltage Lower rpm = Lower voltage Voltage should change with rpm. 왔
OK
왘
Engine revolution signal is OK.
NG
Check the following ● Combination meter terminal 쑗 1 ground circuit ● Harness for open or short between ECM and combination meter
INSPECTION/FUEL LEVEL SENSOR CHECK GROUND CIRCUIT FOR FUEL LEVEL SENSOR UNIT. Check harness continuity between fuel level sensor unit terminal 쑗 3 and ground. Continuity should exist.
Fuel level sensor unit connector
왔 NEL764
NG
왘
Repair harness or connector.
OK
CHECK GAUGE UNITS. Refer to “FUEL LEVEL SENSOR UNIT CHECK”.
NG
왘
Repair or replace. Refer to FE section in Service Manual.
OK 왔
YEL014D
CHECK HARNESS FOR OPEN OR SHORT 1. Disconnect combination connector and fuel level sensor unit connector. 2. Check continuity between combination meter terminal 쑗 24 and fuel level sensor unit terminal 쑗 1 . Continuity should exist. 3. Check continuity between combination meter 쑗 24 and ground. Continuity should exist. 왔
OK
Fuel level sensor is OK.
EL-162
NG
왘
Repair harness or connector.
METER AND GAUGES Trouble Diagnoses (Models after VIN P11U0548750) (Cont’d) INSPECTION/THERMAL TRANSMITTER CHECK THERMAL TRANSMITTER. Refer to “THERMAL TRANSMITTER CHECK”.
NG
왘
Repair or replace.
OK 왔 YEL015D
CHECK HARNESS FOR OPEN OR SHORT 1. Disconnect combination connector and thermal transmitter connector. 2. Check continuity between combination meter terminal 쑗 20 and thermal transmitter terminal 쑗 1 . Continuity should exist. 3. Check continuity between combination meter terminal 쑗 20 and ground. Continuity should exist. 왔
OK
Thermal transmitter is OK.
EL-163
NG
왘
Repair harness or connector.
METER AND GAUGES Fuel Level Sensor Unit Check G
E *3
● For removal, refer to FE section (“FUEL SYSTEM”). Check the resistance between terminals (G) and (E).
QG & SR Engine Models Resistance value (Ω)
Ohmmeter Float position mm (in)
*2
(+)
(−)
*1
*3 NEL330
E
G
E
Full
151 (5.945)
7.5 - 9.5
*2
1/2
88 (3.465)
88.5 - 93.5
*1
Empty
15 (0.591)
180.0 - 186.8
*1 and *3: When float rod is in contact with stopper.
G
CD20T Engine Models *1
Resistance value (Ω)
Ohmmeter
*2
Float position mm (in) *3
(+)
(−)
G
E
NEL329
*3
Full
18 (0.709)
7.5 - 9.5
*2
1/2
84 (3.307)
88.5 - 93.5
*1
Empty
158 (6.220)
180.0 - 186.8
*1 and *3: When float rod is in contact with stopper.
Thermal Transmitter Check Check the resistance between the terminals of thermal transmitter and body ground. Ohmmeter
Water temperature °C (°F)
Resistance (Ω)
65 (149)
Approx. 951 - 1109
91 (196)
Approx. 433 - 510
SEL233P
EL-164
: CVT models : H⋅CVT models IGNITION SWITCH ON or START
: H⋅CVT (M6) models : With GA engine : With SR engine or QG engine
FUSE
: With diesel engine
REAR FRONT DOOR DOOR SWITCH SWITCH (PASSEN- LH GER SIDE)
REAR WASHER BRAKE PARKING VACUUM SEDIMENTER ABS SWITCH SENSOR ACTUATOR DOOR LEVEL FLUID BRAKE AND ELECSWITCH SWITCH LEVEL SWITCH TRIC UNIT RH SWITCH (CONTROL UNIT)
ECM
TCM (TRANSMISSION CONTROL MODULE)
WARNING LAMPS
TRUNK ROOM LAMP SWITCH OR LUGGAGE ROOM LAMP SWITCH
Warning Lamps/Schematic
FUEL OIL PRES- ALTER- FRONT LEVEL SURE NATOR DOOR SENSOR SWITCH SWITCH UNIT (DRIVER SIDE)
GLOW
Electronic speedometer module
DIAGNOSIS SENSOR UNIT
MALFUNCTION INDICATOR LAMP
ABS
BRAKE
WASH
DOOR
CHARGE
OIL
FUEL
COMBINATION METER
EL-165
TIME CONTROL UNIT
CVT WARNING LAMP SPORT INDICATOR LAMP
AIR BAG
MODELS BEFORE VIN - P11U0548750
: M/T models
YEL167C
WARNING LAMPS Warning Lamps/Schematic (Cont’d) MODELS AFTER VIN - P11U0548750
YEL874C
EL-166
WARNING LAMPS Wiring Diagram — WARN — MODELS BEFORE VIN - P11U0548750 IGNITION SWITCH ON or START FUSE BLOCK (J/B)
: CVT models Refer to EL-POWER. : M/T models
Next page
To EL-WARN-06
FUEL
COMBINATION METER
OIL
AIR BAG ELECTRONIC SPEEDOMETER MODULE
FUSE BLOCK (J/B)
FUEL LEVEL SENSOR UNIT
DIAGNOSIS SENSOR UNIT
OIL PRESSURE SWITCH HIGH LOW
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YEL168C
EL-167
WARNING LAMPS Wiring Diagram — WARN — (Cont’d)
EL-WARN-02 C CV Preceding page
A
C CVT WARNING LAMP
CHARGE
14
Y/R
OR/B
GA : With GA engine
E124 CV
: H⋅CVT models
MC : H⋅CVT (M6) models
COMBINATION METER
MC
SPORT INDICATOR LAMP
22
Next page
: CVT models
SQ : With SR engine or QG engine
M38
DI
: With diesel engine
GA SQ
DI
Y/R 8
Y/R E42
6
F4
Y/R
Y/R
E43 F2
Y/R
Y/R
Y/R
1 L
1 L ALTERNATOR
F6
:
OR/B 13 L ALTERNATOR
F6
SQ
:
DI
ALTERNATOR
E72 :
TCM (TRANSMISSION CONTROL MODULE)
GA M48 :
1 2 3 4 5 6 7 8
1 2
F6 GY
F2 GY
33 34 35 36 37 38 39 40 E124 21 22 23 24 25 26 27 28 29 30 31 32 W
1 2 3 4 5 6 7 8 9 10
F4 GY
C
13 14 15 16 17 18 19 20 M38 1 2 3 4 5 6 7 8 9 10 11 12 GY
9 2 7 6 5 4 3 8 1 M48 18 17 16 15 14 13 12 11 10 W 24 23 22 21 20 19
YEL307B
EL-168
WARNING LAMPS Wiring Diagram — WARN — (Cont’d) Preceding page
To EL-WARN-05
COMBINATION METER
DOOR
Next page
TIME CONTROL UNIT
FUSE BLOCK (J/B)
OPEN
FRONT DOOR SWITCH (PASSENGER SIDE)
OPEN
CLOSED
OPEN
REAR DOOR SWITCH RH
CLOSED
FRONT DOOR SWITCH (DRIVER SIDE)
OPEN
CLOSED
REAR DOOR SWITCH LH
CLOSED
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
*:
This connector is not shown in “HARNESS LAYOUT” of el section.
YEL169C
EL-169
WARNING LAMPS Wiring Diagram — WARN — (Cont’d) Preceding page
: 4 door models : 5 door hatchback models : Wagon models : 5 door hatchback models and Wagon models
OPEN
TRUNK ROOM LAMP SWITCH
OPEN
CLOSED
LUGGAGE ROOM LAMP SWITCH
CLOSED
YEL170C
EL-170
WARNING LAMPS Wiring Diagram — WARN — (Cont’d) To EL-WARN-03
Next page WASH
LOW HIGH
WASHER LEVEL SWITCH
LOW
: With diesel engine
COMBINATION METER
BRAKE
BRAKE FLUID LEVEL SWITCH
HIGH
LOW HIGH
VACUUM SWITCH
APPLIED
PARKING BRAKE SWITCH
RELEASED
YEL171C
EL-171
WARNING LAMPS Wiring Diagram — WARN — (Cont’d) To EL-WARN-01 Preceding page
MALFUNCTION INDICATOR LAMP
ABS
GLOW
COMBINATION METER
: CVT models : M/T models : With gasoline engine : With diesel engine : With GA engine : With SR engine or QG engine
HIGH
SEDIMENTER SENSOR
LOW
ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
ECM
REFER TO THE FOLLOWING ELECTRICAL UNITS ELECTRICAL UNITS
YEL172C
EL-172
WARNING LAMPS Wiring Diagram — WARN — (Cont’d) MODELS AFTER VIN - P11U0548750
YEL875C
EL-173
WARNING LAMPS Wiring Diagram — WARN — (Cont’d)
YEL876C
EL-174
WARNING LAMPS Wiring Diagram — WARN — (Cont’d)
YEL877C
EL-175
WARNING LAMPS Wiring Diagram — WARN — (Cont’d)
YEL878C
EL-176
WARNING LAMPS Wiring Diagram — WARN — (Cont’d)
YEL879C
EL-177
WARNING LAMPS Wiring Diagram — WARN — (Cont’d)
YEL880C
EL-178
WARNING LAMPS Electrical Components Inspection FUEL WARNING LAMP OPERATION CHECK Fuel level sensor unit connector
172 - 180Ω resistor
1. Turn ignition switch “OFF”. 2. Disconnect fuel level sensor unit harness connector B31 . 3. Connect a resistor (172 - 180Ω) between fuel tank gauge unit 1 and 쑗 3 . harness connector terminals 쑗 4. Turn ignition switch “ON”. The fuel warning lamp should come on.
YEL455B
OIL PRESSURE SWITCH CHECK Ohmmeter
MEL425F
Oil pressure kPa (kg/cm2, psi)
Continuity
Engine start
More than 10 - 20 (0.1 - 0.2, 1 - 3)
NO
Engine stop
Less than 10 - 20 (0.1 - 0.2, 1 - 3)
YES
Check the continuity between the terminals of oil pressure switch and body ground.
EL-179
WARNING CHIME System Description The warning chime is combined with the time control unit. The light warning chime will not sound, when ignition switch in the ON or START position. (When power supply exists at time control unit terminal 쑗 1 .)
LIGHT WARNING CHIME With ignition switch in the OFF position, driver’s door open, and lighting switch in 1ST or 2ND position, warning chime will sound. A battery positive voltage is supplied ● from lighting switch terminal 쑗 12 or daytime light control unit terminal 쑗 6 ● to time control unit terminal 쑗 10 . Ground is supplied ● through driver side door switch ● to time control unit terminal 쑗 6 .
EL-180
WARNING CHIME Wiring Diagram — CHIME —
YEL348D
EL-181
WARNING CHIME Wiring Diagram — CHIME — (Cont’d)
YEL881C
EL-182
WARNING CHIME Trouble Diagnoses EL-184
EL-184
EL-185
DIAGNOSTIC PROCEDURE 3
DIAGNOSTIC PROCEDURE 1 (Lighting switch input signal check)
EL-183
POWER SUPPLY AND GROUND CIRCUIT CHECK
REFERENCE PAGE
DIAGNOSTIC PROCEDURE 2 (Key switch input signal check)
SYMPTOM CHART
Light warning chime does not activate.
X
X
Ignition key warning chime does not activate.
X
All warning chimes do not activate.
X
SYMPTOM
X X
X X
POWER SUPPLY AND GROUND CIRCUIT CHECK Power Supply Circuit Check Time control unit connector
Terminals
䊝
Ignition switch position 䊞
OFF
ACC
ON
9 쑗
Ground
Battery voltage
Battery voltage
Battery voltage
1 쑗
Ground
0V
0V
Battery voltage
YEL430B
Ground Circuit Check Time control unit connector
Terminals 16 쑗
- Ground
YEL431B
EL-183
Continuity Yes
WARNING CHIME Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1 (Lighting switch input signal check) Time control unit connector
CHECK LIGHTING SWITCH INPUT SIGNAL. Check voltage between control unit terminal 쑗 10 and ground. YEL432B
Condition of lighting switch
Voltage [V]
1ST or 2ND
Approx. 12
OFF
0
NG
왘
Check the following. 15A fuse (No. 34 , located in the fuse and fusible link box) ● Harness for open or short between control unit and lighting switch ●
OK 왔
Go to Procedure 3.
DIAGNOSTIC PROCEDURE 2 (Key switch input signal check)
Time control unit connector : Approx. 12V : 0V
CHECK KEY SWITCH INPUT SIGNAL. Check voltage between control unit terminal 쑗 22 and ground. Condition of key switch
Voltage [V]
Key is inserted.
Approx. 12
Key is withdrawn.
0
YEL433B
OK
왔
Go to Procedure 3.
EL-184
NG
왘
Check the following. Key switch Refer to “Electrical Components Inspection” (EL-185). ● 10A fuse [No. 16 , located in fuse block (J/B)] ● Harness for open or short between key switch and fuse ● Harness for open or short between control unit and key switch ●
WARNING CHIME Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 CHECK DOOR SWITCH INPUT SIGNAL. Check voltage between fuse block (J/B) terminal 16J and ground.
Fuse block (J/B) connector
YEL434B
Condition of driver’s door
Voltage [V]
Driver side door is closed.
Approx. 12
Driver side door is open.
NG
왘
0
OK 왔 Time control unit connector
Fuse block (J/B) connector
Check continuity between fuse block (J/B) terminal 16J and control unit terminal 쑗 6 . Continuity should exist.
NG
왘
Check the following. ● Driver side door switch Refer to “Electrical Components Inspection” (EL-185). ● Door switch ground circuit ● Harness for open or short between control unit and door switch
Replace fuse block (J/B).
OK 왔
Replace time control unit. YEL435B
Electrical Components Inspection KEY SWITCH (insert) Key switch connector
Check continuity between terminals when key is inserted in ignition key cylinder and key is removed from ignition key cylinder. Terminal No. 1 - 쑗 2 쑗
Condition
Continuity
Key is inserted.
Yes
Key is removed.
No
YEL436B
DRIVER SIDE DOOR SWITCH Check continuity between terminals when door switch is pushed and released. Terminal No. 2 - 쑗 3 (Type-1) or 쑗 1 - Ground (Type-2) 쑗
YEL026D
YEL025D
EL-185
Condition
Continuity
Door switch is pushed.
No
Door switch is released.
Yes
FRONT WIPER AND WASHER System Description WIPER OPERATION The wiper switch is controlled by a lever built into the combination switch. There are three wiper switch positions: ● LO speed ● HI speed ● INT (Intermittent). With the ignition switch in the ON or START position, power is supplied ● through 20A fuse (No. located in the fuse block) ● to wiper motor terminal 쑗 6 and 쑗 3 .
Low and high speed wiper operation Ground is supplied to wiper switch terminal 쑗 17 through body grounds E11 and When the wiper switch is placed in the LO position, ground is supplied ● Through terminal 쑗 14 of the wiper switch ● to wiper motor terminal 쑗 2 . With power and ground supplied, the wiper motor operates at low speed. When the wiper switch is placed in the HI position, ground is supplied ● Through terminal 쑗 16 of the wiper switch ● to wiper motor terminal 쑗 1 . With power and ground supplied, the wiper motor operates at high speed.
E37
.
Auto stop operation With wiper switch turned OFF, wiper motor will continue to operate until wiper arms reach windshield base. When wiper arms are not located at base of windshield with wiper switch OFF, ground is provided ● from terminal 쑗 14 of the wiper switch ● to wiper motor terminal 쑗 2 , in order to continue wiper motor operation at low speed. Ground is also supplied ● through terminal 쑗 13 of the wiper switch ● to front wiper relay terminal 쑗 3 ● through terminal 쑗 4 of the front wiper relay ● to wiper motor terminal 쑗 5 ● through terminal 쑗 4 of the wiper motor, and ● through body grounds E11 and E37 . When wiper arms reach base of windshield, wiper motor terminals 쑗 5 and 쑗 3 are connected instead of terminals 쑗 5 and 쑗 4 . Wiper motor will then stop wiper arms at the PARK position.
Intermittent operation With variable intermittent The wiper motor operates the wiper arms at a set interval of approximately 2 to 20 seconds. This feature is controlled by the combination switch wiper amplifier. When the wiper switch is placed in the INT position, ground is supplied ● to front wiper relay terminal 쑗 5 ● from wiper switch terminal 쑗 13 ● through body grounds E37 and E11 . ● to wiper motor terminal 쑗 2 ● through the wiper switch terminal 쑗 14 ● to wiper switch terminal 쑗 13 ● through front wiper relay terminal 쑗 3 The desired interval time is input ● to front wiper relay terminal 쑗 1 ● from wiper switch terminal 쑗 20 . The wiper motor operates at low speed at the desired time interval.
EL-186
FRONT WIPER AND WASHER System Description (Cont’d) WIPER OPERATION Without variable intermittent The wiper motor operates the wiper arms at an interval of approximately 7 seconds. This feature is controlled by the combination switch wiper amplifier. When the wiper switch is placed in the INT position, ground is supplied ● to front wiper relay terminal 쑗 5 ● from wiper switch terminal 쑗 13 ● to wiper motor terminal 쑗 2 ● through the wiper switch terminal 쑗 14 ● to wiper switch terminal 쑗 13 ● through front wiper relay terminal 쑗 3
WASHER OPERATION With the ignition switch in the ON or START position, power is supplied ● through 10A fuse (No. 21 , located in the fuse block) ● to washer switch terminal 쑗 5 . When the lever is pulled to the WASH/F position, ground is supplied ● to washer motor terminal 쑗 2 ● from terminal 쑗 18 of the wiper switch ● through terminal 쑗 4 of the wiper switch, and ● through body grounds E37 and E11 . Power is supplied ● from terminal 쑗 3 of the washer switch ● to washer motor terminal 쑗 1 . With power and ground supplied, the washer motor operates. When the lever is pulled to the WASH position for one second or more, the wiper motor operates at low speed for approximately 3 seconds to clean windshield. This feature is controlled by the combination switch (wiper amplifier) in the same manner as the intermittent operation.
EL-187
FRONT WIPER AND WASHER Wiring Diagram — WIPER — IGNITION SWITCH ON or START
FUSE BLOCK (J/B)
: LHD models
Refer to EL-POWER.
: RHD models
Next page
OFF MIST
Next page
HI
OFF
INT LO
OFF
COMBINATION SWITCH (FRONT WIPER SWITCH)
HI INT LO Next page
LOW
HIGH
FRONT WIPER MOTOR Next page
Next page
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YEL175C
EL-188
FRONT WIPER AND WASHER Wiring Diagram — WIPER — (Cont’d)
YEL882C
EL-189
FRONT WIPER AND WASHER Removal and Installation WIPER ARMS Clearance “C” (Passenger side)
Clearance “C” (Driver side)
Cowl top seal NEL310
1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it “OFF” (Auto Stop). 2. Lift the blade up and then set it down onto glass surface. Set the blade center to clearance “C” immediately before tightening nut. 3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it “OFF”. 4. Ensure that wiper blades stop within clearance “C”. Clearance “C”: 19 - 33 mm (0.75 - 1.30 in) ● Tighten windshield wiper arm nuts to specified torque. : 21 - 26 N·m (2.1 - 2.7 kg-m, 15 - 20 ft-lb)
●
Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness.
SEL024J
EL-190
FRONT WIPER AND WASHER Removal and Installation (Cont’d) WIPER LINKAGE LHD models* 3.8 - 5.1 (0.39 - 0.52, 33.9 - 45.1)
3.8 - 5.1 (0.39 - 0.52, 33.9 - 45.1)
: N·m (kg-m, in-lb) MEL664DA
* Structure is basically the opposite for RHD models.
Removal 1. 2. 3. Be
Remove 4 bolts that secure wiper motor. Detach wiper motor from wiper linkage at ball joint. Remove wiper linkage. careful not to break ball joint rubber boot.
Installation ● Grease ball joint area before installation. 1. Installation is the reverse order of removal.
EL-191
FRONT WIPER AND WASHER Front Washer Nozzle Adjustment
Suitable tool
●
Max. 10°
Nozzle hole bore diameter 0.8 mm (0.031 in)
Adjust washer nozzle with suitable tool as shown in the figure at left. Adjustable range: ±10° (In any direction)
GEL013
Unit: mm (in)
Front washer RHD models
*1
375 (14.76)
*5
115 (4.53)
*2
160 (6.30)
*6
190 (7.48)
*3
440 (17.32)
*7
320 (12.60)
*4
100 (3.94)
*8
450 (17.72)
Circle diameters are approx. 80 mm (3.15 in). Black printed edge
LHD models
Black printed edge NEL311
Front Washer Tube Layout Front washer tube Front washer nozzle
To rear washer
Washer tank NEL312
EL-192
REAR WIPER AND WASHER System Description WIPER OPERATION The rear wiper switch and rear intermittent wiper control is built into the combination switch. There are two rear wiper switch positions: ● ON (LO speed) ● INT (Intermittent). With the ignition switch in the ON or START position, power is supplied ● through 15A fuse (No. 18 , located in the fuse block) ● to rear wiper motor terminal 쑗 3 (Sedan and H/B); 쑗 4 (Wagon), and ● to rear wiper relay terminal 쑗 2 .
Low speed wiper operation Ground is supplied to rear wiper switch terminal 쑗 4 through body grounds E37 and When the rear wiper is placed in the ON position, ground is supplied ● through rear wiper switch terminal 쑗 2 ● to rear wiper relay terminal 쑗 1 . The rear wiper relay is energized and power is supplied ● through 15A fuse (No. 18 , located in the fuse block) ● to rear wiper relay terminal 쑗 5 ● through rear wiper relay terminal 쑗 3 ● to rear wiper motor terminal 쑗 2 . Ground is supplied ● to rear wiper motor terminal 쑗 1 (sedan and H/B); 쑗 3 (Wagon) ● through body grounds B18 and B27 (Sedan); D110 and B48 (H/B and Wagon).
E11
.
Auto stop operation With the rear wiper switch turned OFF, rear wiper motor will continue to operate until wiper arm reaches rear window base. When wiper arm is not located at base of rear window with rear wiper switch OFF, rear wiper relay is not energized. Power is supplied ● through 15A fuse (No. 18 , located in the fuse block) ● to rear wiper motor terminal 쑗 3 (Sedan and H/B); 쑗 4 (Wagon). Ground is also supplied ● to rear wiper motor terminal 쑗 1 (Sedan and H/B); 쑗 3 (Wagon) ● through body grounds B18 and B27 (Sedan); D110 and B48 (H/B and Wagon). When wiper arm reaches base of rear window, rear wiper motor will then stop wiper arm at the PARK position.
Intermittent operation The rear wiper motor operates the wiper arm one time at low speed at an interval of approximately 7 seconds. This feature is controlled by the rear wiper amplifier. With the ignition switch in the ON or START position, power is supplied ● through 15A fuse (No. 18 , located in the fuse block) ● to rear wiper relay terminal 쑗 2 . When the rear wiper is placed in the INT position, ground is supplied ● to rear wiper relay terminal 쑗 1 ● through rear wiper switch terminal 쑗 2 ● to rear wiper amplifier ● from rear wiper switch terminal 쑗 4 ● through bogy grounds E37 and E11 . When the rear wiper relay is energized, power is supplied ● through 15A fuse (No. 18 , located in the fuse block) ● to rear wiper relay terminal 쑗 5 ● through rear wiper relay terminal 쑗 3 ● to rear wiper motor terminal 쑗 2 .
EL-193
REAR WIPER AND WASHER System Description (Cont’d) Ground is also supplied ● to rear wiper motor terminal 쑗 1 (Sedan and H/B); 쑗 3 (Wagon) ● through body grounds B18 and B27 (Sedan); D110 and B48 (H/B and Wagon). With power and ground supplied, the rear wiper motor operates intermittently.
WASHER OPERATION With the ignition switch in the ON or START position, power is supplied ● through 10A fuse (No. 21 , located in the fuse block) ● to rear washer switch connector terminal 쑗 5 . When the rear washer switch is pushed to the WASH/R position, ground is supplied ● to rear washer motor terminal 쑗 1 ● from terminal 쑗 3 of rear wiper switch ● through terminal 쑗 4 of rear wiper switch, and ● through body grounds E37 and E11 . Power is supplied ● from terminal 쑗 18 of the washer switch ● to washer motor terminal 쑗 2 . With power and ground is supplied, the rear washer motor operates. The rear wiper motor operates when the control switch is pushed to WASH position for one second or more and for approximately 3 seconds after the switch is released. This feature is controlled by the rear wiper amplifier in the same manner as the intermittent operation.
EL-194
REAR WIPER AND WASHER Wiring Diagram — WIP/R —
YEL883C
EL-195
REAR WIPER AND WASHER Wiring Diagram — WIP/R — (Cont’d) : 4 door models Preceding page
: 5 door hatch-back models : Wagon models : 5 door hatchback models and Wagon models
STOP
STOP
MOVE REAR WIPER MOTOR
MOVE REAR WIPER MOTOR
YEL178C
EL-196
REAR WIPER AND WASHER Removal and Installation
Sedan 60 (2.4)
WIPER ARM 1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it off (Auto Stop). 2. Lift the blade up and then set it down onto glass surface. Set the blade center before tightening nut. 3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it off. 4. Ensure that wiper blade stops in the correct position. ● Tighten windshield wiper arm nut to specified torque. : 13 - 18 N·m (1.4 - 1.8 kg-m, 10 - 13 ft-lb)
Molding edge
Hatchback
170.3 (6.7)
Back door side
Wagon
66 (2.6) Unit: mm (in)
YEL456B
●
Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness.
SEL024J
Suitable tool
Washer Nozzle Adjustment ●
Adjust washer nozzle with suitable tool as shown in the figure at left. Adjustable range: ±10° (In any direction)
Max. 10°
Nozzle hole bore diameter 1.0 mm (0.039 in)
NEL314
EL-197
REAR WIPER AND WASHER Washer Nozzle Adjustment (Cont’d) *3
*1
*4
Unit: mm (in)
*2
*1
150 (5.91)
*3
135 (5.31)
*2
290 (11.42)
*4
170 (6.69)
Circle diameters are approx. 80 mm (3.15 in)
Black printed edge All these diameters of these circles Unit: mm (in) NEL315 are less than 80 (3.15)
EL-198
REAR WIPER AND WASHER Washer Tube Layout Sedan and Hatchback
Nozzle Check valve Wagon
Rear washer tube To reservoir tank
Rear washer tube
Check valve Nozzle (Sedan)
Nozzle Check valve
● Check valve
To nozzle
A check valve is provided in the washer fluid line. Be careful not to connect check valve to washer tube in the wrong direction.
SEL411H
Hatchback and wagon
From reservoir tank
NEL557
Check Valve
Sedan
From reservoir tank
To reservoir tank
Check valve
To nozzle
NEL552
EL-199
HEADLAMP WASHER Wiring Diagram — HLC —
EL-HLC-01
IGNITION SWITCH ON or START
BATTERY
30A d
10A 12
FUSE BLOCK (J/B)
HD
: With XENON headlamp or daytime light system
XH
: Except
Refer to EL-POWER.
HD
E104 LG/B
13G G
XH LG/B
G
P/L
5
4
2
P/L
A Next page
HD P/L
B
HEADLAMP WASHER TIMER
E126 3
1
OR/B
R/B
OR/B
R/B 2
2
M
HEADLAMP WASHER MOTOR
ON
E38
HEADLAMP WASHER SWITCH
E128 OFF
1
3
B
B
B
B
E11
E37 REFER TO THE FOLLOWING
3 2 4 1 5
E104 E126 B
1 2
E38
1 6 4 3 2 5
FUSE BLOCK - Junction Box (J/B)
E128 L
YEL319B
EL-200
HEADLAMP WASHER Wiring Diagram — HLC — (Cont’d) BATTERY
Refer to EL-POWER. : With gasoline engine : With diesel engine : With XENON headlamp or daytime light system : Except : With daytime light system and without XENON headlamp : With daytime light system and XENON headlamp : With XENON headlamp and without daytime light system.
1ST
OFF
2ND
OFF
1ST
2ND COMBINATION SWITCH (LIGHTING SWITCH)
PASS
LOW HIGH
Preceding page
HEADLAMP RELAY RH
HEADLAMP RELAY RH
DIODE
HEADLAMP RELAY RH
Preceding page To Headlamp RH (Refer to EL-H/LAMP and EL-DTRL)
YEL179C
EL-201
HEADLAMP WASHER Washer Tube Layout Washer nozzle
To reservoir tank
Check valve NEL555
Check Valve
Check valve From reservoir tank
To nozzle
●
A check valve is provided in the washer fluid line. Be careful not to connect check valve to washer tube in the wrong direction.
To nozzle
NEL554
EL-202
HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram — HORN — Type-1 BATTERY : With gasoline engine
Refer to EL-POWER.
: With diesel engine : With steering wheel switch : Without steering wheel switch
HORN RELAY
FUSE BLOCK (J/B)
SPIRAL CABLE
HORN LOW
ON
HORN HIGH OFF
HORN SWITCH
ON
HORN SWITCH
OFF
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
*:
This connector is not shown in “HARNESS LAYOUT” of EL section.
YEL180C
EL-203
HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram — HORN — (Cont’d) IGNITION SWITCH ACC or ON
BATTERY
IGNITION SWITCH ON or START
BATTERY FUSE BLOCK (J/B)
Refer to EL-POWER.
: With gasoline engine : With diesel engine : With XENON headlamp, gasoline engine : Except
POWER FUSE 15A
COMBINATION METER (CLOCK) CLOCK
CIGARETTE LIGHTER SOCKET
ST
OFF ON ACC
IGNITION SWITCH
ACC
POWER SOCKET ACCESSORY RELAY
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YEL181C
EL-204
HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram — HORN — (Cont’d) Type-2
YEL885C
EL-205
HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram — HORN — (Cont’d)
YEL886C
EL-206
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER System Description The rear window and door mirror defogger system is controlled by the time control unit. The rear window and door mirror defogger operates only for approximately 15 minutes. Power is supplied at all times ● to rear window defogger relay With the ignition switch in the ON or START position, power is supplied ● to rear window defogger relay ● to time control unit terminal 쑗 1 ● through 10A fuse [No. 26 , located in the fuse block (J/B)]. Ground is supplied to terminal 쑗 14 of the rear window defogger switch through body grounds M6 , M28 and M26 . When the rear window defogger switch is turned ON, ground is supplied ● through terminal 쑗 16 rear window defogger switch ● to fuse block (J/B) terminal 9C . ● through time control unit terminal 쑗 3 . Terminal 쑗 13 of the time control unit then supplies ground to the rear window defogger relay. With power and ground supplied, the rear window defogger relay is energized. For rear window defogger system, power is supplied ● through 15A fuse [No. 14 and 15 , located in the fuse block (J/B)]. ● to rear window defogger. For door mirror defogger system, power is supplied ● through 10A fuse [No. 1 , located in the fuse block (J/B)]. ● to door mirror defogger. The rear window and door mirror defogger have an independent ground. With power and ground supplied, the rear window and door mirror filaments heat and defog the rear window and door mirrors. When the system is activated, the rear defogger indicator illuminates in the rear window defogger switch. Power is supplied ● to terminal 쑗 13 of the rear window defogger switch ● from 10A fuse [No. 1 , located in the fuse block (J/B)]. M6 , M28 and M26 . 14 of the rear window defogger switch is grounded through body grounds Terminal 쑗
EL-207
IGNITION SWITCH ON or START
BATTERY : With door mirror heater
REAR WINDOW DEFOGGER RELAY
REAR WINDOW DEFOGGER SWITCH FUSE
Schematic
EL-208 DOOR MIRROR HEATER (PASSENGER SIDE)
DOOR MIRROR HEATER (DRIVER’S SIDE)
TIME CONTROL UNIT
REAR WINDOW DEFOGGER
CONDENSER
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER
FUSE
FUSE
YEL182C
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Wiring Diagram — DEF — BATTERY
IGNITION SWITCH ON or START
BATTERY
REAR WINDOW DEFOGGER RELAY
TIME CONTROL UNIT
FUSE BLOCK (J/B)
Refer to EL-POWER.
: With door mirror heater : 4 door models and 5 door hatchback models : Wagon models
To EL-DEF-03
ON
INDICATOR LAMP
REAR WINDOW DEFOGGER SWITCH
Next page
OFF
REAR WINDOW DEFOGGER
REAR WINDOW DEFOGGER CONDENSER
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
: This connector is not shown in “HARNESS LAYOUT” of EL section.
YEL183C
EL-209
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Wiring Diagram — DEF — (Cont’d)
EL-DEF-02 Preceding page
A
L/R
4D
: 4 door models
5H
: 5 door hatchback models
5H 4D
L/R
L/R B44 1
D103
L/R
3 L/R
R/W D113 :
5H
3 REAR WINDOW DEFOGGER
1 B41 :
5H
B B
B59 -3 :
4D
3 REAR WINDOW DEFOGGER
L/R
B
1
2
1 B120 B
B44 L/R
R/W
1
2
CONDENSER
D111 , D115 :
4D
*
*
D111 B
1
B59 -1 B
D115 B
2
2
*
3
B59 -2 B
D103 2
B
CONDENSER
B59 -1 , B59 -2 :
1
B
D113 B
3
1
*
B59 -3 B
B119
B41 B
1 2 3
5H
B
B
B48
D110
B44 W
*
1 B120 B
: These connectors are not shown in “HARNESS LAYOUT” of EL section.
YEL343B
EL-210
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Wiring Diagram — DEF — (Cont’d)
YEL887C
EL-211
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Trouble Diagnoses DIAGNOSTIC PROCEDURE SYMPTOM: Rear window defogger/door mirror defogger does not activate, or does not go off after activating.
Time control unit connector
YEL438B
Time control unit connector
CHECK REAR WINDOW DEFOGGER INPUT SIGNAL. 1. Remove control unit from fuse block (J/B). 2. Check continuity between control unit 3 and ground. harness terminal 쑗 Condition
Continuity
Rear window defogger switch is “OFF”.
No
Rear window defogger switch is “ON”.
Yes
NG 왘
Check the following. ● Rear window defogger switch ● Harness for open or short between control unit and rear window defogger switch ● Rear window defogger switch ground circuit
OK 왔 YEL439B
1. Turn ignition switch to ON position. 2. Check voltage between control unit termi1 and ground. nal 쑗 Battery voltage should exist.
NG 왘
Check the following. ● 10A fuse [No. 26 , located in the fuse block (J/B)]
OK 왔 Time control unit connector
1. Turn ignition switch to ON position. 2. Check voltage between control unit termi13 and ground. nal 쑗 Battery voltage should exist.
NG 왘
Check the following. ● Rear window defogger relay
OK 왔 YEL440B
Fuse block (J/B) connector
CHECK REAR WINDOW DEFOGGER OUTPUT SIGNAL. 1. Install control unit to fuse block (J/B). 2. Turn ignition switch to ON POSITION. 3. Check voltage between fuse block (J/B) harness terminal 1K and ground. Condition
Voltage [V]
Rear window defogger switch is “OFF”.
0
Rear window defogger switch is “ON”.
Approx. 12
OK 왘
Check the following. ● Rear window defogger filament (Refer to EL-213.)
NG YEL441B
Super multiple junction (SMJ) connector
왔
CHECK CONTROL UNIT GROUND CIRCUIT. Check continuity between fuse block (J/B) terminal 1B and ground. Continuity should exist. OK
NG 왘
Check the following. ● 15A fuse [No. 14 , 15 , located in the fuse block (J/B)] ● Rear window defogger relay OK
왔
왔
Replace relay or fuse.
Repair harness or connectors. 왔
Replace control unit. YEL442B
EL-212
NG
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Electrical Components Inspection REAR WINDOW DEFOGGER RELAY Check continuity between terminals
3 쑗
and
Condition
5 . 쑗
Continuity
12V direct current supply between 1 and 쑗 2 terminals 쑗
Yes
No current supply
No
YEL443B
REAR WINDOW DEFOGGER SWITCH Check continuity between terminals when rear window defogger switch is pushed and released.
Rear window defogger switch
Terminals
16 - 쑗 14 쑗
Condition
Continuity
Rear window defogger switch is pushed
Yes
Rear window defogger switch is released
No
YEL444B
Filament Check 1. Attach probe circuit tester (in volt range) to middle portion of each filament.
6 volts (normal filament) SEL263
● Heat wire
Press
When measuring voltage, wrap tin foil around the top of the negative probe. Then press the foil against the wire with your finger.
Tester probe
Tin foil
SEL122R
EL-213
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Filament Check (Cont’d) 2. If a filament is burned out, circuit tester registers 0 or 12 volts.
Burned out point
12 volts
Burned out point
0 volts SEL265
3. To locate burned out point, move probe to left and right along filament. Test needle will swing abruptly when probe passes the point.
SEL266
Filament Repair REPAIR EQUIPMENT
Heat wire
REPAIRING PROCEDURE
5 (0.20)
5 (0.20)
1. Conductive silver composition (Dupont No. 4817 or equivalent) 2. Ruler 30 cm (11.8 in) long 3. Drawing pen 4. Heat gun 5. Alcohol 6. Cloth
Break
Ruler
Drawing pen
Unit: mm (in) BE540
1. Wipe broken heat wire and its surrounding area clean with a cloth dampened in alcohol. 2. Apply a small amount of conductive silver composition to tip of drawing pen. Shake silver composition container before use. 3. 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.
EL-214
REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Filament Repair (Cont’d) 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.
Repaired point
SEL012D
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.
Repaired point
Heat gun SEL013D
EL-215
AUDIO Anti-theft System NATS Audio Link Description The link with the NATS IMMU implies that the audio unit can basically only be operated if connected to the matching NATS IMMU to which the audio unit was initially fitted on the production line. Since radio operation is impossible after the link with the NATS is disrupted theft of the audio unit is basically useless since special equipment is required to reset the audio unit. Initialization process for audio units that are linked to the NATS IMMU New audio units will be delivered to the factories in the “NEW” state, i.e. ready to be linked with the vehicle’s NATS. When the audio unit in “NEW” state is first switched on at the factory, it will start up communication with the vehicle’s immobiliser control unit (IMMU) and send a code (the “audio unit Code”) to the IMMU. The IMMU will then store this code, which is unique to each audio unit, in its (permanent) memory. Upon receipt of the code by the IMMU, the NATS will confirm correct receipt of the audio unit code to the audio unit. Hereafter, the audio unit will operate as normal. During the initialisation process, “NEW” is displayed on the audio unit display. Normally though, communication between audio unit and IMMU takes such a short time (300 ms) that the audio unit seems to switch on directly without showing “NEW” on its display. Normal operation Each time the audio unit is switched on afterwards, the audio unit code will be verified between the audio unit and the NATS before the audio unit becomes operational. During the code verification process, “WAIT” is shown on the audio unit display. Again, the communication takes such a short time (300 ms) that the audio unit seems to switch on directly without showing “WAIT” on its display. When the radio is locked In case of a audio unit being linked with the vehicle’s NATS (immobilizer system), disconnection of the link between the audio unit and the IMMU will cause the audio unit to switch into the lock (“SECURE”) mode in which the audio unit is fully inoperative. Hence, repair of the audio unit is basically impossible, unless the audio unit is reset to the “NEW” state for which special decoding equipment is required. The radio manufacturer has provided their authorized service representatives with so called “decoder boxes” which can bring the audio unit back to the “NEW” state, enabling the audio unit to be switched on after which repair can be carried out. Subsequently, when the repaired audio unit is delivered to the final user again, it will be in the “NEW” state as to enable re-linking the audio unit to the vehicle’s immobiliser system. As a result of the above, repair of the audio unit can only be done by an authorized representative of the radio manufacturer. Service instruction Item
Radio linked with IMMU and/or SECU
Battery disconnection
No additional action required
Radio needs repair
Repair needs to be done by authorised representative of radio manufacturer since radio cannot be operated unless it is reset to NEW state, using special decoding equipment
Replacement of radio by new part
Radio is delivered in NEW state. If possible, the radio will automatically link up with the immobiliser system. If this appears not possible, the audio unit code needs to be manually input
Transferring radio to another vehicle / replacement of radio by an ‘‘old’’part
Radio needs to be reset to NEW state by authorised representative of radio manufacturer
Replacement of IMMU by new part
Radio will request for the audio unit code input prior to establishing the link with the IMMU
Replacement of IMMU by old part
If a radio code has already been stored in memory of the IMMU, the radio cannot be linked to it. After switching on the radio, it will display ‘‘SECURE’’ after 1 minute. Operation can only be established after resetting the ratio by an authorised representative of radio manufacturer
No communication from IMMU to radio
Radio will display ‘‘SECURE’’ after 180 attempts to communicate with IMMU. Further use of radio impossible until communication is established again, or after radio is reset by authorised representative of (radio) manufacturer
EL-216
AUDIO Anti-theft System (Cont’d) Audio unit code input procedure 1. Radio displays “CODE IN” after the power is switched ON. 2. Enter the audio unit code (4−digits) by pressing the preset buttons (using 1 to 4). Press the preset buttons for the necessary amount of times for the number of each digits. e.g. the audio unit code is “5432” Press No. 1 preset button for 5 times Press No. 2 preset button for 4 times Press No. 3 preset button for 3 times Press No. 4 preset button for 2 times 3. Press the button. 4. If the code is OK, the radio will power ON. If the code is NG, the radio will be locked up as below. After the lock up, the radio will display “CODE IN” again. 1st to 3rd attempt: The radio will be locked for 10 seconds after each attempt 4th to 20th attempt: The radio will be locked for 60 minutes after each attempt Over 20th attempt: The radio will be locked completely
Speed Dependent Volume Control Description If activated, the radio output volume will be automatically adjusted to compensate for increasing driving noises at higher driving speeds. The radio receives a speed signal from the vehicle speed sensor (VSS) and selects the output volume.
Personal Audio Settings Description The radio is designed to store several settings (volume, bass, treble, preset stations and level of speed dependent volume control) with every NATS ignition key used. Up to a maximum of 4 NATS keys can be registered. During the communication as mentioned under “Anti-theft System”, the radio will recognize the used ignition key and select the accompanying settings.
EL-217
: RHD models : With steering wheel switch : With daytime light system : Without daytime light system : With CD auto changer
IGNITION SWITCH ACC or ON COMBINATION SWITCH (LIGHTING SWITCH)
FUSE
FUSE
CD AUTO CHANGER
BATTERY
FUSE
COMBINATION METER (SPEEDOMETER) ROOF ANTENNA
DT AUDIO
SOURCE SWITCH SEEK UP SWITCH VOLUME SWITCH
SPIRAL CABLE
SEEK DOWN SWITCH SPECIAL SWITCH AUDIO STEERING WHEEL SWITCH
FRONT SPEAKER LH
TWEETER LH
FRONT SPEAKER RH
TWEETER RH
REAR SPEAKER LH
REAR SPEAKER RH
NATS IMMU
DONGLE CONTROL UNIT
AUDIO
DAYTIME LIGHT CONTROL UNIT
Schematic
EL-218
.
YEL184C
AUDIO Wiring Diagram — AUDIO —
YEL888C
EL-219
AUDIO Wiring Diagram — AUDIO — (Cont’d) BATTERY : LHD models : RHD models : With daytime light system : Without daytime light system
OFF
1ST
2ND
COMBINATION SWITCH (LIGHTING SWITCH)
FUSE BLOCK (J/B)
AUDIO
DAYTIME LIGHT CONTROL UNIT
FRONT SPEAKER LH
FRONT SPEAKER LH
TWEETER LH
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
YEL186C
EL-220
AUDIO Wiring Diagram — AUDIO — (Cont’d) AUDIO : LHD models : RHD models
FRONT SPEAKER RH
FRONT SPEAKER RH
TWEETER RH
YEL187C
EL-221
AUDIO Wiring Diagram — AUDIO — (Cont’d) AUDIO : 4 door models and 5 door hatchback models : Wagon models
REAR SPEAKER LH
REAR SPEAKER LH
YEL188C
EL-222
AUDIO Wiring Diagram — AUDIO — (Cont’d) DONGLE CONTROL UNIT
NATS IMMU
: RHD models : With steering wheel switch ROOF ANTENNA
AUDIO
SPIRAL CABLE
AUDIO STEERING WHEEL SWITCH
SOURCE SWITCH
SEEK UP SWITCH
VOLUME SWITCH
SEEK DOWN SWITCH
SPECIAL SWITCH
: This connector is not shown in “HARNESS LAYOUT” of EL section.
YEL217C
EL-223
AUDIO Wiring Diagram — AUDIO — (Cont’d)
AUDIO
To ELAUDIO-01
CD AUTO CHANGER
YEL189C
EL-224
AUDIO Wiring Diagram — AUDIO — (Cont’d)
AUDIO
CD AUTO CHANGER
YEL190C
EL-225
AUDIO Trouble Diagnoses Symptom
Possible cause
Repair order
Radio inoperative (no digital 1. 10A Fuse display and no sound from speakers). 2. Poor radio case ground 3. Radio
1. Check 10A fuse [No. 3 , located in fuse block (J/B)]. Turn ignition switch ON and verify battery positive voltage is present at terminal 쑗 3 of radio 2. Check radio case ground. 3. Remove radio for repair.
1. Radio output Radio controls are operational, but no sound is 2. Radio heard from any speaker.
1. Check radio output voltages. 2. Remove radio for repair.
Radio presets are lost when ignition switch is turned OFF.
1. 15A fuse
1. Check 15A fuse [No. 35 , located in fuse and fusible box and verify battery positive voltage is present at terminal 쑗 9 of radio. 2. Remove radio for repair.
2. Radio Individual speaker is noisy or inoperative.
4. Radio
1. Check speaker 2. Check radio output voltages. 3. Check wires for open or short between radio and speaker. 4. Remove radio for repair.
Radio stations are weak or noisy.
1. Antenna 2. Poor radio ground 3. Radio
1. Check antenna. 2. Check radio ground. 3. Remove radio for repair.
Radio generates noise in AM and FM modes with engine running.
1. Poor radio ground 2. Loose or missing ground bonding straps 3. Ignition condenser or rear window defogger noise suppressor condenser 4. Alternator 5. Ignition coil or secondary wiring 6. Radio
1. Check radio ground. 2. Check ground bonding straps.
1. Poor radio ground 2. Antenna 3. Accessory ground 4. Faulty accessory
1. Check radio ground. 2. Check antenna. 3. Check accessory ground. 4. Replace accessory.
Radio generates noise in AM and FM modes with accessories on (switch pops and motor noise).
1. Speaker 2. Radio output 3. Speaker circuit
EL-226
3. Replace ignition condenser or rear window defogger noise suppressor condenser. 4. Check alternator 5. Check ignition coil and secondary wiring. 6. Remove radio for repair.
AUDIO Trouble Diagnoses (Cont’d) CD AUTOCHANGER Symptom No play of the CD after CD play button is pushed.
Possible cause 1. Radio (The radio is not working.) 2. Harness connection (Magazine does not eject.) 3. Discs 4. Magazine does not eject or a disc remains in CD player. 5. Changer
CD skipping.
1. Rough road driving 2. Discs 3. Bracket 4. Changer
Error code [NO DISC] is shown on the radio after CD play button is pressed.
1. Magazine setting 2. Magazine
Repair order 1. Remove the radio for repair. 2. Check harness connection. 3. Inspect disc. (Refer to testing magazines and discs.) 4. Reset the changer. (Disconnect harness connector at the changer and reconnect after 30 sec.) 5. Remove the changer for repair. 1. System is not malfunctioning. 2. Inspect discs. (Refer to testing magazines and discs.) 3. Check and repair bracket and installation of changer. 4. Remove the changer for repair. 1. Confirm the magazine is pushed completely. 2. Inspect magazine. (Refer to testing magazines and discs.) 3. Remove the changer for repair.
3. Changer
Testing magazines and discs 1. Confirm discs are installed correctly into the magazine (not upside down). 2. Visually inspect/compare the customer’s discs with each other and other discs. Identify any of the following conditions: ● Discs with a large outside diameter. [Normal size is 120 mm (4.72 in).] ● Discs with rough or lipped edges. ● Discs with excessive thickness [Normal size is 1.2 mm (0.047 in).] ● Discs with scratches, abrasions, or pits on the surface. ● Discs with grease/oil, fingerprints, foreign material. ● Discs are warped due to excessive heat exposure. 3. Slide/place the discs in and out of the various magazine positions. Identify any discs and/or positions that require additional force for placement/ejection. If interference (sticking, excessive tensions) is found, replace the magazine or the discs. Note: ● Discs which are marginally out of specification (ex. dirty, scratched and so on) may play correctly on a home stereo. However, when used in the automative environment skipping may occur due to the added vehicle movement and/or vibration due to road conditions. Autochangers should not be replaced when discs are at fault. ● Use a soft damp cloth to wipe the discs starting from the center outward in radial direction. Never use chemical cleaning solutions to clean the discs.
EL-227
AUDIO Inspection SPEAKER 1. Disconnect speaker harness connector. 1 and 쑗 2 . 2. Measure the resistance between speaker terminals 쑗 ● The resistance should be 2 - 4Ω. 3. Using jumper wires, momentarily connect a 9V battery between speaker terminals ● A momentary hum or pop should be heard.
1 쑗
and
2 . 쑗
ANTENNA Using a jumper wire, clip an auxiliary ground between antenna and body. ● If reception improves, check antenna ground (at body surface). ● If reception does not improve, check main feeder cable for short circuit or open circuit.
RADIO All voltage inspections are made with: ● Ignition switch ON or ACC ● Radio ON ● Radio connected (If removed for inspection, supply a ground to the case using a jumper wire.)
EL-228
AUDIO ANTENNA Location of Antenna
NEL769
EL-229
ELECTRIC SUNROOF Wiring Diagram — SROOF — IGNITION SWITCH ON or START
BATTERY
FUSE BLOCK (J/B)
Refer to EL-POWER.
POWER WINDOW RELAY
CIRCUIT BREAKR-1
: LHD models : RHD models
SUNROOF SWITCH OPEN
CLOSE
OPEN
CLOSE
SUNROOF MOTOR
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
YEL191C
EL-230
POWER DOOR MIRROR Wiring Diagram — MIRROR — LHD models ★ For removal of door mirror, refer to “DOOR MIRROR” in BT section.
YEL890C
EL-231
POWER DOOR MIRROR Wiring Diagram — MIRROR — (Cont’d) RHD models
YEL891C
EL-232
POWER SEAT Power Seat/Wiring Diagram — SEAT —
YEL892C
EL-233
HEATED SEAT Heated Seat/Wiring Diagram — HSEAT — ★ For location of heating unit, refer to “SEAT” in BT section. IGNITION SWITCH ON or START FUSE BLOCK (J/B)
HIGH
LOW
OFF
HIGH HIGH
HIGH
OFF
Refer to EL-POWER
LOW
OFF
HEATED SEAT SWITCH LH
INDICATOR LAMP
HIGH
LOW
OFF
LOW
HIGH
OFF
HIGH
LOW
OFF
HEATED SEAT SWITCH RH
INDICATOR LAMP
Next page
Next page
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)
YEL195C
EL-234
HEATED SEAT Heated Seat/Wiring Diagram — HSEAT — (Cont’d)
Preceding page
Preceding page
THERMOSTAT SWITCH
HEATED SEAT RH
HEATED SEAT LH THERMOSTAT SWITCH
YEL196C
EL-235
POWER WINDOW System Description Power is supplied at all times ● from 40A fusible link (Letter e , located in the fusible link and fuse box) ● through circuit breaker-1 ● to power window relay. With ignition switch in ON or START position, power is supplied ● to power window relay. Ground is supplied to power window relay ● through body grounds M6 , M28 and M26 . The power window relay is energized and power is supplied ● through power window relay. ● to power window main switch terminal 쑗 12 , ● to passenger side power window sub-switch terminal 쑗 5 , ● to rear power window sub-switch LH terminal 쑗 5 , ● to rear power window sub-switch RH terminal 쑗 5 .
MANUAL OPERATION Driver’s door Ground is supplied ● to front power window main switch terminals ● through body grounds B18 and B27 .
2 쑗
WINDOW UP When a driver side switch in the power window main switch is pressed in the up position, power is supplied ● to driver side power window regulator terminal 쑗 1 ● through power window main switch terminal 쑗 3 . Ground is supplied ● to driver side power window regulator terminal 쑗 2 ● through power window main switch terminal 쑗 4 . Then, the motor raises the window until the switch is released. WINDOW DOWN When a driver side switch in the power window main switch is pressed in the down position, power is supplied ● to driver side power window regulator terminal 쑗 2 ● through power window main switch terminal 쑗 4 . Ground is supplied ● to driver side power window regulator terminal 쑗 1 ● through power window main switch terminal 쑗 3 . Then, the motor lowers the window until the switch is released.
Except driver’s door Ground is supplied ● to power window main switch terminal ● through body grounds B18 and B27 .
2 쑗
EL-236
POWER WINDOW System Description (Cont’d) PASSENGER’S DOOR NOTE: Figures in parentheses ( ) refer to terminal Nos. arranged in order when the UP or DOWN section of power window switch is pressed. Operation by main switch. Power is supplied ● through power window main switch (쑗 6 , 쑗 10 ) ● to passenger side power window sub-switch (쑗 3 , 쑗 1 ). The subsequent operations are the same as those outlined under “Operation by sub-switches”. Operation by sub-switches Power is supplied ● through passenger side power window sub-switch (쑗 2 , 쑗 4 ) ● to passenger side power window regulator (쑗 1 , 쑗 2 ). Ground is supplied ● to passenger side power window regulator (쑗 2 , 쑗 1 ) ● through passenger side power window sub-switch (쑗 2 , 쑗 4 ) ● to passenger side power window sub-switch (쑗 1 , 쑗 3 ) ● through power window main switch (쑗 6 , 쑗 10 ). Then, the motor raises or lowers the window until the switch is released. REAR DOOR LH NOTE: Figures in parentheses ( ) refer to terminal Nos. arranged in order when the UP or DOWN section of power window switch is pressed. Operation by main switch Power is supplied ● through power window main switch (쑗 13 , 쑗 14 ) ● to rear power window sub-switch LH (쑗 3 , 쑗 1 ). The subsequent operations are the same as those outlined under “Operation by sub-switches”. Operation by sub-switches Power is supplied ● through rear power window sub-switch LH (쑗 2 , 쑗 4 ) ● to rear power window regulator LH (쑗 1 , 쑗 2 ). Ground is supplied ● to rear power window regulator LH (쑗 2 , 쑗 1 ) ● through rear power window sub-switch LH (쑗 4 , 쑗 2 ) ● to rear power window sub-switch LH (쑗 1 , 쑗 3 ) ● through power window main switch LH (쑗 14 , 쑗 13 ). Then, the motor raises or lowers the window until the switch is released.
EL-237
POWER WINDOW System Description (Cont’d) REAR DOOR RH NOTE: Figures in parentheses ( ) refer to terminal Nos. arranged in order when the UP or DOWN section of power window switch is pressed. Operation by main switch Power is supplied ● through power window main switch (쑗 15 , 쑗 16 ) ● to rear power window sub-switch RH (쑗 3 , 쑗 1 ). The subsequent operations are the same as those outlined under “Operation by sub-switches”. Operation by sub-switches Power is supplied ● through rear power window sub-switch RH (쑗 2 , 쑗 4 ) ● to rear power window regulator RH (쑗 1 , 쑗 2 ). Ground is supplied ● to rear power window regulator RH (쑗 2 , 쑗 1 ) ● through rear power window sub-switch RH (쑗 4 , 쑗 2 ) ● to rear power window sub-switch RH (쑗 1 , 쑗 3 ) ● through power window main switch (쑗 16 , 쑗 15 ) Then, the motor raises or lowers the window until the switch is released.
AUTO OPERATION The power window AUTO feature enables the driver to open or close the driver’s window without holding the window switch in the respective position. When the AUTO switch in the main switch is pressed and released, the driver’s window will travel to the fully open or closed position.
POWER WINDOW LOCK The power window lock is designed to lock-out window operation to all windows except the driver’s door window. When the lock switch is pressed to lock position, ground of the passenger side switch, rear RH switch and rear LH switch in the power window main switch is disconnected. This prevents the power window motors from operating.
EL-238
IGNITION SWITCH ON or START
BATTERY (Via fusible link)
: With rear power window
FUSIBLE LINK
CIRCUIT BREAKER-1 POWER WINDOW MAIN SWITCH
DRIVER’S SIDE
LOCK SWITCH
PASSENGER SIDE
REAR LH
REAR RH
POWER WINDOW RELAY
FRONT POWER WINDOW SUB-SWITCH
AUTO AMP.
UP RELAY
DOWN RELAY
REAR POWER WINDOW SUB-SWITCH RH
REAR POWER WINDOW REGULATOR RH
ILL
FRONT POWER WINDOW REGULATOR (DRIVER’S SIDE)
POWER WINDOW
REAR POWER WINDOW REGULATOR LH
Schematic
EL-239
REAR POWER WINDOW SUB-SWITCH LH
FRONT POWER WINDOW REGULATOR (PASSENGER’S SIDE)
YEL197C
POWER WINDOW Wiring Diagram — WINDOW —
YEL894C
EL-240
POWER WINDOW Wiring Diagram — WINDOW — (Cont’d)
YEL895C
EL-241
POWER WINDOW Wiring Diagram — WINDOW — (Cont’d)
YEL896C
EL-242
POWER WINDOW Trouble Diagnoses Symptom None of the power windows can be operated using any switch.
Possible cause 1. 40A fusible link and circuit breaker-1.
Repair order 1. Check 40A fusible link (letter e , located in fuse and fusible link box) and circuit breaker-1. Turn ignition switch to “ON” position and verify battery positive voltage is present at terminal 쑗 12 of power window main switch, and other switches as follows. Location of sub-switch
Terminals
Passenger Rear RH Rear LH
5 쑗 5 쑗 5 쑗
2. Grounds B18 and B27 . 3. Power window relay. 4. Open/short in power window main switch circuit.
2. Check grounds B18 and B27 . 3. Check power window relay. 4. Check W/R wire between fuse block (J/B) and power window main switch for open/short circuit.
Driver’s side power window cannot be operated but other windows can be operated.
1. Driver’s side power window regulator circuit. 2. Driver’s side power window regulator.
1. Check driver’s side power window regulator circuit
One or more passenger power windows cannot be operated.
1. Power window switches (front sub-switch, rear sub-switch RH, rear sub-switch LH). 2. Power window regulators. (Passenger side, rear LH, rear LH.) 3. Power window main switch. 4. Power window circuit.
1. Check power window switches (front sub-switch, rear sub-switch RH, rear sub-switch LH)
1. Power window main switch.
1. Check power window main switch.
Driver’s side power window auto 1. Power window main switch. function cannot be operated using power window main switch.
1. Check power window main switch.
One or more passenger power windows cannot be operated using power window main switch but can be operated by power window sub-switches.
EL-243
2. Check driver’s side power window regulator
2. Check power window regulators (front sub-switch, rear sub-switch RH, rear sub-switch LH) 3. Check power window main switch 4-1. Check harnesses between power window main switch and power window sub-switches for open/short circuit. 4-2. Check harnesses between power window subswitches and power window regulators for open/ short circuit.
POWER WINDOW NOTE
EL-244
POWER DOOR LOCK System Description/Door Lock for LHD Models OPERATION Power door lock/unlock operation by door key cylinder ● With the key inserted into front door key cylinder, turning it to LOCK will lock all doors. ● With the key inserted into front door key cylinder, turning it to UNLOCK will unlock all doors. Power door lock/unlock operation by multi-remote controller (If equipped) ● Pressing multi-remote controller LOCK button will lock all doors. ● Pressing multi-remote controller UNLOCK button once will unlock driver door. Then, if an unlock signal is sent from the remote controller again within 5 seconds, all other doors will be unlocked. Power door lock/unlock operation by lock/unlock switch ● With lock/unlock switch on driver door trim setting to LOCK will lock all doors. ● With lock/unlock switch on driver door trim setting to UNLOCK will unlock all doors. Key reminder system ● If the ignition key is in the ignition key cylinder and driver door is open, setting lock/unlock switch, lock knob, key or multi-remote controller to “LOCK” locks the door once but then immediately unlocks all doors. (signal from door unlock sensor driver side)
EL-245
POWER DOOR LOCK Schematic
YEL897C
EL-246
POWER DOOR LOCK Schematic (Cont’d)
YEL898C
EL-247
POWER DOOR LOCK Wiring Diagram — D/LOCK —
YEL899C
EL-248
POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)
YEL900C
EL-249
POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)
YEL901C
EL-250
POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)
YEL902C
EL-251
POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)
YEL903C
EL-252
POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)
YEL904C
EL-253
POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)
YEL905C
EL-254
POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)
YEL906C
EL-255
POWER DOOR LOCK Trouble Diagnoses PRELIMINARY CHECK CHECK-IN 왔
Open all windows and remove key from ignition key cylinder. 왔
Does power door lock operate properly?
No (All doors)
왘
Power door lock does not operate by using; — any switch. ...................................................................... — driver side lock knob switch and/or key cylinder. ...................................................................... — passenger side lock knob switch and/or key cylinder.★
Yes
왘
SYMPTOM 1
왘
SYMPTOM 2
왘
SYMPTOM 3
No (Specific door)
SYMPTOM 4
왔
Insert key to ignition key cylinder, open any door and lock the door using driver side knob lock switch. 왔
Does key reminder system operate properly? 왔
No
왘
SYMPTOM 5
Yes
INSPECTION END
After performing preliminary check, go to symptom chart on the next page. ★ When one or more doors are opened, with lock knob on passenger door setting to LOCK, will lock passenger door only. (Power door lock system will not operate.)
EL-256
POWER DOOR LOCK Trouble Diagnoses (Cont’d) Before starting trouble diagnoses below, perform preliminary check, EL-256. Symptom numbers in the symptom chart correspond with those of Preliminary check.
Power door lock does not operate with lock/unlock switch.
3
Power door lock does not operate with door key cylinder switch.
4
Specific door lock acutator does not operate.
5
*Key reminder system does not operate.
EL-262
EL-263
Procedure 5 (Key switch check)
2
EL-261
Procedure 4 (Door switch check)
Power door lock does not operate using any switch.
EL-260
Procedure 3 (Door lock actuator check)
1
EL-259
Procedure 2 (Door key cylinder switch check)
SYMPTOM
EL-258
Procedure 1 (Door unlock sensor check)
REFERENCE PAGE
Power supply and ground circuit check
SYMPTOM CHART
X
X
X
X X X X
X: Applicable *: Make sure the power door lock and key reminder system operate properly.
EL-257
POWER DOOR LOCK Trouble Diagnoses (Cont’d) POWER SUPPLY AND GROUND CIRCUIT CHECK Main power supply circuit check Time control unit connector
Terminals 䊝 9 쑗
Ignition switch position 䊞
LOCK
ACC
ON
Ground
Battery voltage
Battery voltage
Battery voltage
YEL445B
Ground circuit check Time control unit connector
Terminals 16 쑗
- Ground
YEL431B
EL-258
Continuity Yes
POWER DOOR LOCK Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1 (Door unlock sensor check) Time control unit connector
CHECK DOOR UNLOCK SENSOR INPUT SIGNAL. Check voltage between time control unit connector terminals 쑗 35 or 쑗 36 and ground. Terminals
YEL446B
䊝
Driver side
35 쑗
Passenger side
36 쑗
䊞
Condition
Voltage [V]
Locked
Approx. 2 (Approx. 20 sec.)
Unlocked
0
Locked
Approx. 12 (Approx. 20 sec.)
Unlocked
0
Ground
Ground
OK
왘
Door unlock sensor is OK.
왘
Replace door lock actuator assembly.
YEL027D
NG 왔
CHECK DOOR UNLOCK SENSOR. 1) Disconnect door unlock sensor connector. 2) Check continuity between door unlock sensor terminals. Terminals 2 -쑗 5 쑗
Condition
Continuity
Locked
No
Unlocked
Yes
OK 왔
Check the following: ● Door unlock sensor ground circuit. ● Harness for open or short-circuit between control unit and door unlock sensor
EL-259
NG
POWER DOOR LOCK Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 (Door key cylinder switch check) CHECK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK SIGNAL). Check voltage between time control unit connector terminal 쑗 29 and ground. Key cylinder switch operation
Voltage [V]
Between neutral and lock
0
Unlock/neutral
Approx. 5
OK
왘
Door key cylinder switch is OK.
왘
Replace key cylinder switch.
NG 왔
YEL028D
CHECK DOOR KEY CYLINDER SWITCH. 1) Disconnect door key cylinder switch connector. 2) Check continuity between door key cylinder switch terminals. Terminals
Key cylinder switch Driver side
:
Passenger side: 1 -쑗 2 쑗
YEL817
Key position
Continuity
Neutral
No
Between neutral and lock
Yes
Unlock/ neutral
No
Full stroke (Lock)
No
OK 왔
Check the following: ● Harness connectors B3 , M13 ● Harness connectors M7 , D1 ● Harness connectors B5 , D2 ● Harness connectors B56 , D11 ● Door key cylinder switch ground circuit ● Harness for open or short-circuit between super lock control unit and door key cylinder.
EL-260
NG
POWER DOOR LOCK Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 (Door lock actuator check) CHECK DOOR LOCK ACTUATOR CIRCUIT. Check voltage for door lock actuator. Terminals
Knob lock switch condition YEL029D
䊝
䊞
쑗 42 쑗 44 쑗
Ground
41
Unlock , Lock Lock , Unlock
NG
왘
Door lock actuator is OK.
Voltage (V)
Approx. 12 Ground (Approx. 5 seconds) Ground
Before operating passenger side knob lock switch, close all doors. OK 왔
YEL030D
CHECK DOOR LOCK ACTUATOR. 1. Disconnect door lock actuator connector. 2. Apply 12V direct current to door lock actuator and check operation. Driver side Terminals
Door lock actuator operation
YEL031D
䊝
䊞
Unlocked , Locked
6 쑗
3 쑗
Locked , Unlocked
3 쑗
6 쑗
Passenger side Terminals
Door lock actuator operation
䊝
䊞
Unlocked , Locked
3 쑗
6 쑗
Locked , Unlocked
6 쑗
3 쑗
Rear door LH and RH YEL032D
Terminals
Door lock actuator operation Unlocked , Locked Locked , Unlocked
䊝
䊞
4 : (LH) 쑗 1 : (RH) 쑗 1 : (LH) 쑗 4 쑗 : (RH)
1 : (LH) 쑗 4 : (RH) 쑗 4 : (LH) 쑗 1 쑗 : (RH)
NG 왔
Replace door lock actuator assembly.
EL-261
OK
왘
Check harness between control unit and door lock actuator.
POWER DOOR LOCK Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 (Door switch check) Fuse block (J/B) connector
CHECK DOOR SWITCH INPUT SIGNAL. Check voltage between fuse block (J/B) and ground. Terminals YEL450B
Driver side door
Condition
Voltage [V]
Opened
0
OK
왘
Door switch is OK.
16J
Closed
Approx. 12
Other door
Opened
0
Closed
Approx. 12
7J
NG 왔
YEL033D
CHECK DOOR SWITCH. 1) Disconnect door switch connector. 2) Check continuity between door switch terminals. Terminals 1 - ground 쑗
Condition
Continuity
Closed
No
Open
Yes
OK 왔
Check the following. ● Door switch ground condition ● Harness for open or short between control unit and door switch
EL-262
NG
왘
Replace door switch.
POWER DOOR LOCK Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 (Key switch check) CHECK IGNITION KEY SWITCH INPUT SIGNAL. Check voltage between control unit terminal 쑗 22 and ground. Condition of key switch
Voltage [V]
Key is inserted
Approx. 12
Key withdrawn
0
YEL034D
OK
왘
Key switch is OK.
NG 왔
Key switch connector
CHECK KEY SWITCH POWER SUPPLY. Check voltage between key switch harness terminal 쑗 2 and ground. Battery voltage should exist.
왔
CHECK KEY SWITCH. 1) Disconnect key switch connector. 2) Check continuity between key switch terminals. Terminals
쑗 쑗 1
YEL827
왘
OK
YEL826
Key switch connector
NG
-
Condition
Continuity
Key is inserted.
Yes
Key is withdrawn.
No
2
OK 왔
Check harness for open or short between control unit and key switch.
EL-263
NG
왘
Check the following. ● 10A fuse [No. 16 , located in fuse block (J/B)] ● Harness for open or short between key switch and fuse
Replace key switch.
POWER DOOR LOCK NOTE
EL-264
POWER DOOR LOCK — Super Lock — Component Parts Location
Door key cylinder switch Time control unit
Lock knob
Door switch
Door lock actuator assembly Door lock switch
Door key cylinder switch connector D9 , D17 Fuse block (J/B)
Time control unit B11 , B12 , B96
Door lock actuator assembly D7 , D16
NEL562
EL-265
POWER DOOR LOCK — Super Lock — System Description/Super Lock for RHD Models OUTLINE Power door lock system with super lock and key reminder is controlled by time control unit. Super lock has a higher anti-theft performance than conventional power door lock systems. When super lock is in released condition, lock knob operation locks or unlocks door. When super lock is in set condition; lock knob operation cannot lock nor unlock door. With super lock set
With super lock released
Door key cylinder UNLOCK
LOCK
Door lock knob Door knob rod Lever B
Lever B
UNLOCK
With super lock set, the connecting rod is disengaged from lever B. This enables the linkage to convey operational force from lever B to lever A. The door lock knob can still be operated but this operation does not lock nor unlock door.
Connecting rod
LOCK
Door lock actuator assembly Lever A
Door lock actuator assembly Lever A
SEL831U
OPERATION Power door lock/unlock and super lock set/release operation by door key cylinder ● With the key inserted into front door key cylinder, turning it to LOCK will lock all doors and set super lock while all doors are closed or any door is open. (Super lock will not be set while key is inserted in the ignition key cylinder.) ● With the key inserted into front door key cylinder, turning it to UNLOCK will unlock all doors and release super lock. Power door lock/unlock and super lock set/release operation by multi-remote controller (if equipped) ● Pressing multi-remote controller LOCK button will lock all doors and set super lock while all doors are closed and key is not inserted in the ignition key cylinder. ● Pressing once will release super lock and unlock driver’s door. ● Pressing twice will release super lock and unlock all doors. Power door lock and super lock release operation (by NATS IMMU signal) ● When the super lock is set, turning ignition key switch to ON will release super lock and unlock all doors.
EL-266
POWER DOOR LOCK — Super Lock — System Description/Super Lock for RHD Models (Cont’d) Power door lock/unlock operation by lock knob ● With lock knob on driver or passenger door setting to LOCK while all doors are closed will lock all doors. When one or more door is opened, with lock knob on passenger door setting to LOCK will lock passenger door only. (Power door lock system will not operate.) ● With lock knob on driver or passenger door setting to UNLOCK while all doors are closed will unlock all doors. Lock knob operation cannot control super lock. Key reminder system ● If the ignition key is in the ignition key cylinder and any door is open, setting the lock/unlock switch or lock knob on driver or passenger door to “LOCK” locks the door once but then immediately unlocks all doors.
Central unlock/trunk or back door release switch Signal input Short press
Status Long press
DR
AS
RL
RR
Trunk release
U
U
U
U
Trunk release
Trunk release
U
U
U
L
No action
Trunk release
Trunk release
U
U
L
U
No action
Central unlock (not DR door)
Trunk release
Central unlock (not DR door) + Trunk release
U
U
L
L
DR and AS doors unlocked
Central unlock (not DR door)
Central unlock (not DR door)
Central unlock (not DR door) + Trunk release
Central unlock (not DR door) + Trunk release
U
L
X
X
DR door unlocked, AS door locked
Central unlock
Central unlock
Central unlock + Trunk release
Central unlock + Trunk release
L
L
X
X
Both front doors locked
No action
No action
No action
No action
L
L
L
L
Super locked
Without ultra sonic With ultra sonic
Without ultra sonic With ultra sonic
No action
No action
Trunk release
No action
No action
No action
Fully unlocked
U: Unlocked; L: locked; X: Don’t care
System initialisation ● System initialisation is required when battery cables are reconnected. Conduct one of the followings to release super lock once; — insert the key into ignition key cylinder and turn it to ON. — LOCK/UNLOCK operation using door key cylinder.
EL-267
POWER DOOR LOCK — Super Lock — Schematic
YEL907C
EL-268
POWER DOOR LOCK — Super Lock — Schematic (Cont’d)
UNLOCK
LOCK
RELEASE
UNLOCK
UNLOCK
UNLOCK SENSOR
SET
LOCK
SUPER LOCK ACTUATOR
DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE)
DOOR LOCK ACTUATOR
LOCK UNLOCK SENSOR
RELEASE
UNLOCK
RELEASE
SET
SUPER LOCK ACTUATOR
DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE)
LOCK DOOR LOCK ACTUATOR
SET
UNLOCK
LOCK
RELEASE
SET
UNLOCK
LOCK
UNLOCK
LOCK
SUPER LOCK ACTUATOR
DOOR LOCK ACTUATOR
DOOR LOCK ACTUATOR ASSEMBLY REAR LH
SUPER LOCK ACTUATOR
DOOR LOCK ACTUATOR
DOOR LOCK ACTUATOR ASSEMBLY REAR RH
: 4 door models and 5 door hatchbak models : Wagon models
DOOR LOCK ACTUATOR
DOOR LOCK ACTUATOR ASSEMBLY (BACK DOOR)
YEL325B
EL-269
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK —
YEL908C
EL-270
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d)
YEL909C
EL-271
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d)
YEL910C
EL-272
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d)
EL-S/LOCK-04 TIME CONTROL UNIT
B12 35
36
Y/R
Y/L
Y/L
Y/R B5
B56
1
3
D11
D2 Y/R
Y/L
Y/R
Y/L
5
5 DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE) (UNLOCK SENSOR)
UNLOCK
UNLOCK
D7
LOCK
D16
LOCK
2
2
B
B
B
B D11
D2 4
11 B
1 2 3 4 5 6 7 8 9 10 11 12
DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE) (UNLOCK SENSOR)
B5
B
B
B
B18
B27
B56
B5 W
1 2 3 4 B56 5 6 7 8 9 10 W
1 2 3 4 5 6
D7 B
3 2 1 6 5 4
D16 B
24 23 22 21 20 19 18 17 B12 36 35 34 33 32 31 30 29 28 27 26 25 W
YEL329B
EL-273
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-1 for Super Lock Actuator
YEL911C
EL-274
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-1 for Super Lock Actuator
: RHD models Preceding page Next page
Next page Preceding page
DOOR LOCK ACTUATOR UNLOCK
LOCK
SUPER LOCK ACTUATOR SET
DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE)
DOOR LOCK ACTUATOR LOCK
RELEASE
UNLOCK
SUPER LOCK ACTUATOR
DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE)
RELEASE SET
YEL277C
EL-275
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-1 for Super Lock Actuator
YEL913C
EL-276
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-2 for Super Lock Actuator
YEL914C
EL-277
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-2 for Super Lock Actuator
YEL915C
EL-278
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-2 for Super Lock Actuator
YEL916C
EL-279
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) WAGON MODELS
YEL917C
EL-280
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d)
YEL918C
EL-281
POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d)
YEL919C
EL-282
POWER DOOR LOCK — Super Lock — Trouble Diagnoses PRELIMINARY CHECK CHECK-IN 왔
Open all windows and remove key from ignition key cylinder. 왔
Does power door lock operate properly?
No (All doors)
왘
Power door lock does not operate by using; — any switch. ...................................................................... — driver side lock knob switch and/or key cylinder. ...................................................................... — passenger side lock knob switch and/or key cylinder.★
Yes
왘
SYMPTOM 1
왘
SYMPTOM 2
왘
SYMPTOM 3
No (Specific door) 왔
No (All doors)
Does super lock set by using door key cylinder?
SYMPTOM 4
왘
Super lock does not set by using; — both door key cylinders. ...................................................................... — one of door key cylinders.
Yes
왘
SYMPTOM 5
왘
SYMPTOM 6
No (Specific door) 왔
Does super lock release by using door key cylinder or IGN key switch?
No All doors
SYMPTOM 9
왘
Super lock does not release by using; — one or both door key cylinders. ...................................................................... — IGN key switch. (Signal from NATS IMMU)
Yes
왘
SYMPTOM 7
왘
SYMPTOM 8
No (Specific door)
SYMPTOM 9
왔
Insert key to ignition key cylinder, open any door and lock the door using driver side knob lock switch. 왔
Does key reminder system operate properly? 왔
No
왘
SYMPTOM 10
Yes
INSPECTION END
After performing preliminary check, go to symptom chart on the next page. ★ When one or more doors are opened, with lock knob on passenger door setting to LOCK, will lock passenger door only. (Power door lock system will not operate.)
EL-283
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) Before starting trouble diagnoses below, perform preliminary check, EL-283. Symptom numbers in the symptom chart correspond with those of Preliminary check.
SYMPTOM CHART
X
3
Power door lock does not operate with any switch of passenger side.
X
4
Specific door lock acutator does not operate.
5
Super lock cannot be set by both door key cylinders.
6
Super lock cannot be set by one of door key cylinders.
7
*Super lock cannot be released by one or both door key cylinders.
8
*Super lock cannot be released by ignition key switch. (Signal from NATS IMMU)
9
Specific super lock actuator does not operate.
10
*Key reminder system does not operate.
Procedure 6 (NATS release signal check)
Procedure 5 (Door switch check)
Procedure 8 (Ignition switch “ON” circuit check)
Power door lock does not operate with any switch of driver side.
Procedure 7 (Key switch check)
2
Procedure 4 (Super lock actuator check)
X
Power door lock does not operate using any switch.
EL-288, EL-290, EL-292, EL-294 EL-295 EL-295 289 291 293
Procedure 3 (Door lock actuator check)
X
1
Procedure 2 (Door key cylinder switch check)
Procedure 1 (Door unlock sensor check)
SYMPTOM
EL-285 EL-286 EL-287 Power supply and ground circuit check
REFERENCE PAGE
X
X
X
X X
X
X
X
X X
X
X X
X: Applicable *: Make sure the power door lock and key reminder system operate properly.
EL-284
X
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) POWER SUPPLY AND GROUND CIRCUIT CHECK Main power supply circuit check Time control unit connector
Terminals
Ignition switch position
䊝
䊞
LOCK
ACC
ON
9 쑗
Ground
Battery voltage
Battery voltage
Battery voltage
YEL445B
Ground circuit check Time control unit connector
Terminals 16 쑗
- Ground
YEL431B
EL-285
Continuity Yes
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1 (Door unlock sensor check) Time control unit connector
CHECK DOOR UNLOCK SENSOR INPUT SIGNAL. Check voltage between time control unit connector terminals 쑗 35 or 쑗 36 and ground. Terminals
YEL446B
䊝
Driver side
Door lock actuator assembly connectors Driver side :
35 쑗
䊞
36 쑗
Voltage [V]
Locked
Approx. 2 (Approx. 20 sec.)
Unlocked
0
Locked
Approx. 12 (Approx. 20 sec.)
Unlocked
0
Ground
Passenger side:
Passenger side
Condition
Ground
OK
왘
Door unlock sensor is OK.
왘
Replace door lock actuator assembly.
YEL815
NG 왔
CHECK DOOR UNLOCK SENSOR. 1) Disconnect door unlock sensor connector. 2) Check continuity between door unlock sensor terminals. Terminals 2 -쑗 5 쑗
Condition
Continuity
Locked
No
Unlocked
Yes
OK 왔
Check the following: ● Door unlock sensor ground circuit. ● Harness for open or short-circuit between control unit and door unlock sensor
EL-286
NG
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 (Door key cylinder switch check) CHECK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK SIGNAL). Check voltage between time control unit connector terminal 쑗 29 and ground. Key cylinder switch operation
Voltage [V]
Between neutral and lock
0
Unlock/neutral
Approx. 5
OK
왘
Door key cylinder switch is OK.
왘
Replace key cylinder switch.
NG 왔
YEL028D
CHECK DOOR KEY CYLINDER SWITCH. 1) Disconnect door key cylinder switch connector. 2) Check continuity between door key cylinder switch terminals. Terminals
Key cylinder switch Driver side
:
Passenger side: 1 -쑗 2 쑗
YEL817
Key position
Continuity
Neutral
No
Between neutral and lock
Yes
Unlock/ neutral
No
Full stroke (Lock)
No
OK 왔
Check the following: ● Harness connectors B3 , M13 ● Harness connectors M7 , D1 ● Harness connectors B5 , D2 ● Harness connectors B56 , D11 ● Door key cylinder switch ground circuit ● Harness for open or short-circuit between super lock control unit and door key cylinder.
EL-287
NG
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 — Type-1 for Super Lock Actuator — (Door lock actuator check) CHECK DOOR LOCK ACTUATOR CIRCUIT. Check voltage for door lock actuator. Terminals
Knob lock switch condition YEL029D
Unlock , Lock Lock , Unlock
䊝
䊞
41 쑗 42 쑗 44 쑗
NG
왘
Door lock actuator is OK.
왘
Check harness between control unit and door lock actuator.
Voltage (V)
Ground
Approx. 12 Ground (Approx. 5 seconds) Ground
Before operating passenger side knob lock switch, close all doors. OK 왔
YEL035D
CHECK DOOR LOCK ACTUATOR. 1. Disconnect door lock actuator connector. 2. Apply 12V direct current to door lock actuator and check operation. Driver side Terminals
Door lock actuator operation Unlocked , Locked Locked , Unlocked
䊝
䊞
1 : 쑗 (RHD)
4 : (RHD) 쑗
4 : (RHD) 쑗 1 : (RHD) 쑗
YEL036D
Passenger side Door lock actuator assembly connector
Rear door RH
Rear door LH
Terminals
Door lock actuator operation
䊝
䊞
Unlocked , Locked
4 : (RHD) 쑗 1 : (RHD) 쑗
Locked , Unlocked
1 : (RHD) 쑗 4 : (RHD) 쑗
Rear door YEL820
Terminals
Door lock actuator operation Unlocked , Locked Locked , Unlocked
䊝
䊞
쑗 1 : (RHD) 쑗 3 : (LHD) 쑗 4 쑗 : (RHD)
쑗 4 : (RHD) 쑗 6 : (LHD) 쑗 1 쑗 : (RHD)
6 : (LHD)
왔
3 : (LHD)
NG
Replace door lock actuator assembly.
EL-288
OK
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 — Type-2 for Super Lock Actuator — (Door lock actuator check) CHECK DOOR LOCK ACTUATOR CIRCUIT. Check voltage for door lock actuator. Terminals
Knob lock switch condition YEL029D
LHD model
Door lock actuator assembly connector Driver side:
Unlock , Lock RHD model
Lock , Unlock
䊝 41 쑗 42 쑗 44 쑗
䊞
NG
왘
Door lock actuator is OK.
왘
Check harness between control unit and door lock actuator.
Voltage (V)
Ground
Approx. 12 Ground (Approx. 5 seconds) Ground
Before operating passenger side knob lock switch, close all doors. OK 왔
YEL819
CHECK DOOR LOCK ACTUATOR. 1. Disconnect door lock actuator connector. 2. Apply 12V direct current to door lock actuator and check operation. Driver side Terminals
Door lock actuator operation Unlocked , Locked Locked , Unlocked
䊝
䊞
6 : (LHD) 쑗 1 : (RHD) 쑗 3 : (LHD) 쑗 4 : (RHD) 쑗
3 : (LHD) 쑗 4 : (RHD) 쑗 6 : (LHD) 쑗 1 : (RHD) 쑗
YEL022AA
Passenger side Door lock actuator assembly connector
Rear door RH
Rear door LH
Terminals
Door lock actuator operation Unlocked , Locked Locked , Unlocked
䊝
䊞
3 : (LHD) 쑗 4 : (RHD) 쑗 6 : (LHD) 쑗 1 : (RHD) 쑗
6 : (LHD) 쑗 1 : (RHD) 쑗 3 : (LHD) 쑗 4 : (RHD) 쑗
Rear door YEL820
Terminals
Door lock actuator operation Unlocked , Locked Locked , Unlocked
䊝
䊞
6 : (LHD) 쑗 1 : (RHD) 쑗 3 : (LHD) 쑗 4 : (RHD) 쑗
3 : (LHD) 쑗 4 : (RHD) 쑗 6 : (LHD) 쑗 1 : (RHD) 쑗
왔
NG
Replace door lock actuator assembly.
EL-289
OK
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 — Type-1 for Super Lock Actuator — (Super lock actuator check) Time control unit connector
CHECK SUPER LOCK ACTUATOR CIRCUIT. Check voltage for super lock actuator. Door key cylinder switch condition YEL449B
Terminals
䊝
䊞
Lock (Set)
40 쑗
Ground
Unlock (Released)
44 쑗
Ground
Super lock actuator is OK.
왘
Check harness between control unit and door lock actuator assembly.
Voltage (V)
Approx. 12
OK
RHD model 왔
CHECK SUPER LOCK ACTUATOR. 1. Disconnect door lock actuator assembly connector. 2. Set lever A in lock position. 3. Apply 12V direct current to door lock actuator assembly and check operation. Driver side Super lock actuator operation
Lever B
Terminals
䊝
䊞
Connection from lever A to lever B
Front
Door lock actuator assembly
Released , Set
6 : (RHD) 쑗 3 : (RHD) 쑗
Disconnect
Set , Released
3 : (RHD) 쑗 6 : (RHD) 쑗
Connect
NEF767
Passenger side Door lock actuator assembly connector Passenger side:
왘
Note: Put the system in set condition before checking release signal.
Door lock actuator assembly connector Driver side:
Lock lever A
NG
Super lock actuator operation
RHD model
Terminals
䊝
䊞
Connection from lever A to lever B
Released , Set
3 : (RHD) 쑗 6 : (RHD) 쑗
Disconnect
Set , Released
6 : (RHD) 쑗 3 : (RHD) 쑗
Connect
Rear door NEF768
Door lock actuator assembly connector
Super lock actuator operation
Rear door RH Rear door LH
Released , Set Set , Released
Terminals
䊝
䊞
1 : (LH) 쑗 6 : (RH) 쑗 4 : (LH) 쑗 3 : (RH) 쑗
4 : (LH) 쑗 3 : (RH) 쑗 1 : (LH) 쑗 6 : (RH) 쑗 왔
Connection from lever A to lever B Disconnect Connect
NG
Replace door lock actuator assembly. YEL255A
EL-290
OK
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 — Type-2 for Super Lock Actuator — (Super lock actuator check) Time control unit connector
CHECK SUPER LOCK ACTUATOR CIRCUIT. Check voltage for super lock actuator. Door key cylinder switch condition YEL449B
䊝
䊞
Lock (Set)
40 쑗
Ground
Unlock (Released)
44 쑗
Ground
Lever B Front
Lock Lever A
Super lock actuator operation Released , Set
Door lock actuator assembly
Door lock actuator assembly
Set , Released YEL822
Terminals
䊝
䊞
1 : (LHD) 쑗 6 쑗 : (RHD) 4 : (LHD) 쑗 3 : (RHD) 쑗
4 : (LHD) 쑗 3 쑗 : (RHD) 1 : (LHD) 쑗 6 : (RHD) 쑗
Connection from lever A to lever B Disconnect Connect
Passenger side
LHD model
Door lock actuator assembly connector Passenger side:
Check harness between control unit and door lock actuator assembly.
OK CHECK SUPER LOCK ACTUATOR. 1. Disconnect door lock actuator assembly connector. 2. Set lever A in lock position. 3. Apply 12V direct current to door lock actuator assembly and check operation. Driver side
Lock Lever A
왘
Voltage (V)
왔
Front
Super lock actuator is OK.
Approx. 12
RHD model
Lever B
왘
Note: Put the system in set condition before checking release signal.
Door lock actuator assembly connector Driver side: LHD model
Terminals
NG
RHD model
Super lock actuator operation Released , Set Set , Released
Terminals
䊝
䊞
4 : (LHD) 쑗 3 쑗 : (RHD) 1 : (LHD) 쑗 6 : (RHD) 쑗
1 : (LHD) 쑗 6 쑗 : (RHD) 4 : (LHD) 쑗 3 : (RHD) 쑗
Connection from lever A to lever B Disconnect Connect
Rear door YEL023A
Door lock actuator assembly connector
Super lock actuator operation
Rear door RH Rear door LH
Released , Set Set , Released
Terminals
䊝
䊞
1 : (LH) 쑗 6 : (RH) 쑗 4 : (LH) 쑗 3 : (RH) 쑗
4 : (LH) 쑗 3 : (RH) 쑗 1 : (LH) 쑗 6 : (RH) 쑗 왔
Connection from lever A to lever B Disconnect Connect
NG
Replace door lock actuator assembly. YEL255A
EL-291
OK
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 — With driver door switch type-1 — (Door switch check) Fuse block (J/B) connector
CHECK DOOR SWITCH INPUT SIGNAL. Check voltage between fuse block (J/B) and ground. Terminals
YEL450B
Door switch connector Driver side:
Driver side door
16J
Other door
7J
Condition
Voltage [V]
Opened
0
Closed
Approx. 12
Opened
0
Closed
Approx. 12
OK
왘
Door switch is OK.
NG 왔
YEL831
CHECK GROUND CIRCUIT. 1) Disconnect driver side door switch connector. 2) Check harness continuity between terminal 쑗 2 and ground. Continuity should exist.
Door switch connector Driver side:
NG
왘
Repair harness or connector.
OK 왔
CHECK DOOR SWITCH. 1) Disconnect door switch connector. 2) Check continuity between door switch terminals. Terminals Condition Driver side door switch
Door switch connector Passenger side:
Other door switches
Rear side:
2 -쑗 3 쑗 1 쑗 ground
Continuity
Closed
No
Open
Yes
Closed
No
Open
Yes
OK 왔 YEL830
Check the following. ● Door switch ground condition (Except driver side) ● Harness for open or short between control unit and door switch
EL-292
NG
왘
Replace door switch.
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 — With driver door switch type-2 — (Door switch check) Fuse block (J/B) connector
CHECK DOOR SWITCH INPUT SIGNAL. Check voltage between fuse block (J/B) and ground. Terminals
YEL450B
Driver side door Other door
Condition
Voltage [V]
Opened
0
OK
왘
Door switch is OK.
16J
Closed
Approx. 12
Opened
0
Closed
Approx. 12
7J
NG 왔
YEL033D
CHECK DOOR SWITCH. 1) Disconnect door switch connector. 2) Check continuity between door switch terminals. Terminals 1 - ground 쑗
Condition
Continuity
Closed
No
Open
Yes
OK 왔
Check the following. ● Door switch ground condition ● Harness for open or short between control unit and door switch
EL-293
NG
왘
Replace door switch.
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 6 (NATS release signal check) Time control unit connector
NATS IMMU
No
Does engine start properly?
왘
Check NATS system.
Yes 왔
YEL451B
Time control unit connector
CHECK NATS SIGNAL CIRCUIT. 1) Disconnect control unit connector and NATS IMMU connector. 2) Check continuity between control unit terminal 쑗 26 and NATS IMMU terminal 쑗 3 . Continuity should exist. 3) Check continuity between control unit terminal 쑗 26 and ground. Continuity should not exist.
NG
왘
Repair harness.
OK 왔
CHECK NATS RELEASE SIGNAL. 1) Connect control unit connector and NATS IMMU connector. 2) Check voltage between control unit terminal 쑗 26 and ground. Ignition switch condition
Voltage [V]
LOCK More than 10 seconds after ignition switch turned to “ON” position YEL452B
For 10 seconds after ignition switch turned to “ON” position
OK 왔
Replace super lock control unit.
EL-294
12
Pulse
NG
왘
Check NATS system.
POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 7 (Key switch check) Time control unit connector
CHECK IGNITION KEY SWITCH INPUT SIGNAL. Check voltage between control unit terminal 쑗 22 and ground. Condition of key switch
Voltage [V]
Key is inserted
Approx. 12
Key withdrawn
0
YEL453B
OK
왘
Key switch is OK.
NG 왔
Key switch connector
CHECK KEY SWITCH POWER SUPPLY. Check voltage between key switch harness terminal 쑗 2 and ground. Battery voltage should exist.
왘
OK
YEL826 왔
NG
CHECK KEY SWITCH. 1) Disconnect key switch connector. 2) Check continuity between key switch terminals.
Key switch connector
NG
Terminals
쑗 1
-쑗 2
YEL827
Condition
Continuity
Key is inserted.
Yes
Key is withdrawn.
No
왘
Check the following. ● 10A fuse [No. 16 , located in fuse block (J/B)] ● Harness for open or short between key switch and fuse
Replace key switch.
OK 왔
Check harness for open or short between control unit and key switch.
DIAGNOSTIC PROCEDURE 8 (Ignition switch “ON” circuit check) Terminals Time control unit connector
䊝 1 쑗
Ignition switch position 䊞
OFF
ACC
ON
Ground
0V
0V
Battery voltage
If NG, check the following. ● 10A fuse [No. 26 , located in the fuse block (J/B)] ● Harness for open or short YEL454B
EL-295
MULTI-REMOTE CONTROL SYSTEM System Description The multi-remote control system controls operation of the ● power door lock (and super lock)
OPERATED PROCEDURE Power door lock operation When the following input signals are both supplied: ● Key switch OFF (when ignition key is not inserted in key cylinder); ● door switch CLOSED (when all the doors are closed); The two above signals are already input into time control unit. At this point, time control unit receives a LOCK signal from remote controller. Time control unit locks all doors and set super lock with input of LOCK signal from remote controller. When an UNLOCK signal is sent from remote controller once, driver’s door will be unlocked and release super lock. Then, if an UNLOCK signal is sent from remote controller again, all other door will be unlocked.
Multi-remote controller ID code entry For detailed procedure, refer to “ID Code Entry Procedure” in EL-305.
EL-296
MULTI-REMOTE CONTROL SYSTEM Schematic
IGNITION SWITCH On or START
FUSE
BATTERY
BATTERY (Via fusible link)
FUSE
FUSIBLE LINK
KEY SWITCH
CIRCUIT BREAKER-1
To door lock actuators
TIME CONTROL UNIT
DOOR LOCK ACTUATOR ASSEMBLY (REAR LH)
DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE) UNLOCK
LOCK
UNLOCK SENSOR
FRONT DOOR SWITCH (DRIVER’S SIDE)
FRONT DOOR SWITCH (PASSENGER SIDE)
REAR DOOR SWITCH LH
LOCK
UNLOCK SENSOR
DOOR LOCK ACTUATOR ASSEMBLY (REAR RH)
DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE) UNLOCK
UNLOCK LOCK
UNLOCK SENSOR
UNLOCK
LOCK
UNLOCK SENSOR
TRUNK OR LUGGAGE ROOM LAMP SWITCH
REAR DOOR SWITCH RH
YEL206C
EL-297
MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — IGNITION SWITCH ON or START
BATTERY
Refer to EL-POWER
FUSE BLOCK (J/B)
CIRCUIT BREAKER-1
TIME CONTROL UNIT
INSERTED
KEY SWITCH
WITHDRAWN
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
: This connector is not shown in “HARNESS LAYOUT” of EL section.
YEL207C
EL-298
MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — (Cont’d)
YEL920C
EL-299
MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — (Cont’d)
YEL921C
EL-300
MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — (Cont’d) MODELS WITHOUT SUPER LOCK
YEL922C
EL-301
MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — (Cont’d) MODELS WITH SUPER LOCK
YEL923C
EL-302
MULTI-REMOTE CONTROL SYSTEM Trouble Diagnoses If no doors can not be unlocked by remote controller operation then the following procedure is required. A) Unlock the vehicle by a mechanical key in the drivers door key cylinder. Note: this may cause the alarm to sound. B) Put the key in ignition, turn to ON position for at least five seconds. Assuming the ignition key contains a valid transponder then a signal will be generated by the immobilizer which will disarm the alarm and allow key learn mode to be entered. C) Turn ignition OFF and wait for ten seconds.
SYMPTOM CHART Symptom No doors can be locked or unlocked by remote control operation.
Possible cause 1. Remote controller battery 2. Power door lock system 3. Key switch (insert) 4. Door switch 5. Power supply circuit for time control unit 6. Ground circuit for time control unit 7. Remote controller
The new ID of remote controller cannot be entered.
1. Remote controller battery 2. Key switch (insert) 3. Door switch 4. Driver’s door unlock sensor 5. Ignition ON power supply circuit for time control unit 6. Remote controller
Diagnoses/service order 1. Check remote controller battery. Refer to EL-304. 2. Check that power door lock operates properly. If NG, check power door lock. 3. Check key switch (insert) signal at terminal 쑗 22 of time control unit. 4. Check door switch signal at terminals 쑗 6 and 7 of time control unit. 쑗 5. Make sure battery voltage is present at terminal 9 of time control unit. 쑗 6. Check continuity between terminal 쑗 16 of time control unit and ground. 7. Replace remote controller. Refer to EL-305. 1. Check remote controller battery. Refer to EL-304. 29 2. Check key switch (insert) signal at terminal 쑗 of time control unit. 3. Check door switch signal at terminals 쑗 6 and 7 of time control unit. 쑗 4. Check driver’s door unlock sensor signal at terminal 쑗 35 of time control unit. 5. Make sure battery voltage is present at terminal 1 of time control unit while ignition switch is in 쑗 ON position. 6. Replace remote controller. Refer to EL-305.
Refer to “TIME CONTROL UNIT INSPECTION TABLE” on next page to check the control unit signals. NOTE: ● The unlock operation of multi-remote control system does not activate with key inserted in the ignition key cylinder. ● The lock operation of multi-remote controller does not activate with the key inserted ignition key cylinder or if one of the door is opened.
EL-303
MULTI-REMOTE CONTROL SYSTEM Trouble Diagnoses (Cont’d) TIME CONTROL UNIT INSPECTION TABLE Voltage (V) (approximate values)
Terminal No.
Wire color
1
—
Ignition switch (ON)
Ignition key “ON” position
5
—
Driver door switch
OFF (Closed) , ON (Open)
12V , 0V
7
—
All door switches
OFF (Closed) , ON (Open)
12V , 0V
8
—
Power source (C/B)
—
12V
9
—
Power source (Fuse)
—
12V
16
—
Ground
22
Connections
Operated condition
12V
—
Ignition key switch BR/W (Insert)
12V
Key inserted , key removed from IGNB key cylinder
0V , 12V
Rear door unlock sensors
Rear doors: Locked , Unlocked
12V , 0V
Trunk or luggage room lamp switches
OFF (Closed) , ON (Open)
12V , 0V
25
Y/G
33
R
35
Y/R
Driver door unlock sensor
Driver door: Locked , Unlocked
12V , 0V
36
Y/L
Passenger door unlock sensor
Passenger door: Locked , Unlocked
12V , 0V
REMOTE CONTROLLER BATTERY CHECK Remove battery and measure voltage across battery positive and negative terminals, 䊝 and 䊞. Measuring terminal
Stamped (+) SEL672U
䊝
䊞
Standard value
Battery positive terminal 䊝
Battery negative terminal 䊞
2.5 - 3.0V
Note: Remote controller does not function if battery is not set correctly.
EL-304
MULTI-REMOTE CONTROL SYSTEM ID Code Entry Procedure Activation of the registration mode: The vehicle must have been unlocked by either the multi-remote controller or a transponder OK signal (TPOK) from the vehicle’s immobilizer. Preparation: - Make sure all doors unlock. - Make sure all multi-remote controllers to be registered are available. - Make sure the batteries of all multi-remote controllers are in a good condition. - Make sure all transmitting sources are out of the neighbourhood of the vehicle . - Make sure the battery of the vehicle is in a good condition.
왗
왔
Switch ignition-switch exactly six times from the “LOCK” to the “ON” position within 10 seconds and return the ignition switch to the “LOCK” position (leaving the key in the ignition switch).
왗
왔
NG
After 2 seconds the registration mode is activated. The turn signal lamps will flash twice. OK 왔
Proceed with the registration mode. NOTE The registration mode is operated when: ● The ignition-switch is turned to the “ON” position. ● 4 multi remote controllers have been learned. ● No multi-remote controller or ignition switch input is received within 120 seconds.
Registration mode 왔
Press and hold the “UNLOCK” button of the multi-remote controller.
왗
왔
Press the “LOCK” button 3 times. NEL569 왔
Release the “UNLOCK” button.
If the multi-remote controller code is registered correctly, the turn signal lamp will OK flash once. 왘
왔
Do you want to register another multi-remote controller? (max. 4) No
왗
Yes
왔
After registration of the requested No. of multi-remote controller(s), confirm the ID-code(s) by switching the ignition switch to the “ON” position.
Take the ignition key out of the ignition switch and confirm the functioning of all multi-remote controllers by locking and unlocking the vehicle with each of the multi-remote controllers. 왔
End
EL-305
왘
If the multi-remote controller registration is performed correctly, the turn signal lamp will flash twice.
왗
OK
NG
NG
왘 왖
TIME CONTROL UNIT (TCU) System Description The TCU has the following functions.
INTERIOR LAMP TIMER The interior lamp timer is controlled by the TCU. For further information, refer to “INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS” (EL-130).
IGNITION KEY WARNING CHIME AND LIGHT WARNING CHIME The ignition key and light warning chime are controlled by the TCU. For further information, refer to “WARNING CHIME” (EL-180).
REAR WINDOW DEFOGGER TIMER Ther rear window defogger and door mirror defogger system are controlled by the TCU. For further information, refer to “REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER” (EL-207).
POWER DOOR LOCK (Super Lock) The power door lock (super lock) is controlled by the TCU. For further information, refer to “POWER DOOR LOCK — Super Lock” (EL-265).
MULTI-REMOTE CONTROL SYSTEM The multi-remote control system is controlled by the TCU. For further information, refer to “MULTI-REMOTE CONTROL SYSTEM” (EL-296).
THEFT WARNING SYSTEM The theft warning system is controlled by the TCU. For further information, refer to “THEFT WARNING SYSTEM” (EL-311).
EL-306
TIME CONTROL UNIT (TCU) System Description (Cont’d) FUNCTION ●
The TCU has the following control functions.
Item
Details of control
Direction indicators
Switches the director indicators (Left, Right or All) when the combination switch or hazard switch is operated.
Trailer direction indicator buzzer
Sounds a buzzer during direction indicator operation when towing a trailer.
Light warning buzzer
Sounds warning buzzer when driver’s door is opened with light switch in the 1st or 2nd position and ignition switch “OFF”.
Ignition key warning buzzer
Sounds warning buzzer when driver’s door is opened with key in ignition and the driver door lock knob is moved from the “unlock” position to the “lock” position.
Rear window defogger timer
Turn off rear window defogger and door mirror heater, if equipped, about 15 minutes after the rear window defogger switch is turned “ON”.
Battery saver
Shuts off interior lamp in 30 minutes if any door is left open when ignition switch is “OFF”. The battery saver will reset if ignition switch is cycled or any door is opened or closed.
Interior lamp timer
Keep interior lamp illuminated for about 30 seconds when: driver’s door is unlocked, ● the ignition is switched off, ● driver’s door is opened and then closed. The timer is cancelled, and interior lamp turns off when: ● driver’s door is locked, or ● ignition switch is turned “ON”. ●
Theft warning system
Normal operation
Monitors doors, hood, boot lid, door locks, volumetric sensors (if not excluded), ignition and glass break sensors (wagon) when armed. Flashes the direction indicators and sounds the horn for 30 seconds in case one of the monitored sensors is triggered.
Diagnostic mode
Indicates the last three alarm triggers by flashing the direction indicators.
Central door lock
Centrally locks and unlocks the vehicle
Super lock
Activates and de-activates the super lock system.
EL-307
TIME CONTROL UNIT (TCU) System Description (Cont’d) REAR WINDOW DEFOGGER TIMER The rear window defogger and door mirror defogger system are controlled by the TCU. With the ignition switch in the ON or START position, power is supplied ● to the rear window defogger relay ● to TCU terminal 쑗 1 ● through 10A fuses [No. 5 , located in the fuse block (J/B)]. Ground is supplied to terminal 쑗 14 of the rear window defogger switch through body grounds M6 , M26 and M28 . When the rear window defogger switch is ON, ground is supplied ● through terminal 쑗 16 of the rear window defogger switch ● to TCU terminal 쑗 3 . 13 of the TCU then supplies ground to the rear window defogger relay. Terminal 쑗 With power and ground supplied, the rear window defogger relay is energized to operate rear window defogger and door mirror defogger for about 15 minutes. For further information, refer to REAR WINDOW DEFOGGER DOOR and MIRROR DEFOGGER (EL-207).
IGNITION KEY WARNING BUZZER Ground is supplied to TCU terminal 쑗 6 through front driver’s side door switch when switch is in OPEN position from body ground. With the key in the ignition switch in the ACC or OFF position, and locking the driver’s door from the inside, the warning buzzer will sound.
LIGHT WARNING BUZZER Power is supplied at all times ● through 30A fusible link (letter g , located in the fuse and fusible link box) (LHD models) ● through 15A fuse (No. 66 , located in the fuse and fusible link box) (RHD models) ● to lighting switch terminal 쑗 11 . Power is supplied at all times ● through 7.5A fuse [No. 40 , located in the fuse block (J/B)] ● to warning buzzer terminal 쑗 1 . With the ignition switch in the ON or START position, power is supplied ● through 7.5A fuse [No. 12 , located in the fuse block (J/B)] ● to BCM terminal 쑗 29 . Ground is supplied to TCU terminal 쑗 6 through front driver’s side door switch when switch is in OPEN position from body ground. With the ignition switch in the ACC or OFF position, the driver’s door OPEN, and the lighting switch in the 1st or 2nd position, the warning buzzer will sound.
INTERIOR LAMP TIMER Power is supplied at all times ● through 10A fuse [No. 5 , located in the fuse block (J/B)] ● to interior lamp terminal 쑗 1 With the ignition switch in the ON or START position, power is supplied ● through 10A fuse [No. 26 , located in the fuse block (J/B)] ● to TCU terminal 쑗 1 . When the driver’s door is unlocked, a door is opened and then closed, or the ignition is turned from “ON” 2 for approximately 30 seconds. to “Acc” or “LOCK”, ground is supplied to the interior lamp terminal 쑗 The 30 seconds timer will be cancelled if the ignition switch is turned to “ON”, or the driver’s door is locked.
EL-308
TIME CONTROL UNIT (TCU) Trouble Diagnosis The Timer Control Unit includes software to help during development testing, manufacturing and service. It allows the technician to put it into Diagnostic Mode. In this mode, all switch inputs can be tested for continuity and if so equipped, alarm triggers identified. When the time control unit is in Diagnostic Mode, the control unit tests the component and indicate the result by the hazard lamp flashing. On vehicles with a theft warning system, the TCU will first indicate the source of the last three alarm triggers by flashing the hazard lamp. (Refer to “THEFT WARNING SYSTEM”, EL-311.)
왘
START NOTE: Before entering diagnostic mode, make sure the vehicle is fully unlocked, the ignition is switched off and the hazard switch is off.
왔
Press the rear defogger switch exactly 6 times within 10 seconds.
NG 왗
왔
The hazard lamp flash at 3Hz for 1 second to confirm step I. OK 왔
Within 10 seconds after confirmation of step I, turn the ignition ON, for at least 2 seconds.
NG 왗
왔
The hazard lamp flash at 3Hz for 1 second to confirm step II. OK 왔
Within 10 seconds after confirmation of step II, turn the ignition off, remove the ignition key and press the rear defogger switch for at least 5 seconds.
NG
왔
The hazard lamp flash at 3Hz for 3 seconds to confirm diagnostic mode is entered.
EL-309
TIME CONTROL UNIT (TCU) Trouble Diagnosis (Cont’d) Checks Once in Diagnostic Mode (and after identifying the last three alarm triggers in case a theft warning system is equipped on the vehicle), the following inputs can be tested. USER ACTION
TCU Reaction
COMPONENT TESTED
Driver’s door opened from closed (all other doors closed)
Hazards flash once
Driver’s door open signal
Passenger or rear door opened from closed (all other doors closed)
Hazards flash once
Door open signal for opened door
Driver’s door locked from unlocked
Hazards flash once
Driver’s door status signal
Passenger door locked from unlocked
Hazards flash once
Assist door status signal
Rear doors locked from unlocked (with ultrasonic model)
Hazards flash once
Rear doors status signal
Ultrasonics cancel switch is pressed (with ultrasonic model)
Hazards flash once
U/S cancel signal
Trunk or back door is opened from closed
Hazards flash once
Trunk open signal
Hood is opened from closed (with ultrasonic model)
Hazards flash once
Hood open signal
Hazard switch is pressed from off
Hazards flash once
Hazard switch signal
Turn signal switch is moved to left from off
Hazards flash once
Left turn signal
Turn signal switch is moved to right from off
Hazards flash once
Right turn signal
Key turned to lock position in door
Hazards flash once *
Key cylinder lock switch signal
Lighting switch turned 1st position or 2nd position from off
Hazards flash once
Tail lamp signal
Key put in ignition from out
Hazards flash once
Key in detect signal
Central unlock/Trunk release switch is pressed
Hazards flash once
Central unlock/Trunk release signal
External trunk release switch pressed from off
Hazards flash once
External trunk release switch signal
*) Hazards may flash a second time because of Driver’s door status signal change. The min. delay time between flash actions is 100ms.
In case the system does not operate as described above, check the concerned circuit for open or short. After completion, the Diagnostic Mode can be switched off by pressing the rear defogger switch or by turning the ignition to “ON”. The hazard lamp will flash at 3Hz for 3 seconds to confirm that Diagnostic Mode has been switched off.
EL-310
THEFT WARNING SYSTEM Components Parts and Harness Connector Location Rear door switch RH
Door unlock sensor RH
Trunk room/Luggange room lamp switch
Ultrasonic sub sensor
Ultra sonic sensor Door unlock sensor
Theft warning horn
Front door switch RH
Security indicator light
Rear door switch
Door unlock sensor LH
Ultrasonic cancel switch
Door key cylinder switch Door unlock sensor Front door switch LH
Time control unit Hood switch Theft warning horn relay
Time control unit Hood switch
Theft warning horn
.
.
Trunk room/luggage room lamp switch
Door key cylinder switch
Door unlock sensor Ultrasonic sensor
Ultrasonic cancel switch
Ultrasonic sub sensor
NEL529
EL-311
THEFT WARNING SYSTEM System Description OPERATION FLOW The SECURITY indicator can be operated by both the IMMU (for NATS) and the TCU (for Theft Warning). The flow chart shows both operations. SYSTEM phase
Theft warning (TCU)
NATS (IMMU)
Ignition “ON” Disarmed
Ignition “ACC” or “LOCK” Disarmed
T1 (0.2 sec) T2 (2.4 sec)
Ignition “ACC” or “LOCK” Pressing Ultrasonic Cancel Switch
T3 (6 sec)
T4 (30 sec) Ignition “LOCK” Pre-armed (4/5DR)
f=8Mhz
T4 (30 sec) Ignition “LOCK” Pre-armed (Wagon)
T5 (1 sec) Ignition “LOCK” Armed
Ignition “LOCK” Disarmed
NEL568
EL-312
THEFT WARNING SYSTEM System Description (Cont’d) SETTING THE THEFT WARNING SYSTEM Initial condition (1) Close all doors. (2) Close hood and trunk lid.
Pre-armed phase and armed phase The theft warning system turns into the “pre-armed” phase when hood, trunk lid and all doors are closed and locked by key or multi-remote controller. (The security indicator lamp blinks intermittently for 30 seconds.) After about 30 seconds, the system automatically shifts into the “armed” phase (the system is set).
CANCELING THE SET THEFT WARNING SYSTEM When the following (a) or (b) operation is performed, the armed phase is canceled. (a) Unlock the doors with the multi-remote controller. (b) Insert key in ignition key cylinder and turn it to ON. Then NATS IMMU will send a disarm signal to the time control unit.
ACTIVATING THE ALARM OPERATION OF THE THEFT WARNING SYSTEM Make sure the system is in the armed phase. When the following operation (a) (b) (c) (d) or (e)is performed, the system sounds the horns and flashes the hazard lamp for about 30 seconds. (a) Engine hood, trunk lid or any doors is opened before unlocking door with the multi-remote controller. (b) A door is unlocked without using the multi-remote controller. (c) The ignition is switched ON without using a NATS registered key. (d) The ultra sonic sensing is triggered. (e) A rear side or rear screen breakage is detected (Wagon).
POWER SUPPLY AND GROUND CIRCUIT Power is supplied at all times. ● Through 10A fuse [No. 16 , located in the fuse block (J/B)] ● to security indicator lamp terminal 쑗 2 . Power is supplied at all times ● through 10A fuse [No. 5 , located in the fuse block (J/B)] ● to time control unit terminal 쑗 9 . With the ignition switch in the ON or START position, power is supplied ● through 10A fuse [No. 26 , located in the fuse block (J/B)] ● to time control unit terminal 쑗 1 . Ground is supplied ● to time control unit terminal 쑗 16 . ● through body grounds M6 , M28 and M26 .
INITIAL CONDITION TO ARM THE SYSTEM The operation of the theft warning system is controlled by all the doors, hood and trunk lid. To activate the theft warning system, the time control unit must receive signals indicating all the doors, hood and trunk lid are closed and the doors are locked. 6 or 쑗 7 receives a ground signal from each door switch. When a door is open, time control unit terminal 쑗 When a door is unlocked, time control unit terminal 쑗 25 , 쑗 35 or 쑗 36 receives a ground signal from terminal 5 of each door unlock sensor. 쑗 When the hood is open, time control unit terminal 쑗 32 receives a ground signal ● from terminal 쑗 1 of the hood switch ● through body grounds E11 and E37 . When the trunk lid is open, time control unit terminal 쑗 33 receives a ground signal ● from terminal 쑗 1 of the trunk room lamp switch ● through body grounds B18 and B27 . 33 receives a ground signal When the back door, trunk or tail gate is open, time control unit terminal 쑗 ● from terminal 쑗 1 of the luggage room lamp switch ● through body grounds B48 and D110 .
EL-313
THEFT WARNING SYSTEM System Description (Cont’d) THEFT WARNING SYSTEM ARMING (With key or remote controller used to lock doors) If the key is used to lock doors, time control unit terminal 쑗 29 receives a ground signal ● from terminal 쑗 2 of the key cylinder switch ● through body grounds B18 and B27 . If this signal or lock signal from remote controller is received by the time control unit, the theft warning system will arm automatically. When arming the theft warning system, time control unit terminal 쑗 18 supplies ground intermittently to ter1 of the security indicator lamp. The security lamp will blink intermittently for approximately 30 secminal 쑗 onds (and then blink every 2.6 seconds, due to NATS). Now the theft warning system is in armed phase.
THEFT WARNING SYSTEM ALARM OPERATION The theft warning system is triggered by ● opening a door ● opening the trunk lid or back door ● opening the hood ● unlocking door without using the multi-remote controller ● switching the ignition ON without a NATS registered key ● triggering the ultra sonic sensors ● smashing the back door or rear side quarter window (wagon model only). Once the theft warning system is in armed phase, if the time control unit receives a signal at terminal 쑗 25 , 35 , 36 (door unlock sensor), 6 , 7 (door switch), 33 (trunk room lamp switch or luggage room lamp 쑗 쑗 쑗 쑗 쑗 switch), 쑗 32 (hood switch),쑗 31 (smash sensor) or 쑗 17 (ultra sonic sensor) the theft warning system will be triggered. The hazard lamps flash and the horn sounds intermittently. Power is supplied at all times ● through 10A fuse [No. 16 , located in the fuse block (J/B)]. ● to theft warning relay terminal 쑗 2 . If the theft warning system is triggered, ground is supplied ● from terminal 쑗 43 of the time control unit ● to theft warning relay terminal 쑗 1 . The hazard lamps flash and the horn sounds intermittently. The alarm automatically turns off after 30 seconds but will reactivate if the vehicle is tampered with again, or if the initial cause remains present.
THEFT WARNING SYSTEM ALARM DISARMING The theft warning system alarm operation can be deactivated by either unlocking the vehicle with the remote controller, or turning the ignition to the “ON” position with a registered NATS key.
SMASH SENSOR The smash sensor will trigger the alarm when the rear side or rear screen is broken. There are three windshield protected: 1. Back door window. Sensor circuit is bonded to the glass. 2. Rear side quarter windows (one each side). Sensor circuit is bonded to the glass. All three sensor are wired in series. By breaking any of the three windshields (sensor circuit open), the alarm will sound.
EL-314
THEFT WARNING SYSTEM Schematic
YEL924C
EL-315
THEFT WARNING SYSTEM Wiring Diagram — THEFT —
YEL925C
EL-316
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d)
EL-THEFT-02 TIME CONTROL UNIT
B12 32
21
17
20
Y/B
P
PU
B/Y
P
PU
B/Y
7
2
8
Y/B B57
ULTRASONIC SENSOR
E115
B29
9 Y/B
6
5
4
3
Y
L
SB
G
Y/B
P
Y
L
SB
G
B/Y
1
5
4
3
2
1
6 ULTRASONIC SUB SENSOR
HOOD SWITCH
OPEN
B15
E12 CLOSED
2 B
1 2
E12 GY
B
B
E11
E37
1 2 3 4 5 6
1 2 3 4 5 6 7 8
B29 W
B15 W
1 2 3 4 5 6 7 B57 8 9 10 11 12 13 14 15 16 W
24 23 22 21 20 19 18 17 B12 36 35 34 33 32 31 30 29 28 27 26 25 W
YEL358B
EL-317
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d)
YEL927C
EL-318
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models before VIN - P11U0548750 TIME CONTROL UNIT
To EL-THEFT-01
: 4 door models : 5 door hatchback models THEFT WARNING HORN RELAY
OPEN CLOSED
TRUNK ROOM LAMP SWITCH
OPEN
: 5 door hatchback models and wagon models : Wagon models
LUGGAGE ROOM LAMP SWITCH
CLOSED
THEFT WARNING HORN
YEL213C
EL-319
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models before VIN - P11U0548750
YEL928C
EL-320
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models before VIN - P11U0548750
YEL929C
EL-321
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models after VIN - P11U0548750
YEL930C
EL-322
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models after VIN - P11U0548750
YEL931C
EL-323
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models after VIN - P11U0548750
YEL932C
EL-324
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d)
YEL933C
EL-325
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d)
YEL934C
EL-326
THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d)
YEL935C
EL-327
THEFT WARNING SYSTEM Trouble Diagnoses Alarm Trigger Feedback To verify the last three triggers that activated the theft warning system, the Time Control Unit (TCU) can be switched into Diagnostic Mode (see page EL-309 how to enter Diagnostic Mode). Approximately 2 seconds after the TCU has finished flashing the hazard lamp to confirm that the Diagnostic Mode has been successfully entered, the TCU will generate a short beep indicating the trigger that will be displayed. A single beep means the most recent trigger, three beeps means the oldest trigger. Following each beep or group of beeps, the hazard lamp will flash to indicate the alarm trigger. Source of Alarm Trigger
Number (of flashes)
Driver’s door lock status switch
1
Passenger door lock status switch
2
Rear door lock status switch
3
Ignition line
4
Driver’s door open switch
5
Other door open switch
6
Trunk or back door open switch
8
Hood switch
9
Ultra sonic sensors
10
Smash sensor (Wagon vehicles)
11
In case there have been no alarm triggers, there will be no indicator flashes between the audible signals. After completing the alarm trigger feedback, the TCU will enter Diagnostic Mode as described on page EL-309. Before continuing trouble diagnoses on the next page, perform the checks as mentioned in the table on page EL-310.
EL-328
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) PRELIMINARY CHECK The system operation is canceled by turning the ignition switch to “ON” at any step between START and ARMED in the following flow chart. System phase
왘DISARMED
START Note: Before starting operation check, open front windows. 왔
Turn ignition switch “OFF” and remove the ignition key. “SECURITY” indicator lamp will blink every 2.6 seconds. (NATS)
NG
Refer to NATS trouble diagnosis.
NG
SYMPTOM 1
NG
SYMPTOM 2
왘
OK 왔
Close all doors, hood and trunk lid. 왔
Press the ultrasonic cancel switch. The “SECURITY” indicator lamp will go on for approximately 6 seconds. OK
왔
PRE-ARMED
왔
Lock doors using key or multi-remote controller.
왔
ARMED
왘
왔
For about 30 seconds, “SECURITY” indicator lamp will blink intermittently.
왘
OK 왔
Disarm the system by unlocking the vehicle using the remote controller. Arm the system again without excluding the ultrasonic sensors. 왔
ALARM
왔
NG SYMPTOM 3 Unlock any door without multi-remote controller, activate the 왘 ultra sonic sensors by inserting an object into the vehicle’s interior, or open hood or trunk. ....................................................................................................... NG SYMPTOM 4 Alarm (horn and hazard lamp) will operate. 왘 OK
왔 왘DISARMED
왔
Unlock the vehicle using the multi-remote controller or insert the key in the ignition and switch it to ON. Alarm (horn and hazard lamp) will stop. OK 왔
System is OK.
After performing preliminary check, go to symptom chart on next page.
EL-329
NG
왘
SYMPTOM 5
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) Before starting trouble diagnoses below, perform preliminary check, EL-329. Symptom numbers in the symptom chart correspond with those of Preliminary check.
SYMPTOM CHART
EL-331
EL-331
EL-332
EL-336
EL-337
EL-338
EL-339
EL-340
EL-341
EL-296
EL-342
Power supply circuit check
Ground circuit check
Diagnostic Procedure 1 (Door, hood and trunk room lamp switch check)
Diagnostic Procedure 2 (Security indicator lamp check)
Diagnostic Procedure 3 (Door unlock sensor check)
Diagnostic Procedure 4 (Door key cylinder switch check)
Diagnostic Procedures 5 (Smash sensor check)
Diagnostic Procedure 6 (Theft warning horn alarm check)
Diagnostic procedure 7 (Hazard lamp alarm check)
Check “MULTI-REMOTE CONTROL” system.
Check “NATS (Nissan Anti-Theft system)”.
5
Theft warning system cannot be set by... *1 Theft warning system does not alarm when... Theft warning alarm does not activate.
4
—
X
All items
X
X
X
Door out side key
X
X
X
Multi-remote control
X
X
X
Any door is opened.
X
X
X
Any door is unlocked without using key or multi-remote controller
X
X
X
Glass breakage is deteted (Wagon)
X
X
X
All function
X
X
X
Horn alarm
X
X
X
Hazard lamp
X
X
X
Turning the ignition ON *2
X
X
X
Multi-remote controller
X
X
X
Security indicator does not turn “ON” or blinking.
Theft warning system cannot be canceled by...
3
—
X
SYMPTOM
2
Diagnostic procedure
X
REFERENCE PAGE
1
Power supply and ground circuit check
EL-329
—
Preliminary check
Procedure
X X
X X X
X X
X X
X: Applicable *1: Make sure the system is in the armed phase. *2: Make sure the key is NATS registered.
EL-330
X X X
X
X
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) POWER SUPPLY AND GROUND CIRCUIT CHECK Main power supply circuit check Time control unit connector
Terminals 䊝
Ignition switch position 䊞
OFF
ACC
ON
9 쑗
Ground
Battery voltage
Battery voltage
Battery voltage
1 쑗
Ground
0V
0V
Battery voltage
YEL430B
Ground circuit check Time control unit connector
Terminals 16 쑗
- Ground
YEL431B
EL-331
Continuity Yes
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1-(1) — With driver door switch type-1 — (Door switch check) Fuse block (J/B) connector
YEL829
CHECK DOOR SWITCH INPUT SIGNAL. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between fuse block (J/B) and ground. Terminals
Door switch connector Driver side:
Driver side door Other door
Condition
Continuity
Opened
Yes
OK
왘
Door switch is OK.
16J
Closed
No
Opened
Yes
Closed
No
7J
YEL831
NG 왔
CHECK GROUND CIRCUIT. 1) Disconnect driver side door switch connector. 2) Check harness continuity between terminal 쑗 2 and ground. Continuity should exist.
Door switch connector Driver side:
NG
왘
Repair harness or connector.
OK 왔
CHECK DOOR SWITCH. 1) Disconnect door switch connector. 2) Check continuity between door switch terminals. Door switch connector Passenger side:
Terminals Condition
Rear side:
Driver side door switch
YEL830
Other door switches
2 -쑗 3 쑗 1 쑗
ground
Continuity
Closed
No
Open
Yes
Closed
No
Open
Yes
OK 왔
Check the following. ● Door switch ground condition (Except driver side) ● Harness for open or short between control unit and door switch
EL-332
NG
왘
Replace door switch.
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1-(1) — With driver door switch type-2 — (Door switch check) Fuse block (J/B) connector
YEL829
CHECK DOOR SWITCH INPUT SIGNAL. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between fuse block (J/B) and ground. Terminals Driver side door Other door
Condition
Continuity
Opened
Yes
OK
왘
Door switch is OK.
16J
Closed
No
Opened
Yes
Closed
No
7J
YEL033D
NG 왔
CHECK DOOR SWITCH. 1) Disconnect door switch connector. 2) Check continuity between door switch terminals. Terminals 1 - ground 쑗
Condition
Continuity
Closed
No
Open
Yes
OK 왔
Check the following. ● Door switch ground condition ● Harness for open or short between control unit and door switch
EL-333
NG
왘
Replace door switch.
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1-(2) (Hood switch check) Time control unit connector
YEL457B
Hood switch connector
CHECK HOOD SWITCH INPUT SIGNAL. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between control unit terminal 쑗 32 and ground. Condition
Continuity
Hood is open.
Yes
Hood is closed.
No
OK
왘
Hood switch is OK.
Refer to wiring diagram in EL-317. OK 왔 YEL458B
CHECK HOOD SWITCH. 1. Disconnect hood switch connector. 2. Check continuity between hood switch terminals. Terminals 1 -쑗 2 쑗
Condition
Continuity
Pushed
No
Released
Yes
OK 왔
Check the following. ● Hood switch ground circuit ● Harness for open or short between control unit and hood switch
EL-334
NG
왘
Replace hood switch.
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1-(3) (Trunk room or luggage room lamp switch check) Time control unit connector
YEL459B
Trunk room lamp switch connector Luggage room lamp switch
CHECK TRUNK ROOM OR LUGGAGE ROOM LAMP SWITCH INPUT SIGNAL. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between control unit terminal 쑗 33 and ground. Condition
Continuity
Trunk lid or back door is open.
Yes
Trunk lid or back door is closed.
No
OK
왘
Trunk room or luggage room lamp switch is OK.
Refer to wiring diagram in EL-319. NG 왔
CHECK TRUNK ROOM OR LUGGAGE ROOM LAMP SWITCH. 1. Disconnect trunk room or luggage room lamp switch connector. 2. Check continuity between trunk room lamp switch terminals.
Luggage room lamp switch
Terminals
YEL460B
1 -쑗 2 쑗
Condition
Continuity
Closed
No
Open
Yes
OK 왔
Check the following. ● Trunk room or luggage room lamp switch ground circuit ● Harness for open or short between control unit and trunk room or luggage room lamp switch
EL-335
NG
왘
Replace trunk room or luggage room lamp switch.
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 (Security indicator check) Time control unit connector
YEL461B
CHECK INDICATOR LAMP OUTPUT SIGNAL. 1) Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. 2) Check voltage between control unit terminal 쑗 18 and ground. Battery voltage should exist. Refer to wiring diagram EL-316.
Security indicator connector
OK
왘
Security indicator lamp is OK.
NG Security indicator on dashboard
Security indicator built-in combination meter 왔
CHECK INDICATOR LAMP.
NG
YEL462B
왘
왘
A 쑗
Replace indicator lamp.
OK 왔
CHECK POWER SUPPLY CIRCUIT FOR INDICATOR. 1) Disconnect security indicator connector. 2) Check voltage between indicator terminal 쑗 2 and ground. Battery voltage should exist.
NG
왘
OK
Check the following: 10A fuse [No. 16 , located in the fuse block (J/B)] ● Harness for open or short between security indicator lamp and fuse ●
왔
Check harness for open or short between security indicator and control unit.
A 쑗
왔
CHECK INDICATOR LAMP.
NG
왘
Replace combination meter.
왘
Check the following: 10A fuse [No. 16 , located in the fuse block (J/B)] ● Harness for open or short between combination meter and fuse
OK 왔
YEL037D
CHECK POWER SUPPLY CIRCUIT FOR INDICATOR. 1) Disconnect combination meter connector. 2) Check voltage between indicator terminal 쑗 23 and ground. Battery voltage should exist. 왔
OK
Check harness for open or short between combination meter and control unit.
EL-336
NG
●
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 (Door unlock sensor check) Time control unit connector
YEL463B
CHECK DOOR UNLOCK SENSOR INPUT SIGNAL. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between control unit terminals 쑗 25 , 쑗 35 , 쑗 36 and ground.
OK
왘
Door unlock sensor is OK.
왘
Replace door unlock sensor.
Terminals 䊝
䊞
Driver side door
35 쑗
Ground
Passenger side door
36 쑗
Ground
Rear door
25 쑗
Ground
YEL038D
Condition
Continuity
Locked
No
Unlocked
Yes
Locked
No
Unlocked
Yes
Locked
No
Unlocked
Yes
Refer to wiring diagram in EL-327. NG 왔
CHECK DOOR UNLOCK SENSOR. 1. Disconnect door unlock sensor connector. 2. Check continuity between door unlock sensor terminals. Terminals 2 -쑗 5 쑗
Condition
Continuity
Locked
No
Unlocked
Yes
OK 왔
Check the following: ● Door unlock sensor ground circuit ● Harness for open or short between control unit and door unlock sensor
EL-337
NG
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 (Door key cylinder switch check)
Time control unit connector
CHECK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK SIGNAL). Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between time control unit connector terminal 쑗 29 and ground.
Continuity exists Neutral Unlock Lock
LH side Neutral Unlock
OK
왘
Door key cylinder switch is OK.
왘
Replace key cylinder switch.
Continuity exists
Lock
Key cylinder switch operation
Continuity
Between neutral and lock
Yes
Unlock/neutral
No
NG YEL447B
RH side
왔
CHECK DOOR KEY CYLINDER SWITCH. 1) Disconnect door key cylinder switch connector. 2) Check continuity between door key cylinder switch terminals.
Key cylinder switch Driver side
:
Passenger side:
Terminals
YEL817 1 -쑗 2 쑗
Key position
Continuity
Neutral
No
Between neutral and lock
Yes
Unlock/ neutral
No
Full stroke (Lock)
No
OK 왔
Check the following: ● Harness connectors B3 , M13 ● Harness connectors M7 , D1 ● Harness connectors B5 , D2 ● Harness connectors B56 , D11 ● Door key cylinder switch ground circuit ● Harness for open or short-circuit between super lock control unit and door key cylinder.
EL-338
NG
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 (Smash sensor check) Time control unit connector
YEL457B
1. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. 2. Check harness continuity between control unit terminal 쑗 31 and ground. Continuity should exist.
NG
왘
Check the following. ● Smash sensor circuit for open. ● Harness for open between control unit, smash sensors and ground.
OK 왔
1. Disconnect rear window smash sensor connector. 2. Check harness continuity between control unit and ground. Continuity should not exist. NG
Time control unit connector 왔
Check harness for short between control unit and ground.
NEL546
EL-339
OK
왘
Smash sensor is OK.
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 6 (Theft warning horn alarm check) Time control unit connector
YEL465B
Theft warning horn relay connector
CHECK THEFT WARNING HORN ALARM OPERATION. 1. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. 2. Apply ground to control unit connector terminal 쑗 43 . Does horn alarm activate? Refer to wiring diagram EL-319.
Yes
왘
Horn alarm is OK.
No 왔
Check theft warning horn relay.
NG
왘
Replace.
OK YEL466B
왔
CHECK POWER SUPPLY FOR THEFT WARNING HORN RELAY. 1) Disconnect theft warning horn relay connector. 2) Check voltage between terminal 쑗 2 and ground, and 쑗 3 and ground. Battery voltage should exist.
Theft warning horn relay connector
NG
왘
OK 왔 YEL467B
CHECK THEFT WARNING HORN RELAY CIRCUIT. 1. Disconnect theft warning horn relay connector. 2. Check continuity between theft warning horn relay 쑗 1 and control unit terminal 쑗 43 . Continuity should exist. 3. Check continuity between theft warning horn relay 쑗 5 and theft warning horn connector terminal 1 . 쑗 Continuity should exist. OK 왔
Check harness for open or short between theft warning horn relay and control unit.
EL-340
NG
왘
Check the following: ● 10A fuse (No. 16 , located in the fuse and fusible link box) ● Harness for open or short between theft warning horn relay and fuse
Repair harness.
THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 7 (Hazard lamp alarm check) Push hazard switch to ON. Check hazard lamp operation.
Time control unit connector
OK
왘
Replace time control unit.
NG 왔
NEL561
1. Remove time control unit from fuse block (J/B). Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. 2. Check harness continuity between control unit terminals 쑗 11 and 쑗 15 and ground. Continuity should exist. OK 왔
Replace time control unit.
EL-341
NG
왘
Check the following. ● Harness connectors E104 , B96 ● Fuse block (J/B) ● Turn signal lamps
NATS (Nissan Anti-Theft System) Component Parts Location
YEL039D
EL-342
NATS (Nissan Anti-Theft System) Wiring Diagram — NATS — MODELS BEFORE VIN - P11U0548750 (Type-1) BATTERY
IGNITION SWITCH ON or START
BATTERY
FUSE BLOCK (J/B)
: With gasoline engine : With diesel engine
Refer to EL-POWER.
: With GA engine : With SR engine or QG engine : RHD models AUDIO NATS SECURITY INDICATOR
DONGLE CONTROL UNIT
INJECTION PUMP
: Except
TIME CONTROL UNIT
REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)
YEL216C
EL-343
NATS (Nissan Anti-Theft System) Wiring Diagram — NATS — (Cont’d) MODELS AFTER VIN - P11U0548750 (Type-2)
YEL936C
EL-344
NATS (Nissan Anti-Theft System) System Description NATS has the following immobiliser functions: ● This version of NATS has dongle unit to improve its anti-theft performance (RHD models for Europe). Dongle unit has its own ID which is registered into NATS IMMU. So if dongle unit is replaced, initialization must be carried out. ● When malfunction of dongle unit is detected: The security indicator lamp illuminates for about 15 minutes after ignition switch is turned to ON. − When dongle unit has a malfunction, and the indicator lamp is illuminated, engine can not be started. However engine can be started only one time when security indicator lamp turns off in about 15 minutes after ignition switch is turned to ON. ● Since only NATS ignition keys, whose ID nos. have been registered into the ECM and IMMU of NATS, allow the engine to run, operation of a stolen vehicle without a NATS registered key is prevented by NATS. That is to say, NATS will immobilize the engine if someone tries to start it without the registered key of NATS. ● All of the originally supplied ignition key IDs have been NATS registered. If requested by the vehicle owner, a maximum of five key IDs can be registered into the NATS components. ● The NATS security indicator (NATS security ind.) blinks when the ignition switch is in “OFF” or “ACC” position. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system. ● When NATS detects trouble, the security indicator lamp lights up as follows. Condition IGN ON and
With dongle MIL
Security indicator
—
6 times blinking Staying ON after ignition switch is turned ON
—
Staying ON
—
Staying ON for about 15 minutes after ignition switch is turned ON
—
—
Malfunction of NATS and engine related parts are detected.
Staying ON
6 times blinking Staying ON after ignition switch is turned ON
Staying ON
Staying ON
Only engine related part malfunction is detected.
Staying ON
Staying ON
—
—
—
NATS malfunction (except dongle unit) is detected
Only malfunction of dongle unit is detected.
Just after initialization of NATS ●
●
MIL
Without dongle
—
Security indicator
—
6 times blinking
NATS trouble diagnoses, system initialisation and additional registration of other NATS ignition key IDs must be carried out using CONSULT-II hardware and CONSULT-II NATS software. Regarding the procedures of NATS initialisation and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS. When servicing a malfunction of the NATS (indicated by lighting up of security Indicator Lamp) or registering another NATS ignition key ID no., it may be necessary to re-register original key identification. Therefore, be sure to receive all keys and the PIN code from vehicle owner.
EL-345
NATS (Nissan Anti-Theft System) System Composition The immobiliser function of the NATS for Nissan model P11 consists of the following: ● NATS ignition key ● NATS immobiliser control unit (NATS IMMU), located in the ignition key cylinder ● Engine control module (ECM) ● Dongle unit (RHD models for Europe) ● NATS security indicator ● NATS audio link NATS security ind NATS ignition key
NATS IMMU
ECM
DONGLE UNIT (RHD models for Europe)
AUDIO
NEL558
EL-346
NATS (Nissan Anti-Theft System) Data link connector
CONSULT-II CONSULT-II INSPECTION PROCEDURE 1. Turn ignition switch OFF. 2. Connect “CONSULT-II” to Data link connector.
NRS071
3. Insert NATS program card into CONSULT-II. : Program card NATS (AEN00B) 4. Turn ignition switch ON. 5. Touch “START”.
PBR455D
6. Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual, NATS.
SEL150X
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 is necessary. [NATS ignition key/IMMU/ECM/Dongle]
SELF-DIAGNOSTIC RESULTS
Detected items (screen terms) are as shown in the chart below.
NOTE: When any initialisation is performed, all ID previously registered will be erased and all NATS ignition keys must be registered again. The engine cannot be started with an unregistered key. In this case, the system may show “DIFFERENCE OF KEY” or “LOCK MODE” as a self-diagnostic result on the CONSULT-II screen. When initialisation is performed for RHD models for Europe, security indicator will flash six times to demonstrate recognition of dongle ID.
EL-347
NATS (Nissan Anti-Theft System) CONSULT-II (Cont’d) HOW TO READ SELF-DIAGNOSTIC RESULTS
SEL308W
NATS SELF-DIAGNOSTIC RESULTS ITEM CHART Detected items (NATS program card screen terms)
P No. Code (Self-diagnostic result of “ENGINE”)
Malfunction is detected when ...
Reference page
ECM INT CIRC-IMMU
NATS MALFUNCTION P1613
The malfunction of ECM internal circuit of IMMU communication line is detected.
EL-352
CHAIN OF ECM-IMMU
NATS MALFUNCTION P1612
Communication impossible between ECM and IMMU
EL-353
DIFFERENCE OF KEY
NATS MALFUNCTION P1615
IMMU can receive the key ID signal but the result of ID verification between key ID and IMMU is NG.
EL-355
CHAIN OF IMMU-KEY
NATS MALFUNCTION P1614
IMMU cannot receive the key ID signal. Or the registered ID signal from dongle unit can not be received when the IMMU request the ID.
EL-356
ID DISCORD, IMM-ECM
NATS MALFUNCTION P1611
The result of ID verification between IMMU and ECM is NG. System initialization is required.
EL-358
All engine trouble codes except NATS trouble code have been detected in ECM.
EL-349
When the starting operation is carried out five or more times consecutively under the following conditions, NATS will shift the mode to one which prevents the engine from being started. ● Unregistered ignition key is used. ● IMMU or ECM is malfunctioning.
EL-361
DON’T ERASE BEFORE CHECKING ENG DIAG
LOCK MODE
—
NATS MALFUNCTION P1610
EL-348
NATS (Nissan Anti-Theft System) Trouble Diagnoses WORK FLOW CHECK IN 왔
Listen to customer complaints or request. (Get symptoms) TROUBLE
KEY SERVICE REQUEST (Additional key ID registration) 왔
왔
Verify the security indicator and MI*.
INITIALISATION (Refer to CONSULT-II operation manual NATS.)
왔 왘
Using the CONSULT-II program card for NATS check the “SELF-DIAG RESULTS” with CONSULT-II.
왗
왔
왔
왔
Self-diagnostic results referring to NATS and “DON’T ERASE BEFORE CHECKING ENG DIAG” are displayed on CONSULT-II. (This means that engine trouble data has been detected in ECM.)
왔
Turn ignition switch “OFF”.
Self-diagnostic results referring to NATS, but no information about engine self-diagnostic results is displayed on CONSULT-II.
Turn ignition switch “OFF”.
왔
Repair NATS. (If necessary, carry out “C/U INITIALIZATION” with CONSULT-II.) 왔
Turn ignition switch “ON”.
왔
왔
Erase the NATS “SELF-DIAG RESULTS” by using CONSULT-II. (Touch “ERASE”.)
Do not erase the NATS “SELF-DIAG RESULTS” by using CONSULT-II. 왔
왔
Check the engine “SELF-DIAG RESULTS” with CON왗 SULT-II by using the CONSULT-II generic program card. (Engine diagnostic software included)
Start the engine.
NG
왔
Repair NATS according to self-diagnostic results referring to NATS. (If necessary, carry out “C/U INITIALIZATION” with CONSULT-II.)
왔
Verify no lighting up of the security indicator. 왔
OK
CHECK OUT
왔
Repair engine control system (Refer to EC section.) when self-diagnostic results except “NATS MALFUNCTION” are detected. When only “NATS MALFUNCTION” is detected, erase the self-diagnostic results and go to the next step.
왔
Perform running test with CONSULT-II in engine “SELFDIAG RESULTS” mode.
왔
Start the engine. Does the engine start properly? 왔
왔
NG Verify “NO DTC IS DETECTED” displayed on the CONSULT-II screen. 왔
OK
Erase the NATS and engine “SELF-DIAG RESULTS” by using the CONSULT-II program card for NATS and generic program card.
OK 왔
CHECK OUT Start the engine.
EL-349
NG
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) SYMPTOM MATRIX CHART 1 (Self-diagnosis related item) SYMPTOM ● ●
Security indicator lighting up* Engine does not start
Displayed “SELF-DIAG RESULTS” on CONSULT-II screen ECM INT CIRC-IMMU
CHAIN OF ECM-IMMU
● ●
Security indicator lighting up* Engine does not start
DIFFERENCE OF KEY
CHAIN OF IMMU-KEY
ID DISCORD, IMM-ECM
LOCK MODE ● ●
MI staying ON Security indicator lighting up*
DON’T ERASE BEFORE CHECKING ENG DIAG
DIAGNOSTIC PROCEDURE (Reference page) PROCEDURE 1 (EL-352)
PROCEDURE 2 (EL-353)
PROCEDURE 3 (EL-355)
PROCEDURE 4 (EL-356)
PROCEDURE 5 (EL-358) PROCEDURE 7 (EL-361) WORK FLOW (EL-349)
SYSTEM (Malfunctioning part or mode)
ECM
REFERENCE PART NO. OF ILLUSTRATION ON NEXT PAGE B
Open circuit in battery voltage line of IMMU circuit
C1
Open circuit in ignition line of IMMU circuit
C2
Open circuit in ground line of IMMU circuit
C3
Open circuit in communication line between IMMU and ECM
C4
Short circuit between IMMU and ECM communication line and battery voltage line
C4
Short circuit between IMMU and ECM communication line and ground line
C4
ECM
B
IMMU
A
Unregistered key
D
IMMU
A
Malfunction of key ID chip
E
IMMU
A
Open circuit in ground line of dongle circuit
C6
Open or short circuit in communication line between IMMU and dongle unit
C5
Dongle control unit
G
System initialisation has not yet been completed.
F
ECM
B
LOCK MODE
D
Engine trouble data and NATS trouble data have been detected in ECM.
—
*: When NATS detects trouble, the security indicator lights up while ignition key is in the “ON” position. *: When the vehicle is equipped with dongle unit (RHD models for Europe), the security indicator blinks 6 times just after ignition switch is turned to ON. Then the security indicator lights up while ignition key is in the “ON” position.
EL-350
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) SYMPTOM MATRIX CHART 2 (Non self-diagnosis related item) DIAGNOSTIC PROCEDURE (Reference page)
SYMPTOM
REFERENCE PART NO. OF ILLUSTRATION ON NEXT PAGE
SYSTEM (Malfunctioning part or mode) Security ind.
●
Open circuit between Fuse and NATS IMMU
PROCEDURE 6 (EL-360)
Security ind. does not light up.
Continuation of initialization mode NATS IMMU Security ind. does not blink just after initialization even if the vehicle is equipped with dongle unit.
NATS might be initialized without connecting dongle unit properly.
PROCEDURE 8 (EL-362)
Security ind. does not blink just after ignition switch is turned to ON when some malfunction related to NATS is detected even if the vehicle is equipped with dongle unit.
Open circuit in ground line of dongle circuit
C6
Open or short circuit in communication line between IMMU and dongle unit
C5
Dongle control unit
G
DIAGNOSTIC SYSTEM DIAGRAM PART D
Key ID chip (PART E)
Security indicator
PART C2 PART C1
PART C5 PART C4
NATS ignition key
PART G
PART A
PART B
PART F PART C6
PART C3
NEL559
EL-351
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1 Self-diagnostic results: “ECM INT CIRC-IMMU” displayed on CONSULT-II screen Confirm SELF-DIAGNOSTIC RESULTS “ECM INT CIRC-IMMU” displayed on CONSULT-II screen. Ref. part No. B. 왔
Replace ECM.
SEL314W
왔
Perform initialisation with CONSULT-II. For the operation of initialisation, refer to “CONSULT-II operation manual NATS”.
EL-352
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 SELF DIAGNOSIS DTC RESULTS
Self-diagnostic results: “CHAIN OF ECM-IMMU” displayed on CONSULT-II screen
TIME
CHAIN OF ECM-IMMU
0
Confirm SELF-DIAGNOSTIC RESULTS “CHAIN OF ECMIMMU” displayed on CONSULT-II screen. OK YEL471B 왔
CHECK POWER SUPPLY CIRCUIT FOR IMMU. Check voltage between IMMU terminal 8 and ground. 쑗 Battery voltage should exist.
IMMU connector
NG
왘
OK
YEL472B
왔
CHECK IGN SW. ON SIGNAL. Check voltage between IMMU terminal 7 and ground while ignition switch is 쑗 “ON” position. Battery voltage should exist.
IMMU connector
NG
왘
OK
왔 YEL473B
CHECK GROUND CIRCUIT FOR IMMU. Check continuity between IMMU terminal 쑗 4 and ground. Continuity should exist.
Check the following. 10A fuse [No. 12 , located in the fuse block (J/B)] ● Harness for open or short between fuse and IMMU connector Ref. part No. C2 ●
왘
Repair harness. Ref. part No. C3
왘
Repair harness. Ref. part No. C4
OK
IMMU connector 왔
YEL474B
CHECK COMMUNICATION OPEN CIRCUIT. Check continuity between IMMU termi116 (Gasonal 쑗 1 and ECM terminal line engine) or 410 (Diesel engine). Continuity should exist. OK 왔
ECM connector
NG
Check the following. 10A fuse (No. 39 : gasoline engine, located in the fuse and fusible link box) ● Harness for open or short between fuse and IMMU connector Ref. part No, C1 ●
IMMU connector
A 쑗
NEL762
EL-353
NG
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) A 쑗
IMMU connector
왔
CHECK COMMUNICATION LINE SHORT CIRCUIT. 1. Disconnect ECM connector and IMMU connector. 2. Check continuity between IMMU terminal 쑗 1 and ground. Continuity should not exist. 3. Turn ignition switch to ON. 4. Check voltage between IMMU terminal 쑗 1 and ground. No voltage should exist.
Short to ground check
IMMU connector
NG
왘
Repair harness. Ref. part No. C4
OK 왔
Short to power circuit check YEL476B
Check the signal from ECM to IMMU. 1. Check the signal between ECM terminal 쑗 116 and ground with CONSULT-II or oscilloscope when ignition switch is turned ON. 2. Some signals can be detected during 750 msec. just after ignition switch is turned “ON”. OK 왔
IMMU is malfunctioning. 1. Replace IMMU. Ref. part No. A 2. Perform initialization with CONSULTII. For the initialization procedure, refer to “CONSULT-II operation manual NATS”.
NEL543
EL-354
NG
왘
ECM is malfunctioning. 1. Replace ECM. Ref part No. B 2. Perform initialization procedure, refer to “CONSULT-II operation manual NATS”.
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 SELF DIAGNOSIS DTC RESULTS
Self-diagnostic results: “DIFFERENCE OF KEY” displayed on CONSULT-II screen
TIME
DIFFERENCE OF KEY
0
Confirm SELF-DIAGNOSTIC RESULTS “DIFFERENCE OF KEY” displayed on CONSULT-II screen. OK 왔
YEL478B
PERFORM INITIALISATION. Perform initialisation with CONSULT-II. Re-register all NATS ignition key IDs. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”. Can the system be initialized? Note: If the initialisation is not completed or fails, CONSULT-II shows message on the screen.
IMMU INITIALIZATION
INITIALIZATION FAIL
THEN IGN KEY SW ‘OFF’ AND ‘ON’, AFTER CONFIRMING SELF-DIAG AND PASSWORD, PERFORM C/U INITIALIZATION AGAIN.
Yes YEL479B
왔
Start engine. 왔
END (Ignition key ID had been unregistered.)
EL-355
No
왘
IMMU is malfunctioning. 1. Replace IMMU. Ref. part No. A 2. Perform initialisation with CONSULT-II. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”. ●
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 SELF DIAGNOSIS DTC RESULTS
CHAIN OF IMMU-KEY
Self-diagnostic results: “CHAIN OF IMMU-KEY” displayed on CONSULT-II screen
TIME
0
Confirm SELF-DIAGNOSTIC RESULTS “CHAIN OF IMMUKEY” displayed on CONSULT-II screen. OK YEL480B
왔
CHECK NATS IGNITION KEY ID CHIP. Can the engine start with another registered NATS ignition key?
Yes
왘
No
왔
CHECK NATS IMMU INSTALLATION. Refer to “How to Replace NATS IMMU” in EL-363.
NG
왘
Ignition key ID chip is malfunctioning. 1. Replace the ignition key. Ref. part No. E 2. Perform initialisation with CONSULT-II. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”. ●
Reinstall NATS IMMU correctly.
OK 왔
Is this vehicle equipped with dongle unit (RHD models for Europe)? Yes
왔
A 쑗
EL-356
No
왘
IMMU is malfunctioning. 1. Replace IMMU. Ref part No. A 2. Perform initialisation with CONSULT-II For the initialisation procedure, refer to “CONSULT-II operation manual NATS”.
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) A 쑗
Dongle unit connector
왔
CHECK HARNESS CONNECTOR CONNECTION. Check the following harness connector connection. E125 / M70
Yes
왘
System is OK. (The malfunction is caused by improper connector connection.)
M85 SEL417W
Does the engine start? No 왔
IMMU connector
Dongle unit connector
CHECK GROUND CIRCUIT FOR DONGLE UNIT. Check continuity between dongle unit terminal 쑗 3 and ground. Continuity should exist.
No
왘
Repair harness.
Yes 왔 Short circuit check
SEL418W
IMMU connector
CHECK INTERFACE CIRCUIT. 1. Check continuity between IMMU terminal 쑗 2 and dongle unit terminal 5 (Open circuit check) 쑗 Continuity should exist. 2. Check continuity between IMMU terminal 쑗 2 and ground. (Short circuit check) Continuity should not exist. Yes 왔
Short circuit check SEL419W
Dongle unit is malfunctioning. 1. Replace dongle unit. 2. Perform initialisation with CONSULTII. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”.
EL-357
No
왘
Repair harness.
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 Self-diagnostic results: “ID DISCORD, IMM-ECM” displayed on CONSULT-II screen Confirm SELF-DIAGNOSTIC RESULTS “ID DISCORD, IMMECM*” displayed on CONSULT-II screen.
C2SDD01
왔
PERFORM INITIALISATION. Perform initialisation with CONSULT-II. Re-register all NATS ignition key IDs. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”. Can the system be initialized? Note: If the initialisation is not completed or fails, CONSULT-II message on the shows screen.
IMMU INITIALIZATION
INITIALIZATION FAIL
THEN IGN KEY SW ‘OFF’ AND ‘ON’, AFTER CONFIRMING SELF-DIAG AND PASSWORD, PERFORM C/U INITIALIZATION AGAIN.
Yes YEL479B
왔
Start engine. (END) (System initialisation was not completed. Ref. part No. F)
EL-358
* “ID DISCORD, IMM-ECM”: Registered ID of IMMU is in discord with that of ECM.
No
왘
● ECM is malfunctioning. 1. Replace ECM. Ref. part No. B 2. Perform initialisation with CONSULT-II. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”.
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 6 — With security indicator on dashboard — “SECURITY INDICATOR LAMP DOES NOT LIGHT UP”
Security indicator lamp connector
Check 10A fuse [No. 16 , located in the fuse block (J/B)].
NG
왘
Replace fuse.
OK 왔
YEL482B
IMMU connector
NATS INITIALISATION 1) Install the 10A fuse. 2) Perform initialisation with CONSULT-II. For the operation of initialisation, refer to “CONSULT-II operation manual NATS”. 왔
Turn ignition switch “OFF”. 왔 YEL483B
Start engine and turn ignition switch “OFF”. 왔
Check the security ind. lighting.
OK
왘
INSPECTION END
NG 왔
Check voltage between security indicator lamp connector terminal 쑗 2 and ground. Voltage: Battery voltage
NG
왘
Check harness for open or short between fuse and security indicator lamp.
OK 왔
CHECK INDICATOR LAMP.
NG
왘
Replace indicator lamp.
OK 왔
CHECK NATS IMMU FUNCTION. 1. Connect NATS IMMU connector. 2. Disconnect security indicator lamp connector. 3. Check continuity between NATS IMMU terminal 쑗 6 and ground. Continuity should exist intermittently. OK
왔
Check harness for open or short between security indicator and NATS IMMU.
EL-359
NG
왘
NATS IMMU is malfunctioning. Replace IMMU. 왔
Perform initialisation with CONSULT-II. For the operation of initialisation, refer to “CONSULT-II operation manual NATS”.
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 6 — With security indicator built-in combination meter — “SECURITY INDICATOR LAMP DOES NOT LIGHT UP” Check 10A fuse [No. 16 , located in the fuse block (J/B)].
NG
왘
Replace fuse.
OK 왔 YEL037D
IMMU connector
NATS INITIALISATION 1) Install the 10A fuse. 2) Perform initialisation with CONSULT-II. For the operation of initialisation, refer to “CONSULT-II operation manual NATS”. 왔
Turn ignition switch “OFF”.
YEL483B
왔
Start engine and turn ignition switch “OFF”. 왔
Check the security ind. lighting.
OK
왘
INSPECTION END
NG 왔
Check voltage between combination meter connector terminal 쑗 2 and ground. Voltage: Battery voltage
NG
왘
Check harness for open or short between fuse and combination meter.
OK 왔
CHECK INDICATOR LAMP.
NG
왘
Replace combination meter.
왘
NATS IMMU is malfunctioning. Replace IMMU.
OK 왔
CHECK NATS IMMU FUNCTION. 1. Connect NATS IMMU connector. 2. Disconnect combination meter connector. 3. Check continuity between NATS IMMU terminal 쑗 6 and ground. Continuity should exist intermittently. OK
왔
Check harness for open or short between combination meter and NATS IMMU.
EL-360
NG
왔
Perform initialisation with CONSULT-II. For the operation of initialisation, refer to “CONSULT-II operation manual NATS”.
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 7 SELF DIAGNOSIS DTC RESULTS
Self-diagnostic results: “LOCK MODE” displayed on CONSULT-II screen
TIME
LOCK MODE
0
Confirm SELF-DIAGNOSTIC RESULTS “LOCK MODE” is displayed on CONSULT-II screen. 왔 YEL484B
IMMU INITIALIZATION
INITIALIZATION FAIL
THEN IGN KEY SW ‘OFF’ AND ‘ON’, AFTER CONFIRMING SELF-DIAG AND PASSWORD, PERFORM C/U INITIALIZATION AGAIN.
1. Turn the ignition switch to OFF position. 2. Turn the ignition key switch to ON position with a registered key. (Do not start engine.) Wait for 5 seconds. 3. Return the key to the OFF position. 4. Repeat steps 2 and 3 twice (total of three cycles). 5. Start the engine. Can the engine start?
Yes
왘
System is OK. (Now the system is escaped from “LOCK MODE”.)
No YEL479B
왔
CHECK NATS IMMU INSTALLATION. Refer to “How to Replace NATS IMMU” in EL-363.
NG
왘
Reinstall NATS IMMU correctly.
OK 왔
PERFORM INITIALISATION. Perform initialisation with CONSULT-II. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”. Can the system be initialized? Note: If the initialisation is incompleted or failed, CONSULT-II shows message on the screen. No 왔
Go to DIAGNOSTIC PROCEDURE 4, EL-356 to check “CHAIN OF IMMUKEY”.
EL-361
Yes
왘
System is OK.
NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 8 Perform initialization with CONSULT-II Check the following harness connector connection. E125 / M70
Dongle unit connector
Yes
왘
System is OK. (The malfunction is caused by improper connector connection.)
M85
SEL417W
Then initialize NATS. For the operation of initialization, refer to “CONSULT-II operation manual NATS”. Does the security indicator blink just after the initialization? No 왔
IMMU connector
Dongle unit connector
CHECK GROUND CIRCUIT FOR DONGLE UNIT. Check continuity between dongle unit terminal 쑗 3 and ground. Continuity should exist.
No
왘
Repair harness.
Yes 왔 Short circuit check
SEL418W
IMMU connector
CHECK INTERFACE CIRCUIT. 1. Check continuity between IMMU terminal 쑗 2 and dongle unit terminal 5 (Open circuit check) 쑗 Continuity should exist. 2. Check continuity between IMMU terminal 쑗 2 and ground. (Short circuit check) Continuity should not exist. Yes 왔
Short circuit check SEL419W
Dongle unit is malfunctioning. 1. Replace dongle unit. 2. Perform initialisation with CONSULTII. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”.
EL-362
No
왘
Repair harness.
NATS (Nissan Anti-Theft System) NVIS (NATS) IMMU
How to Replace NATS IMMU NOTE: ● If NATS IMMU is not installed correctly, NATS system will not operate properly and SELF-DIAG RESULTS on CONSULT-II screen will show “LOCK MODE” or “CHAIN OF IMMU-KEY”.
SEL096WA
EL-363
NATS (Nissan Anti-Theft System) NOTE
EL-364
LOCATION OF ELECTRICAL UNITS Engine Compartment Front wiper motor (LHD models)
Front wiper motor (RHD models)
Relay box ABS actuator and electric unit (Control unit)
Fusible link and fuse box
Glow relay (CD engine models)
Headlamp relay LH Horn relay Cooling fan relay-3 ECM relay
Cooling fan relay-1 Cooling fan relay-2 or power fuse
Accessory relay Glow relay (CD engine models)
Park/Neutral position relay Air conditioner relay Rear wiper relay Headlamp relay RH Front wiper relay YEL234C
EL-365
LOCATION OF ELECTRICAL UNITS Passenger Compartment LHD MODELS
NATS IMMU Auto level control unit Headlamp washer timer
Daytime light control unit
Indicator control unit
Stop lamp switch
Time control unit
Fuse block (J/B) Time control unt
Blower relay Circuit breaker-1
Ignition relay
Circuit breaker-2
Theft warning horn relay
Air bag diagnosis sensor unit TCM (Transmission control module)
Fuse block (J/B) Rear window defogger relay Power window relay
ECM A/C LOW relay, A/C MED-LOW relay, A/C MED-HIGH relay, A/C HIGH relay
Front fog lamp relay Fuel pump relay YEL235C
EL-366
LOCATION OF ELECTRICAL UNITS Passenger Compartment (Cont’d) RHD MODELS
Headlamp washer timer
NATS IMMU Indicator control unit
Stop lamp switch
Auto level control unit
Time control unit
Fuse block (J/B) Time control unit
Ignition relay Circuit breaker-1 Blower relay
Circuit breaker-2 Theft warning horn relay Air bag diagnosis sensor unit
Fuse block (J/B)
TCM (Transmission control module) ECM A/C LOW relay. A/C MED-LOW relay. A/C MED-HIGH relay. A/C HIGH relay
Fuel pump relay Front fog lamp relay Power window relay Rear window defogger relay
YEL236C
EL-367
HARNESS LAYOUT Outline
LHD MODELS
Room lamp harness
Rear door harness RH (5-door Hatchback and Wagon)
Back door harness
Front door harness RH Main harness
Hatchback and Wagon
Rear door harness LH (5-door Hatchback and Wagon) Tail harness Tail sub harness Tail harness No. 2 Rear door harness RH Body harness Front door harness LH Console harness Engine room harness Air conditioner harness Engine control harness
Sedan Rear door harness LH Body harness Console harness YEL367B
RHD MODELS Rear door harness RH (5-door Hatchback and Wagon)
Room lamp harness Back door harness
Front door harness RH Main harness
Hatchback and Wagon Rear door harness LH (5-door Hatchback and Wagon) Tail harness Tail sub harness Tail harness No. 2 Rear door harness RH Body harness Front door harness LH Console harness Engine room harness Air conditioner harness Engine control harness
Sedan Rear door harness LH Body harness Console harness
EL-368
YEL237C
HARNESS LAYOUT How to Read Harness Layout Example: G2
E1
B/6
: ASCD ACTUATOR
Connector color / Cavity Connector number Grid reference
The following Harness Layouts use a map style grid to help locate connectors on the drawings: ● Engine Room Harness (Engine Compartment) ● Main Harness ● Body Harness To 1) 2) 3) 4) 5)
use the grid reference Find the desired connector number on the connector list. Find the grid reference. On the drawing, find the crossing of the grid reference letter column and number row. Find the connector number in the crossing zone. Follow the line (if used) to the connector.
CONNECTOR SYMBOL Main symbols of connector (in Harness Layout) are indicated in the below. Connector type
●
Cavity: Less than 4 Relay connector
●
Cavity: From 5 to 8
●
Cavity: More than 9
●
Ground terminal etc.
●
Water proof type Male
Female
—
—
Standard type Male
—
EL-369
Female
HARNESS LAYOUT Engine Control Harness QG ENGINE
YEL957C
EL-370
HARNESS LAYOUT Engine Control Harness (Cont’d)
YEL958C
EL-371
HARNESS LAYOUT Engine Control Harness (Cont’d) SR20DE ENGINE
YEL959C
EL-372
HARNESS LAYOUT Engine Control Harness (Cont’d)
YEL960C
EL-373
CD20T ENGINE
Body ground
Engine ground
LHD models
Be sure to connect and lock the connectors securely after repair work. Failure to do so may cause the ECM to have diagnostic trouble codes. Do not disconnect these connectors except in the case of working according to WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.
HARNESS LAYOUT Engine Control Harness (Cont’d)
EL-374
RHD models
YEL243C
HARNESS LAYOUT Engine Control Harness (Cont’d)
YEL962C
EL-375
HARNESS LAYOUT Engine Room Harness ENGINE COMPARTMENT — LHD models
YEL963C
EL-376
HARNESS LAYOUT Engine Room Harness (Cont’d)
YEL964C
EL-377
HARNESS LAYOUT Engine Room Harness (Cont’d) ENGINE COMPARTMENT — RHD models
YEL965C
EL-378
HARNESS LAYOUT Engine Room Harness (Cont’d)
YEL966C
EL-379
HARNESS LAYOUT Engine Room Harness (Cont’d) PASSENGER COMPARTMENT — LHD models
YEL967C
EL-380
HARNESS LAYOUT Engine Room Harness (Cont’d) PASSENGER COMPARTMENT — RHD models
YEL968C
EL-381
HARNESS LAYOUT Main Harness LHD MODELS
YEL969C
EL-382
HARNESS LAYOUT Main Harness (Cont’d)
YEL970C
EL-383
HARNESS LAYOUT Main Harness (Cont’d) RHD MODELS
YEL971C
EL-384
HARNESS LAYOUT Main Harness (Cont’d)
YEL972C
EL-385
★
Be sure to connect and lock the connectors securely after repair work. Failure to do so may cause the ECM to have diagnostic trouble codes. Do not disconnect these connectors except in the case of working according to WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.
Body ground
HARNESS LAYOUT
Body ground
Body Harness
EL-386 Body ground
SEDAN — LHD models before VIN - P11U0548750
.
YEL253C
Body harness B3 B4 B5 B8 B11 B12 B15 B16 B17 B18 B19 B20 B21 B22 B24 B26 B27 B28 B29 B30 B31 B32 B33 B34 B37 B38 B40 B47 B50 B51 B52 B53 B54 B56 B57 B58 B59 B61 B65 B66 B67 B68
YEL254C
B69 B70
W/24 W/6 W/12 BR/16 W/8 W/20 W/6 W/8 W/4 — BR/1 B/3 W/3 W/2 B/1 W/4 — W/8 W/8 GY/2 GY/3 GY/2 BR/2 BR/1 B/2 BR/1 B/2 W/16 B/1 W/2 W/4 W/8 W/8 W/10 W/16 W/12 B/1 W/3 — Y/12 Y/12 Y/2 Y/2 OR/2
: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
To M13 To M14 To D2 Fuse block (J/B) Time control unit Time control unit Ultra sonic sub-sensor To D22 Seat belt pre-tensioner (Passenger side) Body ground Front door switch (Passenger side) Front door switch (Driver’s side) Heated seat LH Power seat Parking brake switch Seat belt pre-tensioner (Driver’s side) Body ground To D18 Ultra sonic sensor Fuel pump Fuel level sensor unit Rear wheel sensor RH Rear wheel sensor LH Rear door switch RH Rear speaker RH Rear door switch LH Rear speaker LH CD auto changer High mounted stop lamp Trunk room lamp Rear wiper motor To T1 To T14 To D11 To E115 To B101 Rear window defogger Heated seat RH Body ground Diagnosis sensor unit Diagnosis sensor unit Side air bag module LH Side air bag module RH Satellite sensor LH
D2 D2 B1 A3 A3 A1 C3 C2 C4 C4 B2 D4 F3
B71 B72 B97 B98 B99 B121 B122 B123 B124 B130 B131 B132 B133
Y/2 — B/2 L/4 GY/2 W/6 W/3 W/12 W/3 W/3 −/3 W/3 −/3
: : : : : : : : : : : : :
Satellite sensor RH Body ground Fuse block (J/B) Theft warning horn relay Circuit breaker-2 Central unlock/trunk release switch To B130 Auto level control unit To B132 To B122 Front sensor To B124 Rear sensor
Console harness C2 C2 B3 C2 C2
B101 B102 B104 B105 B106
W/12 W/6 L/4 W/4 W/4
: : : : :
To B58 Ultrasonic cancel switch Heated seat switch LH Heated seat switch RH Headlamp aiming switch
: : : : : : : : : :
To B53 Rear combination lamp LH Body ground Body ground Rear combination lamp RH Theft warning horn License plate lamp LH Not used (To trailer tow connection) Link License plate lamp RH
Tail harness E3 F4 F3 G3 G3 G2 F4 D4 E4 F3
T1 T2 T3 T4 T5 T6 T9 T17 T18 T19
W/8 W/4 — — W/4 B/1 BR/2 BR/4 BR/4 BR/2
Tail harness No. 2 F3 F4 G3 G2 G2 G3
T7 T8 T10 T12 T13 T20
W/8 W/2 B/2 W/4 W/2 W/3
: : : : : :
To T16 Rear fog lamp Trunk room lamp switch Door unlock actuator assembly (Trunk) Back-up lamp External trunk release switch
Tail sub-harness E4 E4
T14 T16
W/8 W/8
: :
To B54 To T7
HARNESS LAYOUT Body Harness (Cont’d)
EL-387
A3 A2★ A1 B2 A1 A1 D1 E1 E2 E1 D2 B3 B4 C4 C2 B4 B2 B2 B3 D4 D4★ E3 D4 E1 F2 D3 E2 D2 F2 F3 F3 E3 E3 C1 C1 C2 D1 D3 B3 C3 C3 B4 D3 B4
HARNESS LAYOUT Body Harness (Cont’d) SEDAN — LHD models after VIN - P11U0548750
YEL973C
EL-388
HARNESS LAYOUT Body Harness (Cont’d)
YEL974C
EL-389
Body ground
Body ground
.
★
Be sure to connect and lock the connectors securely after repair work. Failure to do so may cause the ECM to have diagnostic trouble codes. Do not disconnect these connectors except in the case of working according to WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.
HARNESS LAYOUT Body Harness (Cont’d)
SEDAN — RHD models before VIN - P11U0548750
EL-390 Body ground
YEL255C
Body harness B3 B4 B5 B8 B11 B12 B15 B16 B17 B18 B19 B20 B21 B22 B24 B26 B27 B28 B29 B30 B31 B32 B33 B34 B37 B38 B40 B47 B50 B51 B52 B53 B54 B56 B57 B58 B59 B61 B65 B66 B67 B68
YEL256C
B69 B70
W/24 W/6 W/12 BR/16 W/8 W/20 W/6 W/8 W/4 — BR/1 B/3 W/3 W/2 B/1 W/4 — W/8 W/8 GY/2 GY/3 GY/2 BR/2 BR/1 B/2 BR/1 B/2 W/16 B/1 W/2 W/4 W/8 W/8 W/10 W/16 W/12 B/1 W/3 — Y/12 Y/12 Y/2 Y/2 OR/2
: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
To M13 To M14 To D2 Fuse block (J/B) Time control unit Time control unit Ultra sonic sub-sensor To D22 Seat belt pre-tensioner (Driver’s side) Body ground Front door switch (Passenger side) Front door switch (Driver’s side) Heated seat LH Power seat Parking brake switch Seat belt pre-tensioner (Passenger side) Body ground To D18 Ultra sonic sensor Fuel pump Fuel level sensor unit Rear wheel sensor RH Rear wheel sensor LH Rear door switch RH Rear speaker RH Rear door switch LH Rear speaker LH CD auto changer High mounted stop lamp Trunk room lamp Rear wiper motor To T1 To T14 To D11 To E115 To B101 Rear window defogger Heated seat RH Body ground Diagnosis sensor unit Diagnosis sensor unit Side air bag module LH Side air bag module RH Satellite sensor LH
F4 F3 F1 G3 G3 G1 D3 E1 B2 D3 F2 B2 B3
B71 B72 B97 B98 B99 B121 B122 B123 B124 B130 B131 B132 B133
Y/2 — B/2 L/4 GY/2 W/6 W/3 W/12 W/3 W/3 —/3 W/3 —/3
: : : : : : : : : : : : :
Satellite sensor RH Body ground Fuse block (J/B) Theft warning horn relay Circuit breaker-2 Central unlock/trunk release switch To B130 Auto level control unit To B132 To B122 Front sensor To B124 Rear sensor
Console harness E2 D2 D2 E2 E2
B101 B102 B104 B105 B106
W/12 W/6 L/4 W/4 W/4
: : : : :
To B58 Ultrasonic cancel switch Heated seat switch LH Heated seat switch RH Headlamp aiming switch
: : : : : : : : : :
To B53 Rear combination lamp LH Body ground Body ground Rear combination lamp RH Theft warning horn License plate lamp LH Not used (To trailer tow connection) Link License plate lamp RH
Tail harness A2 A3 B4 B4 B4 C4 A3 A3 A3 A3
T1 T2 T3 T4 T5 T6 T9 T17 T18 T19
W/8 W/4 — — W/4 B/1 BR/2 BR/4 BR/4 BR/2
Tail harness No. 2 A3 A3 B3 C3 B3 B3
T7 T8 T10 T12 T13 T20
W/8 W/2 B/2 W/4 W/2 W/3
: : : : : :
To T16 Back-up lamp Trunk room lamp switch Door unlock actuator assembly (Trunk) Rear fog lamp External trunk release switch
Tail sub-harness A2 A2
T14 T16
W/8 W/8
: :
To B54 To T7
HARNESS LAYOUT Body Harness (Cont’d)
EL-391
G3 G3★ G2 F1 F1 G1 F3 F2 E4 F2 D1 F3 C3 E3 E3 C1 C2 D1 C1 D4 D3★ E4 C2 D1 C1 C1 B1 A1 B1 B2 C1 A2 A2 E1 E1 E2 B1 E3 C2 D3 E3 C3 E3 C2
HARNESS LAYOUT Body Harness (Cont’d) SEDAN — RHD models after VIN - P11U0548750
YEL975C
EL-392
HARNESS LAYOUT Body Harness (Cont’d)
YEL976C
EL-393
HARNESS LAYOUT Body Harness (Cont’d) 5-DOOR HATCHBACK — LHD models
YEL977C
EL-394
HARNESS LAYOUT Body Harness (Cont’d)
YEL978C
EL-395
HARNESS LAYOUT Body Harness (Cont’d) 5-DOOR HATCHBACK — RHD models
YEL979C
EL-396
HARNESS LAYOUT Body Harness (Cont’d)
YEL980C
EL-397
HARNESS LAYOUT Body Harness (Cont’d) WAGON — LHD MODELS
YEL981C
EL-398
HARNESS LAYOUT Body Harness (Cont’d)
YEL982C
EL-399
HARNESS LAYOUT Body Harness (Cont’d) WAGON — RHD models
YEL983C
EL-400
HARNESS LAYOUT Body Harness (Cont’d)
YEL984C
EL-401
HARNESS LAYOUT LHD MODELS
Air Conditioner Harness
YEL985C
RHD MODELS
YEL986C
EL-402
R1 R2 R3 R4 R5 R6 R8 R9 R10
W/6 B/2 W/2 W/8 W/2 W/2 W/2 B/2 W/6
: : : : : : : : :
To M15 (RHD models) Vanity mirror lamp (RHD models) Sunroof motor Sunroof switch Spot lamp Interior lamp (Without sunroof) Interior lamp (With sunroof) Vanity mirror lamp (LHD models) Fuse block (J/B) (LHD models)
HARNESS LAYOUT
Room Lamp Harness
EL-403 .
YEL267C
HARNESS LAYOUT Back Door Harness 5-DOOR HATCHBACK
YEL988C
EL-404
HARNESS LAYOUT Back Door Harness (Cont’d) WAGON
D108
D109
D110 D116
D107
D105 D102
D106 D104
D113
D101
.
D101 D101 D102 D102 D104 D104 D105 D105 D106 D106 D107
D107
D108
D108
D109
D109
D110
D110
D113
D113
D116
D116
W/4 W/4 W/6 W/6 W/4 W/4 W/2 W/2 W/2 W/2 W/4 W/4 W/4 W/4 W/4 W/4 — – B/1 B/1 W/2 W/2
: : : : : : : : : : :
B42 : To B42 B43 : To B43 : Rear combination lamp LH : Luggage room lamp switch : Licence plate lamp LH : Rear wiper motor Rear combination lamp RH : Door lock actuator assembly : Body ground : Rear window defogger : Licence plate lamp RH :
Body ground
D110
YEL405B
EL-405
HARNESS LAYOUT LHD MODELS
Front Door Harness (LH side)
YEL989C
RHD MODELS
YEL990C
EL-406
HARNESS LAYOUT LHD MODELS
Front Door Harness (RH side)
YEL991C
RHD MODELS
YEL992C
EL-407
HARNESS LAYOUT LH SIDE
Rear Door Harness
YEL993C
RH SIDE
YEL994C
EL-408
ALPHABETICAL INDEX SECTION
IDX
IDX
ALPHABETICAL INDEX A
B
AAC/V - Wiring diagram....EC-QG-276, EC-SR-265 ABS (anti-lock brake system).........................BR-50 A/C control linkage adjustment (manual A/C).............................................................HA-82 A/C control operation (auto A/C) ....................HA-19 A/C diagnostic work flow (auto A/C) ..............HA-26 A/C performance chart ...................................HA-35 A/C performance test diagnoses....................HA-33 A/C relay.........................................................HA-78 A/C service data specification ......................HA-118 A/C switch ......................................................HA-78 A/C symptom chart (auto A/C) .......................HA-28 A/C trouble diagnoses (auto A/C) ..................HA-26 Accelerator control system ...............................FE-3 Accelerator position sensor ...................EC-CD-108 Accelerator position switch ....................EC-CD-108 Accelerator wire adjustment .............................FE-4 A/CCUT - Wiring diagram ......................EC-CD-127 Air bag disposal..............................................RS-27 Air bag precautions ...........................................GI-3 Air bleeding for brake system ..........................BR-8 Air cleaner filter replacement ............MA-23, 34, 44 Air conditioner cut control.....EC-QG-24, EC-SR-26, EC-CD-20, 126 Air flow meter - See Mass air flow sensor ............................EC-QG-110, EC-SR-120 Air mix. door motor.........................................HA-92 Alternator ..................................................EL-53, 56 Ambient sensor ..............................................HA-86 Antenna.........................................................EL-229 Anti-lock brake system - See ABS .................BR-50 APS - Wiring diagram ............................EC-CD-109 A/T - Wiring diagram - AT - FTS .....................AT-56 A/T - Wiring diagram - AT - MAIN...................AT-45 A/T - Wiring diagram - AT - PNP/SW..............AT-50 A/T - Wiring diagram - AT - VSS A/T ..............AT-64 A/T diagnosis communication line .........EC-SR-295 A/T fluid temperature sensor...........................AT-54 A/T trouble diagnoses ...............................AT-29, 30 A/T Wiring diagram - AT - ENG SS ................AT-67 A/T Wiring diagram AT - LPSV .......................AT-76 A/T Wiring diagram AT - TCV .........................AT-71 A/T Wiring diagram AT - TPS..........................AT-81 ATDIAG - Wiring diagram ......................EC-SR-296 Audio .............................................................EL-216 AUDIO - Wiring diagram ...............................EL-219 Audio and A/C control removal and installation - See Instrument panel .............BT-15 Auto air conditioner - Wiring diagram ............HA-42 Automatic amplifier .........................................HA-87 Automatic transaxle number............................GI-44 Automatic transmission fluid replacement..........................................MA-49, 50 Auxiliary air control (AAC) valve ..............................EC-QG-274, EC-SR-263
Back door opener - See Back door ............BT-9, 11 Back door trim.................................................BT-30 Back door window ....................................BT-35, 56 Back-up lamp ................................................EL-107 BACK/L - Wiring diagram..............................EL-107 Ball joint front axle ....................................FA-32, 33 Base idle air volume initialiging...........................EC-QG-33, EC-SR-46 Basic inspection ....................EC-QG-72, EC-SR-84 Battery .............................................................EL-29 Body alignment ...............................................BT-60 Brake booster .................................................BR-18 Brake control valve (Proportioning valve)...........................................................BR-11 Brake fluid change ...........................................BR-7 Brake fluid level .............................................MA-51 Brake fluid level and line check .......................BR-7 Brake hydraulic line ..........................................BR-9 Brake inspection ............................................MA-51 Brake lining wear temporary checking ..........MA-51 Brake pedal ....................................................BR-13 Bulb specifications ........................................EL-137 Bumper, front ....................................................BT-5 Bumper, rear .......................................BT-5, 7, 9, 11 BUZZER - Wiring diagram ............................EL-181 C Camshaft inspection ...............EM-35, 91, 138, 147, 183, 192, 196 Camshaft position sensor (CMPS)..........................EC-QG-238, EC-SR-239 Camshaft position sensor (PHASE) ......EC-QG-238 Canister-See EVAP canister ..............................EC-QG-25, EC-SR-27 CHARGE - Wiring diagram .............................EL-53 Charging system .............................................EL-53 Chassis and body maintenance ....................MA-48 CHIME - Wiring diagram...............................EL-181 Cigarette lighter.............................................EL-203 Circuit breaker.................................................EL-22 CKPS - Wiring diagram....EC-QG-234, EC-SR-236, 292, EC-CD-115 Clock .............................................................EL-203 Closed throttle position switch ...............EC-SR-271 Clutch cover ....................................................CL-13 Clutch damper ................................................CL-10 Clutch disc ......................................................CL-13 Clutch fluid level.............................................MA-48 Clutch master cylinder ......................................CL-8 Clutch operating cylinder ..................................CL-9 Clutch release mechanism..............................CL-11 CMPS - Wiring diagram ....EC-QG-240, EC-SR-242 Coil spring (rear).............................................RA-11 Collision diagnosis..........................................RS-57 Combination meter........................................EL-138
IDX-2
ALPHABETICAL INDEX Combination meter removal and installation - See Instrument panel......................BT-15 Combination switch .........................................EL-64 Combustion chamber replacement ..............EM-146 Component location (cool box) ......................HA-39 Compression pressure ..........EM-69, 126, 188, 196 Compressor clutch removal and installation .................................................HA-111 Compressor mounting ..................................HA-109 Compressor precaution ....................................HA-7 Compressor special service tool ......................HA-7 Connecting rod......EM-55, 171, 176, 186, 193, 200 Connecting rod bearing clearance....EM-58, 111, 115, 170, 187, 195, 201 Connecting rod bushing clearance ........EM-59, 116 Console box - See Instrument panel ..............BT-15 CONSULT for ABS .........................................BR-69 CONSULT for engine ...........EC-QG-55, EC-SR-68, EC-CD-27 CONSULT-II general information.....................GI-39 Control sleeve position sensor ................EC-CD-74 Converter housing installation .......................AT-117 COOL/F - Wiring diagram ....................EC-QG-292, EC-SR-282, EC-CD-89 Coolant replacement .........................MA-19, 29, 40 Cooling circuit (engine) ........................LC-8, 21, 31 Cooling fan control ...........EC-QG-289, EC-SR-279, EC-CD-20, 87 Cooling fan motor .............EC-QG-299, EC-SR-289 Cooling fan relay ..............EC-QG-299, EC-SR-289, EC-CD-96 Crank angle sensor built into distributor - See Camshaft position sensor .......EC-QG-238, EC-SR-239 ‘‘Crankcase emission control system See positive crankcase ventilation’’.........................EC-QG-28, EC-SR-30 Crankcase ventilation system - See Positive crankcase ventilation ..........................EC-QG-28, EC-SR-30 Crankshaft ........EM-53, 57, 61, 110, 113, 118, 131, 138, 139, 167, 172, 175, 186, 194, 200 Crankshaft position sensor (OBD) .......EC-QG-232, EC-SR-234, 290 Crankshaft position sensor (POS).........EC-QG-232 Crankshaft position sensor (TDC)..........EC-CD-114 CSPS - Wiring diagram ...........................EC-CD-75 Cylinder block .........................EM-52, 55, 109, 166, 173, 184, 192, 199 Cylinder head ..........EM-31, 86, 140, 178, 188, 196 D Data link connector for Consult ..............................EC-QG-29, EC-SR-31 Daytime light system.......................................EL-78 DEF - Wiring diagram ...................................EL-209 Detonation sensor - See Knock sensor............................EC-QG-228, EC-SR-230 Diagnosis sensor unit .....................................RS-13
Diagnostic trouble code (DTC) for OBD system ...................................EC-QG-6, EC-SR-6 Diagnostic trouble code (DTC) inspection priority chart...............EC-QG-80, EC-SR-92, EC-CD-39 Dimensions ......................................................GI-45 Direct ignition system ..............................EC-QG-32 Door lock .........................................................BT-13 Door mirror ......................................................BT-58 Door trim .........................................................BT-24 Door, front .......................................................BT-13 Door, rear ........................................................BT-13 Drive belt inspection ..........................MA-18, 28, 39 Drive plate runout...................................EM-60, 117 Drive shaft (front) ............................................FA-15 Dropping resistor (A/T)....................................AT-78 DTC work support .................EC-QG-63, EC-SR-76 DTRL - Wiring diagram ...................................EL-79 E ECCS relay ............................................EC-CD-140 ECM input/output signal......EC-QG-91, EC-SR-103 ECTS - Wiring diagram....EC-QG-122, EC-SR-134, EC-CD-67 EGR control (EGRC) - solenoid valve ...EC-CD-129 EGR control valve..........................EC-QG-252, 311 EGR temperature sensor ......................EC-QG-300 EGR/TS - Wiring diagram .....................EC-QG-302 EGRC - Wiring diagram .........................EC-CD-131 EGRC1 - Wiring diagram ..............EC-QG-248, 309 Electric governer ......................................EC-CD-78 Electric sun roof ............................................EL-230 Electrical diagnoses.........................................GI-24 Electrical ignition system.......EC-QG-23, EC-SR-25 Electrical unit ................................................Foldout Electronic fuel injection pump ..................EC-CD-24 Engine control circuit diagram ...........EC-QG-17, EC-SR-19, EC-CD-11 Engine control component parts location ..............................EC-QG-14, EC-SR-15 Engine control module (ECM) .....EC-QG-282, EC-SR-277, EC-CD-9, 86 Engine control system diagram and chart................EC-QG-18, EC-SR-20, EC-CD-12 Engine coolant temperature sensor (ECTS)........EC-QG-120, EC-SR-132, EC-CD-66 Engine fail-safe system.........EC-QG-81, EC-SR-93 Engine oil filter replacement ....................MA-24, 45 Engine oil precautions .......................................GI-6 Engine oil replacement ......................MA-24, 34, 45 Engine removal..............................EM-48, 106, 162 Engine serial number ......................................GI-44 Engine trouble diagnoses ........................EC-CD-33 EVAP canister .......................EC-QG-26, EC-SR-28 EVAP canister purge volume control solenoid valve ...........EC-QG-26, 262, EC-SR-28 EVAP canister purge volume control valve ..............................EC-QG-262, EC-SR-250 EVAP vapor lines inspection....................MA-26, 37
IDX-3
ALPHABETICAL INDEX Evaporative emission (EVAP) system ...............................EC-QG-25, EC-SR-27 Exhaust gas recirculation (EGR) valve...........................................EC-QG-244, 305 Exhaust system ................................................FE-9 Exhaust system inspection ............................MA-48 Exterior ............................................................BT-31 F FCUT - Wiring diagram..........................EC-CD-101 F/FOG - Wiring diagram................................EL-110 Final drive (FF M/T) ...........................MT-32, 51, 71 Floor trim .........................................................BT-18 Fluid temperature sensor (A/T) .......................AT-94 Fluids..............................................................MA-16 Flywheel (clutch) .............................................CL-14 Flywheel runout..............................EM-60, 117, 177 Fog lamp, front ..............................................EL-110 Fog lamp, rear...............................................EL-112 F/PUMP - Wiring diagram..........................EC-QG-338, EC-SR-317 Freeze frame data ................EC-QG-38, EC-SR-50 Fresh vent door control linkage adjustment ..................................................HA-83 FRO2 - Wiring diagram ........EC-QG-135, 154, 162, EC-SR-147, 165, 172 FRO2/H - Wiring diagram..........................EC-QG-168, EC-SR-177 Front axle ..........................................................FA-9 Front bumper ....................................................BT-5 Front disc brake .............................................BR-23 Front door .......................................................BT-13 Front fog lamp .......................................EL-110, 111 Front fog lamp removal and installation ...........BT-5 Front heated oxygen sensor (HO2S)......................................EC-QG-132, 139, EC-SR-144, 150, 156, 162, 170 Front heated oxygen sensor (HO2S) heater ............................EC-QG-166, EC-SR-175 Front passenger air bag .................................RS-17 Front seat ........................................................BT-40 Front seat belt ..................................................RS-3 Front suspension ............................................FA-26 Front washer .................................................EL-186 Front wiper ....................................................EL-186 FTS - Wiring diagram ............................EC-CD-105 FUEL - Wiring diagram .........EC-QG-210, 217, EC-SR-213, 220 Fuel cut control (at no load & high engine speed)....................EC-QG-25, EC-SR-27 Fuel cut solenoid valve ..........................EC-CD-100 Fuel filter ...............................EC-QG-29, EC-SR-31 Fuel filter replacement .......................MA-23, 33, 43 Fuel gauge ............................................EL-141, 146 Fuel injection system....................EC-QG-208, 215, EC-SR-212, 218, EC-CD-15, 18 Fuel injector ......................EC-QG-318, EC-SR-302 Fuel line inspection............................MA-22, 33, 43
Fuel precautions ................................................GI-7 Fuel pressure check .............EC-QG-29, EC-SR-31 Fuel pressure regulator.........EC-QG-30, EC-SR-32 Fuel pressure release ...........EC-QG-29, EC-SR-31 Fuel pump .........................EC-QG-336, EC-SR-316 Fuel pump and gauge ......................................FE-7 Fuel pump relay ................EC-QG-336, EC-SR-316 Fuel system ......................................................FE-6 Fuel tank vacuum relief valve ..................................EC-QG-26, EC-SR-28 Fuel temperature sensor .................EC-CD-17, 104 Fuse ..................................................EL-22, Foldout Fuse block ....................................................Foldout Fusible link ........................................EL-22, Foldout G Garage jack and safety stand .........................GI-47 Gauges..........................................................EL-138 Gear components (M/T) ...........................MT-16, 49 Generic scan tool (GST) .......EC-QG-66, EC-SR-78 GLOW - Wiring diagram ........................EC-CD-120 Glow plug .........................................EC-CD-15, 118 Glow relay ................................................EC-CD-15 GOVNR - Wiring diagram ........................EC-CD-79 Grille - See Exterior ........................................BT-38 Ground distribution..........................................EL-23 H H/AIM - Wiring diagram ....................EL-87, 93, 200 Harness connector ............................................EL-6 Harness layout ..............................................EL-368 Hazard warning lamp ....................................EL-117 Headlamp..................................................EL-67, 69 Headlamp aiming control ................................EL-87 Headlamp washer .........................................EL-200 Headlining - See Roof trim .............................BT-25 Heated oxygen sensor (HO2S) (front) ........................................EC-QG-132, 139, EC-SR-144, 150, 156, 162, 170 Heated oxygen sensor (HO2S) heater (front) .............................EC-QG-166, EC-SR-175 Heated oxygen sensor (HO2S) heater (rear)..............................EC-QG-203, EC-SR-207 Heated oxygen sensor (rear) ...............EC-QG-171, EC-SR-180, 187, 194, 201 Heated oxygen sensor inspection ...........MA-27, 38 Heated seat .......................................BT-42, EL-234 HEATER - Wiring diagram .............................HA-40 HFC134a (R134a) system service procedure..................................................HA-100 HFC134a (R134a) system service tools ..........HA-8 H/LAMP - Wiring diagram ...............................EL-67 Hood..................................................................BT-5 Horn ..............................................................EL-203 HORN - Wiring diagram................................EL-203
IDX-4
ALPHABETICAL INDEX How to erase DTC for OBD system ...............................EC-QG-44, EC-SR-56 HSEAT - Wiring diagram...............................EL-234 Hydraulic lash adjuster inspection .........EM-96, 189
Lubrication circuit (engine) ...................LC-4, 15, 26 Lubrication-locks, hinges and hood latches ........................................................MA-54 Luggage compartment trim .............................BT-29 Luggage room lamp ......................................EL-131
I M IACV-AAC valve ................EC-QG-274, EC-SR-263 IATS - Wiring diagram.......EC-QG-117, EC-SR-128 Identification plate............................................GI-44 Idle air control (IAC) system ...........................EC-QG-274, EC-SR-263 Idle air control valve (IACV)............................EC-QG-274, EC-SR-263 Idle mixture ratio ...................EC-QG-32, EC-SR-34 Idle speed .............................EC-QG-32, EC-SR-34 IGN/SG - Wiring diagram .......................EC-SR-308 Ignition coil .............................................EC-SR-310 Ignition control system ......EC-QG-323, EC-SR-306 Ignition timing ........................EC-QG-32, EC-SR-34 Ignition wire inspection ..............MA-36, EC-SR-229 ILL - Wiring diagram .....................................EL-125 Illumination ....................................................EL-124 INJECT - Wiring diagram..EC-QG-319, EC-SR-303 Injection nozzle inspection .............................MA-46 Injection timing control valve ...................EC-CD-82 Injector ...................................................EC-QG-318 Injector removal and installation..........................EC-QG-30, EC-SR-32 Input shaft (FF M/T) .................................MT-21, 58 Instrument panel .............................................BT-15 INT/L - Wiring diagram..................................EL-132 Intake air temparature sensor ............................EC-QG-116, EC-SR-127 Intake door control linkage adjustment ..........HA-83 Intake door motor .....................................HA-81, 83 Intake valve timing control solenoid valve...................................................EC-QG-284 Interior .............................................................BT-18 Interior lamp ..........................................EL-124, 130
MAFS - Wiring diagram .......EC-QG-112, EC-SR-122, EC-CD-63 MAIN - Wiring diagram .......EC-QG-103, EC-SR-115, EC-CD-59 Mainshaft (M/T) ........................................MT-24, 63 Malfunction indicator lamp (MIL) ..................................EC-QG-45, EC-SR-58 Manual transmission number ..........................GI-44 Manual transmission oil replacement ......MA-48, 49 Mass air flow sensor (MAFS)........EC-QG-110, EC-SR-120, EC-CD-62 METER - Wiring diagram .....................EL-141, 146 MIL & Data link connectors circuit .............................EC-QG-354, EC-SR-329 MIL/DL - Wiring diagram.....EC-QG-354, EC-SR-329, EC-CD-142 MIRROR - Wiring diagram............................EL-231 Mirror defogger .............................................EL-207 Mirror, door......................................................BT-58 Mirror, out side ................................................BT-58 Misfire................................EC-QG-222, EC-SR-224 Mode door control linkage adjustment ...........HA-82 Model variation ................................................GI-41 Molding - See Exterior ....................................BT-31 M/T major overhaul ..................................MT-14, 47 M/T removal and installation ..........................MT-10 Mud guard - See Exterior ...............................BT-37 MULTI - Wiring diagram................................EL-298 Multi-remote control system..........................EL-296 Multiport fuel injection (MFI) system ...............................EC-QG-21, EC-SR-23 Multiport fuel injection precautions ....................GI-6
K
N
Knock sensor (KS) .......................EC-QG-228, 229, EC-SR-230, 231 KS - Wiring diagram ..............................EC-QG-229
NATS (Nissan anti-theft system)...................EL-342 NATS (Nissan anti-theft system) precautions ..............................................GI-3, 25 NATS - Wiring diagram .................................EL-343 Needle lift sensor .....................................EC-CD-97 Neutral position switch ......EC-QG-313, EC-SR-298 NLS - Wiring diagram ..............................EC-CD-98 NVH troubleshooting (BR)................................BR-6 NVH troubleshooting (CL) ................................CL-3 NVH troubleshooting (EM)...............EM-11, 64, 121 NVH troubleshooting (M/T) ..............................MT-7 NVH troubleshooting (RA)................................RA-3
L License lamp .................................................EL-100 Lifting points ....................................................GI-46 Line pressure solenoid valve ..........................AT-74 Line pressure test (A/T) ..................................AT-35 Liquid gasket application .................................EM-5 LOAD - Wiring diagram .........................EC-QG-352 Location of electrical units ............................EL-365 Lubricants.......................................................MA-16
IDX-5
ALPHABETICAL INDEX O Oil cooler (engine) ....................................LC-20, 30 Oil pan (engine) ...............................EM-17, 70, 129 Oil pressure (engine)............................LC-5, 16, 27 Oil pump (engine).................................LC-5, 17, 27 Oil pump regulator valve (engine) ....................LC-7 Oil seal replacement (engine)................................EM-29, 84, 138, 139 On board diagnostic system ...............................EC-QG-36, EC-SR-48 Operational check (cool box) .........................HA-24 P Park/Neutral position switch.............................EC-QG-313, EC-SR-298 Park/neutral position switch (A/T) ...................AT-48 Parking brake control .....................................BR-48 Parking lamp .................................................EL-100 PCV (positive crankcase ventilation) .........................EC-QG-28, EC-SR-30 PCV system inspection............................MA-26, 36 Periodic maintenance (for Europe) ..................MA-6 PGC/V - Wiring diagram ...EC-QG-264, EC-SR-252 PHASE - Wiring diagram.......................EC-QG-240 Pilot bushing replacement - See Pilot converter...................................................EM-117 Piston assembly..............EM-53, 60, 110, 117, 167, 175, 176, 185, 193, 199 Piston pin inspection.............EM-54, 110, 168, 171, 185, 193, 199 Piston ring inspection....................EM-54, 111, 168, 185, 193, 199 Piston to bore clearance........................EM-56, 174 PNP/SW - Wiring diagram..........................EC-QG-315, EC-SR-300 POWER - Wiring diagram...............................EL-12 Power door lock ....................................EL-245, 265 Power door mirror .........................................EL-231 Power seat ....................................................EL-233 Power steering fluid level...............................MA-53 Power steering oil pressure switch.............................EC-QG-342, EC-SR-321 Power supply routing ......................................EL-10 Power transistor......................................EC-SR-311 Power transistor & ignition coil ..............EC-SR-306 Power window ...............................................EL-236 Pre-delivery inspection.....................................MA-4 Precautions (General) .......................................GI-4 Pressure test (A/T) ..........................................AT-35 PST/SW - Wiring diagram..........................EC-QG-343, EC-SR-322 R Radiator ..........................................LC-9, 13, 25, 36
Rear axle (disc brake type) ..............................RA-5 Rear bumper ...........................................BT-7, 9, 11 Rear combination lamp removal and installation ...................................................BT-37 Rear disc brake ........................................BR-33, 40 Rear door ........................................................BT-14 Rear drum brake ............................................BR-44 Rear fog lamp................................................EL-112 Rear heated oxygen sensor (HO2S)..EC-QG-171, EC-SR-180, 187, 194, 201 Rear heated oxygen sensor (HO2S) heater ............................EC-QG-203, EC-SR-207 Rear seat ........................................................BT-43 Rear seat belt ...................................................RS-4 Rear suspension ..............................................RA-4 Rear washer..................................................EL-193 Rear window ...................................................BT-53 Rear window defogger ..................................EL-207 Rear wiper.....................................................EL-193 Refrigerant connection precaution ...................HA-4 Refrigerant general precaution.........................HA-4 Refrigerant lines ...........................................HA-104 Refrigerant pressure sensor....................EC-QG-299, 347, EC-SR-289 Refrigeration cycle..........................................HA-12 Removal and installation (A/T) ......................AT-116 Revolution sensor (A/T) ............................AT-61, 65 R/FOG - Wiring diagram ...............................EL-112 Roof trim .........................................................BT-25 RRO2 - Wiring diagram.....................EC-QG-174, 183, 191, 199, EC-SR-183, 190, 197, 203 RRO2/H - Wiring diagram..........................EC-QG-205, EC-SR-209 S SAE J1930 terminology list .............................GI-51 Seal - See Exterior .........................................BT-31 SEAT - Wiring diagram .................................EL-233 Seat belt inspection .......................................MA-54 Seat belt pre-tensioner ...................................RS-13 Seat belt pre-tensioner disposal ....................RS-27 Seat, front .......................................................BT-40 Self-diagnostic results ...........EC-QG-46, EC-SR-59 Shift control components (M/T) .........MT-17, 50, 74 Shock absorber (rear).....................................RA-11 Side air bag ....................................................RS-19 Side trim ..........................................................BT-18 Side window - See Rear side window ............BT-55 S/LOCK - Wiring diagram .....................EL-248, 270 Spark plug replacement...........................MA-25, 35 Speedometer ........................................EL-141, 146 Spiral cable.....................................................RS-14 Spot lamp..............................................EL-130, 131 SROOF - Wiring diagram .............................EL-230 SRS - See Supplemental Restraint System ..........................................................RS-8 SRS - Wiring diagram ....................................RS-33
IDX-6
ALPHABETICAL INDEX S/SIG - Wiring diagram....EC-QG-333, EC-SR-313, EC-CD-145 Stabilizer bar (front) ........................................FA-32 Stall test (A/T) .................................................AT-34 Standardized relay ............................................EL-8 START - Wiring diagram .................................EL-37 Start signal .................EC-QG-38, 332, EC-SR-312, EC-CD-145 Starter .......................................................EL-37, 43 Starting system ...............................................EL-37 Steering gear and linkage inspection ............MA-53 Steering knuckle........................................FA-11, 12 Stop lamp ......................................................EL-104 STOP/L - Wiring diagram..............................EL-104 Sun roof, electric ...........................................EL-230 Sunload sensor ..............................................HA-86 Sunroof .....................................................BT-31, 46 Super lock .............................................EL-245, 265 Supplemental Restraint System .......................RS-8 Supplemental restraint system - Wiring diagram .......................................................RS-33 Symbols and abbreviations .............................GI-38 Symptom matrix chart ...........EC-QG-82, EC-SR-94 Synchronizer (M/T) ......................MT-22, 27, 59, 65 System readiness test (SRT) code ..........EC-SR-50 T Tachometer ...........................................EL-141, 146 Tail lamp ........................................................EL-100 TCM circuit diagram ........................................AT-10 TCM inspection table ......................................AT-41 Temperature control cable and linkage adjustment ..................................................HA-83 THEFT - Wiring diagram...............................EL-316 Theft warning system ....................................EL-311 Thermal protector .........................................HA-113 Thermo control amp .......................................HA-80 Thermostat..........................................LC-11, 23, 34 Third link (front susp.) .....................................FA-29 Three way catalyst ............EC-QG-258, EC-SR-246 Three way catalyst precautions.........................GI-6 Throttle position sensor (TPS) .............................EC-QG-125, EC-SR-137 Throttle position sensor adjustment .........................EC-QG-72, EC-SR-84 Throttle position switch ...............EC-SR-271, AT-85 Tightening torque of standard bolts.................GI-50 Time control system......................................EL-306 Timing belt....................................................EM-131 Timing chain.............................................EM-19, 75 Tire rotation ....................................................MA-53 Tire size ...........................................................GI-45 Torque converter installation .........................AT-117 Torque convertor clutch solenoid valve...........AT-69 Tow truck towing ..............................................GI-46 Towing point.....................................................GI-49 TP/SW - Wiring diagram ........................EC-SR-273 TPS - Wiring diagram .......EC-QG-128, EC-SR-140 Transmission case (M/T)................................MT-39
Transverse link (front) .....................................FA-32 Trim .................................................................BT-18 Triple pressure switch ....................................HA-79 Trouble diagnoses ...........................................GI-35 Trunk lid ............................................................BT-7 Trunk lid opener - See Trunk lid .......................BT-7 Trunk room lamp...................................EL-130, 131 Trunk room trim...............................................BT-28 Turbocharger........................................EM-156, 201 Turbocharger precautions..................................GI-6 TURN - Wiring diagram.................................EL-118 Turn signal lamp............................................EL-117 Two trip detection logic .........EC-QG-36, EC-SR-48 U Upper link (front susp.) ...................................FA-29 V Vacuum hose (brake system).........................BR-20 Vacuum hose drawing (Engine control)............EC-QG-19, EC-SR-21, EC-CD-13 Valve clearance .............................EM-40, 179, 191 Valve guide..............EM-36, 93, 142, 180, 189, 197 Valve lifter ..............................EM-40, 145, 179, 198 Valve seat................EM-38, 95, 143, 182, 190, 198 Valve spring.............EM-39, 96, 145, 179, 189, 197 Vehicle identification number...........................GI-43 Vehicle speed sensor (VSS) ..........EC-QG-267, EC-SR-255, EC-CD-70 Viscosity number (SAE) .................................MA-17 VSS - Wiring diagram.......EC-QG-269, EC-SR-257, EC-CD-71 W WARN - Wiring diagram ...............................EL-167 Warning buzzer .............................................EL-180 Warning chime ..............................................EL-180 Warning lamps ..............................................EL-165 Washer, front.................................................EL-186 Washer, rear..................................................EL-193 Water cock control rod adjustment ................HA-82 Water pump ........................................LC-10, 22, 33 Water temperature gauge.....................EL-141, 146 Weatherstrip - See Exterior ............................BT-31 Wheel alignment (front) ..................................FA-35 Wheel alignment (rear).....................................RA-6 Wheel balance ...............................................MA-53 Wheel bearing (front axle) ....................FA-6, 12, 35 Wheel bearing (rear) ........................................RA-5 Wheel hub (front) ............................................FA-12 Wheel hub (rear) ..............................................RA-7 Wheel sensors (ABS) .....................................BR-53 Wheel size .......................................................GI-45 Wheelbase (Dimensions) ................................GI-45
IDX-7
ALPHABETICAL INDEX Wide open & closed throttle position switch.............................EC-QG-125, EC-SR-137 Width (Dimensions) .........................................GI-45 WINDOW - Wiring diagram ..........................EL-240 Windshield.......................................................BT-53 WIP/R - Wiring diagram ................................EL-195
Wiper and washer .........................................EL-188 Wiper, front....................................................EL-186 Wiper, rear ....................................................EL-193 Wiring diagrams ...............................................GI-11
IDX-8
FUSE BLOCK — Junction Box (J/B) Terminal Arrangement To time control unit
UP
Fuel pump relay Spare fuse
Front fog lamp relay Power window relay Rear window defogger relay To room lamp harness :
To air bag harness
To main harness: To main harness
Ignition relay
To engine room harness
Circuit breaker-1
Blower relay
: LHD models : RHD models To body harness
YEL232C
FUSE AND FUSIBLE LINK BOX Terminal Arrangement
With gasoline engine With diesel engine
YEL419B
ELECTRICAL UNITS Terminal Arrangement
TCM (Transmission control module)
TCM (Transmission control module)
ABS CONTROL UNIT
ECM (SR engine and QG engine)
ECM (CD engine)
YEL233C
NOTES
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