2002 Xterra Service Manual.pdf

Edition: September 2002 Revision: September 2002 Publication No. SM2E-1W22U 1

QUICK REFERENCE INDEX

© 2002 NISSAN NORTH AMERICA, INC. All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photo-copying, recording or otherwise, without the prior written permission of Nissan North America, Inc., Gardena, California.

FOREWORD This manual contains maintenance and repair procedures for the 2002 Nissan XTERRA. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.

NISSAN NORTH AMERICA, INC. Technical Service information Department Gardena, California

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NOTES

Attachment No.31

KA24DE

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II) The following is the information specified in Mode 6 of SAE J1979. 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. These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen.

SRT item

CATALYST

EVAP SYSTEM

Self-diagnostic test item

Three way catalyst function EVAP control system (Small leak) EVAP control system purge flow monitoring EVAP control system (Very small leak)

Heated oxygen sensor 1 HO2S

Heated oxygen sensor 2

Heated oxygen sensor 1 heater HO2S HTR Heated oxygen sensor 2 heater

EGR function EGR SYSTEM

EGRC-BPT valve function

DTC P0420 P0420 P0442 P0441 P0456 P1456 P0133 P1143 P1144 P0132 P0134 P0139 P1147 P1146 P0138 P0032 P0031 P0038 P0037 P0400 P0400 P0400 P0400 P1402 P0402 P0402

Test value (GST display) TID 01H 02H 05H 06H 07H 07H 09H 0AH 0BH 0CH 0DH 19H 1AH 1BH 1CH 29H 2AH 2DH 2EH 31H 32H 33H 34H 35H 36H 37H

CID 01H 81H 03H 83H 03H 03H 04H 84H 04H 04H 04H 86H 86H 06H 06H 08H 88H 0AH 8AH 8CH 8CH 8CH 8CH 0CH 0CH 8CH

Test limit

Conversion

Max. Min. Max. Min. Max. Max. Max. Min. Max. Max. Max. Min. Min. Max. Max. Max. Min. Max. Min. Min. Min. Min. Min. Max. Max. Min.

1/128 1 1/128mm2 20mV 1/128mm2 1/128mm2 16ms 10mV 10mV 10mV 1s 10mV/500ms 10mV 10mV 10mV 20mV 20mV 20mV 20mV 1 1 1 1 1 1count 1count

Attachment No.29

VG33E/VG33ER

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II) The following is the information specified in Mode 6 of SAE J1979. The test value is a parameter used to determine whether a system/circuit diagnostic test is “OK” or “NG” while being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored. These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen.

SRT item

Self-diagnostic test item

Three way catalyst function (Bank 1) CATALYST Three way catalyst function (Bank 2) EVAP control system (Small leak) EVAP SYSTEM

EVAP control system purge flow monitoring EVAP control system (Very small leak)

Heated oxygen sensor 1 (Bank 1)

Heated oxygen sensor 1 (Bank 2) HO2S

Heated oxygen sensor 2 (Bank 1)

Heated oxygen sensor 2 (Bank 2)

Heated oxygen sensor 1 heater (Bank 1) Heated oxygen sensor 1 heater (Bank 2) HO2S HTR Heated oxygen sensor 2 heater (Bank 1) Heated oxygen sensor 2 heater (Bank 2)

DTC P0420 P0420 P0430 P0430 P0442 P1442 P0441 P0456 P1456 P0133 P1143 P1144 P0132 P0134 P0153 P1163 P1164 P0152 P0154 P0139 P1147 P1146 P0138 P0159 P1167 P1166 P0158 P0032 P0031 P0052 P0051 P0038 P0037 P0058 P0057

Test value (GST display) TID 01H 02H 03H 04H 05H 05H 06H 07H 07H 09H 0AH 0BH 0CH 0DH 11H 12H 13H 14H 15H 19H 1AH 1BH 1CH 21H 22H 23H 24H 29H 2AH 2BH 2CH 2DH 2EH 2FH 30H

CID 01H 81H 02H 82H 03H 03H 83H 03H 03H 04H 84H 04H 04H 04H 05H 85H 05H 05H 05H 86H 86H 06H 06H 87H 87H 07H 07H 08H 88H 09H 89H 0AH 8AH 0BH 8BH

Test limit

Conversion

Max. Min. Max. Min. Max. Max. Min. Max. Max. Max. Min. Max. Max. Max. Max. Min. Max. Max. Max. Min. Min. Max. Max. Min. Min. Max. Max. Max. Min. Max. Min. Max. Min. Max. Min.

1/128 1 1/128 1 1/128mm2 1/128mm2 20mV 1/128mm2 1/128mm2 16ms 10mV 10mV 10mV 1s 16ms 10mV 10mV 10mV 1s 10mV/500ms 10mV 10mV 10mV 10mV/500ms 10mV 10mV 10mV 20mV 20mV 20mV 20mV 20mV 20mV 20mV 20mV

GENERAL INFORMATION SECTION

GI

MA EM LC EC

CONTENTS PRECAUTIONS ...............................................................3 Precautions ..................................................................3 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″.........3 GENERAL PRECAUTIONS .........................................3 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM ...................................................................5 PRECAUTIONS FOR THREE WAY CATALYST ...........5 PRECAUTIONS FOR HOSES .....................................6 PRECAUTIONS FOR ENGINE OILS ...........................6 PRECAUTIONS FOR FUEL ........................................7 PRECAUTIONS FOR AIR CONDITIONING ..................7

HOW TO USE THIS MANUAL........................................8 HOW TO READ WIRING DIAGRAMS..........................10 Sample/Wiring Diagram - EXAMPL - ........................10 OPTIONAL SPLICE..................................................11 Description .................................................................12 CONNECTOR SYMBOLS .........................................14 SWITCH POSITIONS ...............................................15 DETECTABLE LINES AND NON-DETECTABLE LINES .....................................................................15 MULTIPLE SWITCH .................................................16 REFERENCE AREA .................................................17

HOW TO CHECK TERMINAL .......................................19 Connector and Terminal Pin Kit.................................19 How to Probe Connectors .........................................19 PROBING FROM HARNESS SIDE ............................19 PROBING FROM TERMINAL SIDE ...........................19 How to Check Enlarged Contact Spring of Terminal .....................................................................20 Waterproof Connector Inspection ..............................21 RUBBER SEAL INSPECTION ...................................21 WIRE SEAL INSPECTION ........................................21 Terminal Lock Inspection ...........................................21 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT ...............................22 Work Flow..................................................................22 Incident Simulation Tests...........................................23 INTRODUCTION ......................................................23 VEHICLE VIBRATION ..............................................23

HEAT SENSITIVE ....................................................24 FREEZING ..............................................................24 WATER INTRUSION ................................................25 ELECTRICAL LOAD .................................................25 COLD OR HOT START UP.......................................25

Circuit Inspection .......................................................25 INTRODUCTION ......................................................25 TESTING FOR ″OPENS″ IN THE CIRCUIT ................26 TESTING FOR ″SHORTS″ IN THE CIRCUIT ..............27 GROUND INSPECTION ...........................................28 VOLTAGE DROP TESTS ..........................................28 CONTROL UNIT CIRCUIT TEST ...............................30 HOW TO FOLLOW TROUBLE DIAGNOSES...............32 How to Follow Test Groups in Trouble Diagnoses....33 Harness Wire Color and Connector Number Indication....................................................................34 TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION .......................................................34 TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT.........35

Key to Symbols Signifying Measurements or Procedures.................................................................35 CONSULT–II CHECKING SYSTEM ..............................38 Function and System Application ..............................38 Nickel Metal Hydride Battery Replacement...............38 Checking Equipment..................................................39 Loading Procedure ....................................................39 CONSULT-II Data Link Connector (DLC) Circuit ......39 INSPECTION PROCEDURE .....................................39 IDENTIFICATION INFORMATION ................................40 Model Variation ..........................................................40 Identification Number.................................................42 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT .....................................................42 ENGINE SERIAL NUMBER.......................................43 TRANSFER SERIAL NUMBER ..................................43 MANUAL TRANSMISSION NUMBER.........................43 AUTOMATIC TRANSMISSION NUMBER ...................43

Dimensions ................................................................44 Wheels & Tires ..........................................................44

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS LIFTING POINTS AND TOW TRUCK TOWING ...........45 Pantograph Jack........................................................45 Garage Jack and Safety Stand .................................45 2-pole Lift ...................................................................46 Tow Truck Towing ......................................................46 2-WHEEL DRIVE MODELS.......................................47 4-WHEEL DRIVE MODELS.......................................47

(Cont’d) TOWING POINT .......................................................47 VEHICLE RECOVERY (FREEING A STUCK VEHICLE) ................................................................48

TIGHTENING TORQUE OF STANDARD BOLTS ........49 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ....................................................................50 SAE J1930 TERMINOLOGY LIST ................................51 SAE J1930 Terminology List .....................................51

GI-2

PRECAUTIONS Precautions

Precautions

NGGI0001

Observe the following precautions to ensure safe and proper servicing.

MA EM LC SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER” NGGI0001S01

SGI646

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 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), 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 this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

EC FE CL MT AT TF PD AX SU BR ST RS

GENERAL PRECAUTIONS 쐌

NGGI0001S02

Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle.

BT HA SC EL

SGI285

GI-3

IDX

PRECAUTIONS Precautions (Cont’d)

쐌

쐌

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 it. Also, do not allow it to strike adjacent parts, especially the brake tubes and master cylinder.

SGI231

쐌

Before starting repairs which do not require battery power: Turn off ignition switch. Disconnect the negative battery terminal.

쐌

To prevent serious burns: Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot.

쐌

Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint.

쐌

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.

SEF289H

SGI233

SGI234

쐌 쐌 쐌 쐌

GI-4

PRECAUTIONS Precautions (Cont’d)

쐌

After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. 쐌 Use only the fluids and lubricants specified in this manual. 쐌 Use approved bonding agents, sealants or their equivalents when required. 쐌 Use tools and recommended special tools where specified for safe and efficient service repairs. 쐌 When repairing fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. 쐌 Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. 쐌 Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow resulting in fuel spray and possibly a fire. WARNING: To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the engine control system and TCM (Transmission Control Module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.

MA EM LC EC FE CL MT

PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM AT NGGI0001S03 쐌

쐌 쐌 SGI787

Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM: Turn ignition switch to OFF position. Disconnect negative battery terminal. Otherwise, there may be damage to ECM. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure. Be careful not to jar components such as ECM and mass air flow sensor.

PRECAUTIONS FOR THREE WAY CATALYST

NGGI0001S04

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: 쐌 Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. 쐌 When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. 쐌 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.

TF PD AX SU BR ST RS BT HA SC EL

GI-5

IDX

PRECAUTIONS Precautions (Cont’d)

PRECAUTIONS FOR HOSES Hose removal and installation

NGGI0001S08 NGGI0001S0801

쐌

To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver.

쐌

To reinstall the rubber hose securely, make sure of hose insertion length and clamp orientation. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

SMA019D

SMA020D

Hose clamping 쐌

쐌

NGGI0001S0802

If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position. Discard old clamps; replace with new ones.

SMA021D

쐌

After installing leaf spring clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around.

PRECAUTIONS FOR ENGINE OILS

NGGI0001S05

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 SMA022D

쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGGI0001S0501

Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes, 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.

GI-6

PRECAUTIONS Precautions (Cont’d)

쐌 쐌 쐌 쐌 쐌

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

LC

FE CL

NGGI0001S0601

MT AT

NGGI0001S0602

Use unleaded premium gasoline with an octane rating of at least 91 AKI (Anti-Knock Index) number (research octane number 96) for the VG33ER engine. If premium gasoline is not available, unleaded regular gasoline with an octane rating of 87 AKI number (research octane number 91) may be temporarily used, but only under the following precautions: 쐌 Have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gasoline as soon as possible. 쐌 Avoid full throttle driving and abrupt acceleration. CAUTION: Use unleaded fuel only. Under no circumstances should leaded gasoline be used. It will damage the three way catalyst and increase dangerous emissions from the vehicle exhaust. Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

PRECAUTIONS FOR AIR CONDITIONING

EC

NGGI0001S06

Use unleaded gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (research octane number 91) for the KA24DE and VG33E engines.

VG33ER ENGINES

EM

NGGI0001S0502

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 onto the ground, down sewers or drains, or into water courses. The regulations concerning the pollution vary between regions.

PRECAUTIONS FOR FUEL KA24DE and VG33E Engines

MA

NGGI0001S07

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA-3, “HFC-134a (R-134a) Service Procedure”, for specific instructions.

TF PD AX SU BR ST RS BT HA SC EL

GI-7

IDX

NGGI0002

HOW TO USE THIS MANUAL 쐌

쐌 쐌 쐌 쐌 쐌 쐌

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. 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 matching it to the section’s black tab. THE CONTENTS are listed on the first page of each section. THE TITLE is indicated on the upper portion of each page and shows the part or system. THE PAGE NUMBER of each section consists of two 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 (e.g. SEC.440) and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG.

SBR364AC

쐌

쐌

쐌

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. The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. “Example” 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.

GI-8

HOW TO USE THIS MANUAL 쐌 쐌

SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. The following SYMBOLS AND ABBREVIATIONS are used: SYMBOL

ABBREVIATION

SYMBOL

Tightening torque

ABBREVIATION Air Conditioner

MA

A/C

EM Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease.

P/S

Should be lubricated with oil.

Tool

Special Service Tools

Sealing point

SAE

Society of Automotive Engineers, Inc.

Checking point

ATF

Automatic Transmission Fluid

Always replace after every disassembly.

D1

Apply petroleum jelly.

D2

쎻 P

SDS

Power Steering

LC

Drive range 2nd gear

D3

Drive range 3rd gear

Service Data and Specifications

D4

Drive range 4th gear

LH, RH

Left-Hand, Right-Hand

FR, RR

Front, Rear

22

2nd range 2nd gear

Automatic Transaxle/Transmission

21

2nd range 1st gear

A/T ,

4-Wheel Drive

12

4WD 2WD

2-Wheel Drive

11

FE

Drive range 1st gear

Apply ATF.

O/D

EC

CL MT

Overdrive

1st range 2nd gear 1st range 1st gear

AT TF PD AX SU BR ST RS BT HA SC EL

GI-9

IDX

NGGI0003

HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL —

Sample/Wiring Diagram — EXAMPL — 쐌

NGGI0003S01

For Description, refer to GI-12.

SGI091A

GI-10

HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL — (Cont’d)

OPTIONAL SPLICE

NGGI0003S0101

MA EM LC EC FE CL MT AT SGI942

TF PD AX SU BR ST RS BT HA SC EL

GI-11

IDX

HOW TO READ WIRING DIAGRAMS Description

Description Number

Item

=NGGI0003S02

Description

1

Power condition

쐌 This shows the condition when the system receives battery positive voltage (can be operated).

2

Fusible link

쐌 The double line shows that this is a fusible link. 쐌 The open circle shows current flow in, and the shaded circle shows current flow out.

3

Fusible link/fuse location

쐌 This shows the location of the fusible link or fuse in the fusible link or fuse box. Refer to EL-12, “Wiring Diagram - POWER -”.

4

Fuse

쐌 The single line shows that this is a fuse. 쐌 The open circle shows current flow in, and the shaded circle shows current flow out.

5

Current rating

쐌 This shows the current rating of the fusible link or fuse.

6

Connectors

쐌 This shows that connector E3 is female and connector M1 is male. 쐌 The G/R wire is located in the 1A terminal of both connectors. 쐌 Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ connector. Refer to “Super Multiple Junction (SMJ)”, GI-17.

7

Optional splice

쐌 The open circle shows that the splice is optional depending on vehicle application.

8

Splice

쐌 The shaded circle shows that the splice is always on the vehicle.

9

Page crossing

쐌 This arrow shows that the circuit continues to an adjacent page. 쐌 The A will match with the A on the preceding or next page.

10

Common connector

쐌 The dotted lines between terminals show that these terminals are part of the same connector.

11

Option abbreviation

쐌 This shows that the circuit is optional depending on vehicle application.

12

Relay

쐌 This shows an internal representation of the relay. Refer to EL-8, “Description”.

13

Connectors

쐌 This shows that the connector is connected to the body or a terminal with bolt or nut. 쐌 This shows a code for the color of the wire.

14

Wire color

B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green

BR = Brown OR = Orange P = Pink PU = Purple GY = Gray SB = Sky Blue 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 15

Option description

쐌 This shows a description of the option abbreviation used on the page.

16

Switch

쐌 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.

17

Assembly parts

쐌 Connector terminal in component shows that it is a harness incorporated assembly.

18

Cell code

쐌 This identifies each page of the wiring diagram by section, system and wiring diagram page number.

19

Current flow arrow

쐌 Arrow indicates electric current flow, especially where the direction of standard flow (vertically downward or horizontally from left to right) is difficult to follow. ” shows that current can flow in either direction depending on circuit 쐌 A double arrow “ operation.

20

System branch

쐌 This shows that the system branches to another system identified by cell code (section and system).

GI-12

HOW TO READ WIRING DIAGRAMS Description (Cont’d) Number

Item

Description

21

Page crossing

쐌 This arrow shows that the circuit continues to another page identified by cell code. 쐌 The C will match with the C on another page within the system other than the next or preceding pages.

22

Shielded line

쐌 The line enclosed by broken line circle shows shield wire.

23

Component box in wave line

쐌 This shows that another part of the component is also shown on another page (indicated by wave line) within the system.

24

Component name

쐌 This shows the name of a component.

Connector number

쐌 This shows the connector number. 쐌 The letter shows which harness the connector is located in. 쐌 Example: M: main harness. For detail and to locate the connector, refer to EL-252, “Main Harness”. A coordinate grid is included for complex harnesses to aid in locating connectors.

25

Ground (GND)

쐌 The line spliced and grounded under wire color shows that ground line is spliced at the grounded connector.

27

Ground (GND)

쐌 This shows the ground connection. For detailed ground distribution information, refer to EL-18, “GROUND DISTRIBUTION”.

28

Connector views

쐌 This area shows the connector faces of the components in the wiring diagram on the page.

29

Common component

쐌 Connectors enclosed in broken line show that these connectors belong to the same component.

30

Connector color

쐌 This shows a code for the color of the connector. For code meaning, refer to wire color codes, Number 14 of this chart.

Fusible link and fuse box

쐌 This shows the arrangement of fusible link(s) and fuse(s), used for connector views of the power supply routing. Refer to EL-10, “Circuit Diagram”. The open square shows current flow in, and the shaded square shows current flow out.

Reference area

쐌 This shows that more information on the Super Multiple Junction (SMJ), Electrical Units, etc. exists at the end of this manual. Refer to “REFERENCE AREA”, GI-17 for details.

26

31

32

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

GI-13

IDX

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

CONNECTOR SYMBOLS

=NGGI0003S0201

Most of connector symbols in wiring diagrams are shown from the terminal side. 쐌 Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. 쐌 Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. 쐌 Certain systems and components, especially related to OBD, may use a new style slide-locking type harness connector. For description and how to disconnect, refer to EL-6, “Description”.

SGI364

쐌

Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

SGI363

GI-14

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

SWITCH POSITIONS

NGGI0003S0202

Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. A vehicle is in the “normal” condition when: 쐌 ignition switch is OFF, 쐌 doors, hood and trunk lid/back door are closed, 쐌 pedals are not depressed, and 쐌 parking brake is released.

MA EM LC EC FE CL MT

SGI860

DETECTABLE LINES AND NON-DETECTABLE LINES NGGI0003S0203 In some wiring diagrams, two kinds of lines, representing wires, with different weight are used. 쐌 A line with regular weight (wider line) represents a “detectable line for DTC (Diagnostic Trouble Code)”. A “detectable line for DTC” is a circuit in which ECM can detect its malfunctions with the on board diagnostic system. 쐌 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.

AT TF PD AX SU BR ST RS

AGI095

BT HA SC EL

GI-15

IDX

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

MULTIPLE SWITCH

=NGGI0003S0204

The continuity of multiple switch is described in two ways as shown below. 쐌 The switch chart is used in schematic diagrams. 쐌 The switch diagram is used in wiring diagrams.

SGI875

GI-16

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

REFERENCE AREA

=NGGI0003S0205

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 connectors symbols are not shown in the Connector Area.

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

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 the “SUPER MULTIPLE JUNCTION (SMJ)” electrical reference page at the end of the manual.

GI-17

HA SC EL IDX

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

Fuse block—Junction box (J/B) Fuse block—Junction box (J/B) connector number is shown in the Reference Area of the wiring diagram. For connector terminal and fuse arrangement, refer to the “FUSE BLOCK—Junction Box (J/B)” electrical reference page at the end of the manual. Fuse and fusible link box For fuse arrangement in the fuse and fusible link box, refer to the “FUSE AND FUSIBLE LINK BOX” electrical reference page at the end of the manual. Electrical units Electrical unit connector symbols are shown in the Connector Area of the wiring diagram. However, when there is not enough space to show the connector terminal arrangement in the Connector Area of the wiring diagram, the electrical unit connector number is shown in the Reference Area of the wiring diagram. For electrical unit connector terminal arrangement, refer to the “ELECTRICAL UNITS” electrical reference page at the end of the manual. Most of the electrical unit connectors on this page are shown from the harness side for the connector. Joint connector Joint connector symbols are shown in the connector area of the wiring diagram. For connector internal wiring layout and joint connector terminal arrangement, refer to the “JOINT CONNECTOR” electrical reference page at the end of the manual.

GI-18

NGGI0011

HOW TO CHECK TERMINAL Connector and Terminal Pin Kit

Connector and Terminal Pin Kit

NGGI0011S01

Use the connector and terminal pin kit listed below when replacing connectors or terminals. The connector and terminal pin kit contains some of the most commonly used NISSAN connectors and terminals. Tool number (Kent-Moore No.) Tool name

MA

Description

EM

(J38751-95NI) Connector and terminal pin kit (NISSAN) (J38751-95INF) Connector and terminal pin kit (INFINITI) (J42992-98KIT) OBD and terminal repair kit (J42992-2000UPD) WGI043 OBD-II connector kit update

LC EC FE WGI044

CL MT

How to Probe Connectors

NGGI0011S02

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.

AT TF PD AX

PROBING FROM HARNESS SIDE

NGGI0011S0201

Standard type (not waterproof type) connector should be probed from harness side with “T” pin. 쐌 If the connector has a rear cover such as an ECM connector, remove the rear cover before probing the terminal. 쐌 Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result.

SU BR ST RS

SGI841

PROBING FROM TERMINAL SIDE

NGGI0011S0202

Female Terminal 쐌 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.

BT HA SC EL

SEL265V

GI-19

IDX

HOW TO CHECK TERMINAL How to Probe Connectors (Cont’d)

쐌

Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing.

SEL266V

Male Terminal Carefully probe the contact surface of each terminal using a “T” pin. Do not bend terminal.

SEL267V

How to Check Enlarged Contact Spring of Terminal

NGGI0011S03

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. 2.

Assemble a male terminal and approx. 10 cm (3.9 in) of wire. Use a male terminal which matches the female terminal. Disconnect the suspected faulty connector and hold it terminal side up.

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.

SEL271V

GI-20

HOW TO CHECK TERMINAL How to Check Enlarged Contact Spring of Terminal (Cont’d)

4.

While moving the connector, check whether the male terminal can be easily inserted or not.

MA EM LC

SEL272V

쐌

If the male terminal can be easily inserted into the female terminal, replace the female terminal.

EC FE CL MT

SEL273V

Waterproof Connector Inspection

NGGI0011S04

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.

RUBBER SEAL INSPECTION 쐌

SEL275V

쐌

NGGI0011S0401

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

AT TF PD AX SU BR

NGGI0011S0402

The wire seal must be installed on the wire insertion area of a waterproof connector. Be sure that the seal is installed properly.

ST RS

Terminal Lock Inspection

NGGI0011S05

Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit.

BT HA SC EL

SEL330V

GI-21

IDX

NGGI0004

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Work Flow

Work Flow

NGGI0004S01

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 Aftermarket Accessories have been installed.

STEP 2

Operate the system, road test if necessary. Verify the parameter of the incident. If the problem cannot be duplicated, refer to “Incident Simulation Tests” next page.

STEP 3

Get the proper diagnosis materials together including: POWER SUPPLY ROUTING System Operation Descriptions Applicable Service Manual Sections Check for any Service Bulletin. 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-22

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests

Incident Simulation Tests INTRODUCTION

NGGI0004S02 NGGI0004S0201

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: 쐌 Vehicle vibration 쐌 Heat sensitive 쐌 Freezing 쐌 Water intrusion 쐌 Electrical load 쐌 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

NGGI0004S0202

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.

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

SGI839

HA SC EL

GI-23

IDX

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: 쐌 Connectors not fully seated. 쐌 Wiring harness not long enough and is being stressed due to engine vibrations or rocking. 쐌 Wires laying across brackets or moving components. 쐌 Loose, dirty or corroded ground wires. 쐌 Wires routed too close to hot components. To inspect components under the hood, start by verifying the integrity of ground connections. Refer to GI-28, “GROUND INSPECTION”. 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

NGGI0004S0203

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. SGI842

FREEZING

NGGI0004S0204

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. SGI843

GI-24

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d)

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.

MA EM LC WATER INTRUSION

NGGI0004S0205

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.

EC FE CL MT

SGI844

ELECTRICAL LOAD

NGGI0004S0206

The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on.

COLD OR HOT START UP

AT TF

NGGI0004S0207

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.

PD AX

SGI845

Circuit Inspection INTRODUCTION

NGGI0004S03

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

SU

NGGI0004S0302

A circuit is open when there is no continuity through a section of the circuit.

SHORT There are two types of shorts.

BR ST RS BT HA

쐌 SHORT CIR- When a circuit contacts another circuit and causes CUIT the normal resistance to change. 쐌 SHORT TO GROUND

When a circuit contacts a ground source and grounds the circuit.

NOTE: Refer to “HOW TO CHECK TERMINAL”, GI-19 to probe or check terminal.

GI-25

SC EL IDX

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

TESTING FOR “OPENS” IN THE CIRCUIT

NGGI0004S0303

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.

AGI083

Continuity Check Method The continuity check is used to find an open in the circuit. The Digital Multimeter (DMM) set on the resistance function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Make sure to always start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits please refer to the schematic above. 1) Disconnect the battery negative cable. 2) Start at one end of the circuit and work your way to the other end. (At the fuse block in this example) 3) Connect one probe of the DMM to the fuse block terminal on the load side. 4) 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. 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.

GI-26

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

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

NGGI0004S0304

To simplify the discussion of shorts in the system please refer to the schematic below.

MA EM LC EC FE CL

AGI084

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. 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 battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground). 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).

GI-27

MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

5)

no voltage; short is further down the circuit than the relay. With SW1 closed, relay contacts jumped with fused jumper wire check for voltage. voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage; retrace steps and check power to fuse block.

GROUND INSPECTION

NGGI0004S0305

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 or screw. 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. For detailed ground distribution information, refer to EL-18, “GROUND DISTRIBUTION”.

SGI853

VOLTAGE DROP TESTS

NGGI0004S0306

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

GI-28

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

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: 쐌 Undersized wiring (single strand example) 쐌 Corrosion on switch contacts 쐌 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.

MA EM LC EC FE CL MT AT TF PD AX SU BR

SGI974

Measuring Voltage Drop — Step by Step The step by step method is most useful for isolating excessive drops in low voltage systems (such as those in “Computer Controlled Systems”). Circuits in the “Computer Controlled System” operate on very low amperage. The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the system. Such resistance variation may be caused by poor connection, improper installation, improper wire gauge or corrosion. The step by step voltage drop test can identify a component or wire with too much resistance.

ST RS BT HA SC EL

GI-29

IDX

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

SGI854

CONTROL UNIT CIRCUIT TEST

NGGI0004S0307

System Description: When the switch is ON, the control unit lights up the lamp.

MGI034A

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)

Switch OFF

Approx. 0

Approx. 0

Switch ON

Battery voltage

Approx. 0 (Inoperative lamp)

Switch OFF

Approx. 0

Approx. 0

2

Lamp

The voltage value is based on the body ground. * : If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the lamp.

GI-30

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

MA EM MGI035A

LC

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)

Switch OFF

Battery voltage

Battery voltage

Switch ON

Approx. 0

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

Approx. 5

2

Switch

The voltage value is based on the body ground. * : If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp.

EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

GI-31

IDX

NGGI0005

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 for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be “OFF”. 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.

GI-32

HOW TO FOLLOW TROUBLE DIAGNOSES How to Follow Test Groups in Trouble Diagnoses

How to Follow Test Groups in Trouble Diagnoses

NGGI0005S01

MA EM LC EC FE CL MT AT TF PD WGI027

1)

2)

3)

4)

Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups. Questions and required results. Questions and required results are indicated in bold type in test group. The meanings are as follows: a. Battery voltage → 11 - 14V or approximately 12V b. Voltage: Approximately 0V → Less than 1V c. Resistance: Continuity should exist → Approximately 0Ω Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Refer to “CONNECTOR SYMBOLS”, GI-14 and “Key to Symbols Signifying Measurements or Procedures”, GI-35. 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-33

AX SU BR ST RS BT HA SC EL IDX

HOW TO FOLLOW TROUBLE DIAGNOSES Harness Wire Color and Connector Number Indication

Harness Wire Color and Connector Number Indication

NGGI0005S03

There are two types of harness wire color and connector number indication.

TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION NGGI0005S0301 쐌 쐌 쐌

Letter designations next to test meter probe indicate harness wire color. Connector numbers in a single circle (e.g. M33) indicate harness connectors. Connector numbers in a double circle indicate component connectors.

AGI070

GI-34

HOW TO FOLLOW TROUBLE DIAGNOSES Harness Wire Color and Connector Number Indication (Cont’d)

TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT NGGI0005S0302

MA EM LC EC FE CL MT AT TF PD AX SU BR SGI144A

ST RS

Key to Symbols Signifying Measurements or Procedures

BT

NGGI0005S02

Symbol

Symbol explanation

Symbol

Symbol explanation

Check after disconnecting the connector to be measured.

Procedure with Generic Scan Tool (GST, OBD-II scan tool)

Check after connecting the connector to be measured.

Procedure without CONSULT-II or GST

GI-35

HA SC EL IDX

HOW TO FOLLOW TROUBLE DIAGNOSES Key to Symbols Signifying Measurements or Procedures (Cont’d) Symbol

Symbol explanation

Symbol

Symbol explanation

Insert key into ignition switch.

A/C switch is “OFF”.

Remove key from ignition switch.

A/C switch is “ON”.

Turn ignition switch to “OFF” position.

REC switch is “ON”.

Turn ignition switch to “ON” position.

REC switch is “OFF”.

Turn ignition switch to “START” position.

DEF switch is “ON”.

Turn ignition switch from “OFF” to “ACC” position.

VENT switch is “ON”.

Turn ignition switch from “ACC” to “OFF” position.

Fan switch is “ON”. (At any position except for “OFF” position)

Turn ignition switch from “OFF” to “ON” position.

Fan switch is “OFF”.

Turn ignition switch from “ON” to “OFF” position.

Apply positive voltage from battery with fuse directly to components.

Do not start engine, or check with engine stopped.

Drive vehicle.

Start engine, or check with engine running.

Disconnect battery negative cable.

Apply parking brake.

Depress brake pedal.

Release parking brake.

Release brake pedal.

Check after engine is warmed up sufficiently.

Depress accelerator pedal.

Voltage should be measured with a voltmeter.

Release accelerator pedal.

GI-36

HOW TO FOLLOW TROUBLE DIAGNOSES Key to Symbols Signifying Measurements or Procedures (Cont’d) Symbol

Symbol explanation

Symbol

Circuit resistance should be measured with an ohmmeter.

Symbol explanation Pin terminal check for SMJ type ECM and TCM connectors. For details regarding the terminal arrangement, refer to the reference area.

Current should be measured with an ammeter. Procedure with CONSULT-II

MA EM LC

Procedure without CONSULT-II

EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

GI-37

IDX

NGGI0006

CONSULT–II CHECKING SYSTEM Function and System Application

Function and System Application Diagnostic test mode

NGGI0006S01

Function

ENGINE

A/T

Air bag

ABS

Work support

This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-II.

x

x

—

—

DTC work support

Select the operating condition to confirm Diagnosis Trouble Codes.

—

x

—

—

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

x

x

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.

—

—

x

—

Data monitor

Input/Output data in the ECU (ECM) can be read.

x

x

—

x

Data monitor (spec.)

The specified values will be displayed when an OK/NG judgment is difficult for the DATA MONITOR items by Bar Chart and Line Graph.

x

—

—

—

Active test

Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECUs and also shifts some parameters in a specified range.

x

—

—

x

SRT & DTC confirmation

The results of SRT (System Readiness Test) and the self-diagnosis status/result can be confirmed.

x

x*

—

—

x

x

—

x

ECU (ECM) part number

ECU (ECM) part number can be read.

x: Applicable *: For VG33E and VG33ER engine

Nickel Metal Hydride Battery Replacement

NGGI0006S02

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.

GI-38

CONSULT–II CHECKING SYSTEM Checking Equipment

Checking Equipment

=NGGI0006S03

When ordering the below equipment, contact your NISSAN distributor. Tool name

Description

NISSAN CONSULT-II 쎻 1 CONSULT-II unit (Tester internal soft: Resident version 3.2.0) and accessories 쎻 2 Program card AED01B For details, refer to CONSULT-II Operation Manual.

MA EM LC EC AGI123

FE

Loading Procedure

NGGI0006S04

NOTE: 쐌 The CONSULT-II must be used in conjunction with a program card. CONSULT-II does not require loading (Initialization) procedure. 쐌 Be sure the CONSULT-II is turned off before installing or removing a program card.

CONSULT-II Data Link Connector (DLC) Circuit

NGGI0006S05

CL MT AT TF PD AX

SGI122A

SU INSPECTION PROCEDURE

NGGI0006S0501

If the CONSULT-II cannot diagnose the system properly, check the following items. Symptom CONSULT-II cannot access any system.

BR

Check item 쐌 CONSULT-II DLC power supply circuit (Terminal 8) and ground circuit (Terminal 4) ST (For detailed circuit, refer to EC-598 (KA24DE), EC-979 (VG33E) or EC-1197 (VG33ER), “MIL & Data Link Connectors Wiring Diagram”). 쐌 CONSULT DDL cable

CONSULT-II cannot access 쐌 CONSULT-II program card (Check the appropriate CONSULT-II program card for the system. individual system. (Other sysRefer to “Checking Equipment”, GI-39. tems can be accessed). 쐌 Power supply and ground circuit for the control unit of the system Refer to “Function and Sys(For detailed circuit, refer to wiring diagram for each system). tem Application” for the sys쐌 Open or short circuit between the system and CONSULT-II DLC tems supported by CONSULT(For detailed circuit, refer to wiring diagram for each system). II.

NOTE: The DDL1 and DDL2 circuits from DLC pins 12, 13, 14, and 15 may be connected to more than one system. A short in a DDL circuit connected to a control unit in one system may affect CONSULT-II access to other systems.

GI-39

RS BT HA SC EL IDX

NGGI0007

IDENTIFICATION INFORMATION Model Variation

Model Variation

NGGI0007S01

2– WHEEL DRIVE Body

Engine

Transmission

Destination

Grade

Model

KA24DE

FS5W71C (Manual)

U.S.A.

XE

TBGALEF-EUA

XE

TLPALEA-EUA

SE

TLPALFA-EUA

XE

—

SE

—

XE

TLPALEF-EUA

SE

TLPALFA-EUA

XE

—

SE

—

XE

TLPALEF-RUA

SE

TLPALFF-RUA

XE

—

SE

—

XE

TLPALEA-RUA

SE

TLPALFA-RUA

XE

—

SE

—

Grade

Model

XE

TLPNLEF-EUA

SE

TLPNLFF-EUA

XE

TLPNLEF-ENA

SE

TLPNLFF-ENA

XE

TLPNLEA-EUA

SE

TLPNLFA-EUA

XE

TLPNLEA-ENA

SE

TLPNLFA-ENA

XE

TLPNLEF-RUA

SE

TLPNLFF-RUA

XE

TLPNLEF-RNA

SE

TLPNLFF-RNA

XE

TLPNLEA-RUA

SE

TLPNLFA-RUA

XE

TLPNLEA-RNA

SE

TLPNLFA-RNA

U.S.A. RE4R01A (Automatic) Canada VG33E U.S.A. FS5R30A (Manual) Canada

Wagon

U.S.A. FS5R30A (Manual) Canada VG33ER U.S.A. RE4R01A (Automatic) Canada

4– WHEEL DRIVE Body

Engine

Transmission

Destination U.S.A.

FS5R30A (Manual) Canada VG33E U.S.A. RE4R01A (Automatic) Canada Wagon U.S.A FS5R30A (Manual) Canada VG33ER U.S.A RE4R01A (Automatic) Canada

GI-40

IDENTIFICATION INFORMATION Model Variation (Cont’d)

MA EM LC EC FE CL MT AT WGI037

TF PD AX SU BR ST RS BT HA SC EL

GI-41

IDX

IDENTIFICATION INFORMATION Identification Number

Identification Number

=NGGI0007S02

AGI104

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT NGGI0007S0201

WGI038

GI-42

IDENTIFICATION INFORMATION Identification Number (Cont’d)

ENGINE SERIAL NUMBER

NGGI0007S0203

MA EM LC

AGI106

EC FE CL MT

WGI029

TRANSFER SERIAL NUMBER

NGGI0007S0207

AT TF PD AX

AGI108

MANUAL TRANSMISSION NUMBER

NGGI0007S0210

SU BR ST RS

AGI109

AUTOMATIC TRANSMISSION NUMBER

NGGI0007S0205

BT HA SC EL

AGI111

GI-43

IDX

IDENTIFICATION INFORMATION Dimensions

Dimensions

NGGI0007S03

Unit: mm (in) 4x2 KA24DE

4x2 VG33E

4x2 VG33ER

4x4 VG33E

4x4 VG33ER

4x2 VG33E

4x2 VG33ER

4x4 VG33E

4x4 VG33ER

XE

XE

XE

XE

XE

SE

SE

SE

SE

Overall length

4250 (178)

4250 (178)

4250 (178)

4250 (178)

4250 (178)

4250 (178)

4250 (178)

4250 (178)

4250 (178)

Overall width *1

1788 (70.4)

1788 (70.4)

1788 (70.4)

1788 (70.4)

1788 (70.4)

1788 (70.4)

1788 (70.4)

1788 (70.4)

1788 (70.4)

Overall height *2

1872 (73.7)

1872 (73.7)

1890 (74.4)

1872 (73.7)

1887 (74.3)

1890 (74.4)

1877 (73.9)

1885 (74.2)

1874 (73.8)

Front tread

1525 (60)

1525 (60)

1525 (60)

1525 (60)

1525 (60)

1525 (60)

1525 (60)

1525 (60)

1525 (60)

Rear tread

1505 (59.3)

1505 (59.3)

1505 (59.3)

1505 (59.3)

1505 (59.3)

1505 (59.3)

1505 (59.3)

1505 (59.3)

1505 (59.3)

Wheelbase

2649 (104.3)

2649 (104.3)

2649 (104.3)

2649 (104.3)

2649 (104.3)

2649 (104.3)

2649 (104.3)

2649 (104.3)

2649 (104.3)

239 (9.4)

236 (9.3)

264 (10.4)

244 (9.6)

244 (9.6)

262 (10.3)

251 (9.9)

Drive type & engine Grade

Minimum Running Ground Clearance (at front suspension)

262 (10.3) 254 (10.0)

*1 Excludes Mirrors *2 With roof rack

Wheels & Tires Drive type

NGGI0007S04

Engine

Grade

Road wheel

Tire

Spare tire size

KA24DE

XE

15X7J Steel

P265/70R15

P265/70R15

XE

15x7J Steel 16x7JJ Aluminum

P265/70R15 P265/70R16

P265/70R15 P265/70R16

SE

16x7 Aluminum

P265/70R16

P265/70R16

XE

16x7JJ Aluminum

P265/70R16

P265/70R16

SE

17x8JJ Aluminum

P265/65R17

P265/65R17

XE

15x7J Steel 16x7JJ Aluminum

P265/70R15 P265/70R16

P265/70R15 P265/70R16

SE

16x7 Aluminum

P265/70R16

P265/70R16

XE

16x7JJ Aluminum

P265/70R16

P265/70R16

SE

17x8JJ Aluminum

P265/65R17

P265/65R17

VG33E 4x2

VG33ER

VG33E 4x4 VG33ER

GI-44

NGGI0008

LIFTING POINTS AND TOW TRUCK TOWING WARNING: 쐌 Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. 쐌 Place wheel chocks at both front and back of the wheels on the ground.

Pantograph Jack

NGGI0008S01

MA EM LC EC FE

AGI133

CL MT

Garage Jack and Safety Stand

NGGI0008S02

CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat.

AT TF PD AX SU BR ST RS

AGI113

BT HA SC EL

GI-45

IDX

LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift

2-pole Lift

=NGGI0008S03

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, brake cable, or fuel lines.

WGI025

Tow Truck Towing

AGI114

NGGI0008S04

CAUTION: 쐌 All applicable State or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. 쐌 It is necessary to use proper towing equipment to avoid possible damage during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. 쐌 Always attach safety chains before towing. 쐌 When towing, make sure that the transmission, steering system and power train are in good order. If any unit is damaged, dollies must be used. 쐌 Never tow an automatic transmission model from the rear (i.e., backward) with four wheels on the ground as this may cause serious and expensive damage to the transmission.

GI-46

LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont’d)

2-WHEEL DRIVE MODELS

NGGI0008S0406

NISSAN does not recommend towing automatic transmission equipped vehicles with the drive wheels on the ground. CAUTION: 쐌 When towing with the front wheels on the ground: Turn the ignition key to the OFF position and move the transmission shift lever to the neutral position. On automatic transmission models, to move the selector lever to N (neutral) position, turn the ignition key to OFF position and secure the steering wheel in a straight ahead position with a rope or similar device. Never place the ignition key in the LOCK position. This will result in damage to the steering lock mechanism. 쐌 When towing manual transmission models with the rear wheels on the ground (if you do not use a towing dollies): Always release the parking brake and move the transmission shift lever to the neutral position.

MA EM LC EC FE CL MT

AGI115

4-WHEEL DRIVE MODELS

NGGI0008S0407

NISSAN does not recommend towing automatic transmission equipped vehicles with the drive wheels on the ground. CAUTION: 쐌 When towing with the front wheels on the ground or rear wheels on the ground (If you do not use towing dollies): Set the free-running hubs to the free position and move the transfer case shift lever into the “2H” position. 쐌 When towing with the front on the ground: Turn the ignition key to the OFF position and secure the steering wheel in a straight ahead position with a rope or similar device. Never place the ignition key in the LOCK position. This will result in damage to the steering lock mechanism. 쐌 When towing manual transmission models with the rear wheels on the ground: Always release the parking brake and move the transmission shift lever to the neutral position.

AT

TOWING POINT

ST

NGGI0008S0409

Never tow the vehicle using only the towing points. To avoid damaging the vehicle body, use proper towing equipment when towing.

TF PD AX SU BR

RS

AGI116

BT HA SC EL

GI-47

IDX

LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont’d)

AGI117

VEHICLE RECOVERY (FREEING A STUCK VEHICLE) NGGI0008S0403 쐌 쐌 쐌 쐌

Tow chains or cables must be attached only to the main structural members of the vehicle. Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or cooling systems Always pull the cable straight out from the front or rear of the vehicle. Never pull the vehicle at a sideways angle. Pulling devices such as ropes or canvas straps are not recommended for use for vehicle towing or recovery.

GI-48

NGGI0009

TIGHTENING TORQUE OF STANDARD BOLTS

Grade

4T

Bolt diameter Bolt size * mm M6

6.0

M8

8.0

M10

M12

7T

Hexagon head bolt

Hexagon flange bolt

N·m

kg-m

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

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

—

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

—

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

1.25

21

2.1

15

—

25

2.5

18

—

M8

8.0 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

—

1.25

77

7.9

57

—

92

9.4

68

—

M10

M12

9T

Tightening torque (Without lubricant) Pitch mm

10.0

12.0

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

—

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

—

M10

M12 M14

MA EM LC EC FE CL MT AT TF PD AX

10.0

SU

12.0 14.0

*: Nominal diameter 1) Special parts are excluded. 2) This standard is applicable to bolts having the following marks embossed on the bolt head.

BR ST RS BT HA SC

MGI044A

EL

GI-49

IDX

NGGI0012

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS Refer to the following chart for help in selecting the appropriate chemical product or sealant. Product Description

1

2

3

4

5

6

Rear View Mirror Adhesive

Anaerobic Liquid Gasket

High Performance Thread Sealant

Silicone RTV

High Temperature, High Strength Thread Locking Sealant (Red)

Medium Strength Thread Locking Sealant (Blue)

NISSAN North America Part No. (USA)

Purpose

Used to permanently remount 999MP-AM000P rear view mirrors to windows. For metal-to-metal flange sealing. Can fill a .015″ gap and provide instant sealing for most powertrain applications.

999MP-AM001P

Provides instant sealing on any threaded or parallel threaded fitting. (Thread seal- 999MP-AM002P ant only, no locking ability.) 쐌 Do not use on plastic.

Gasket Maker

Threadlocker

Threadlocker (service tool removable)

GI-50

999MP-AM003P (Ultra Grey)

999MP-AM004P

999MP-AM005P

NISSAN Canada Part No. (Canada)

Aftermarket Cross Reference Part Nos.

99998-50505

Permatex 81844

99998-50503

Three Bond 1215; Permatex 51813 and 51817

999MP-AM002P

Permatex 56521

99998-50506 (Ultra Grey)

Permatex Ultra Grey 82194; Three Bond 1207 and 1216; NISSAN RTV Part No. 999MPA7007

999MP-AM004P

Permatex 27200; Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E, and 1388

999MP-AM005P

Permatex 24200, 81788, -89, -90; Three Bond 1322, 1322N, 1324 D&N, 1333D, 1361C, 1364D, 1370C and 1374

NGGI0010

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List

SAE J1930 Terminology List

NGGI0010S01

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. NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

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

Canister

***

Canister

Carburetor

CARB

Carburetor

Charge air cooler

CAC

Intercooler

Closed loop

CL

Closed loop

Closed throttle position switch

CTP switch

Idle switch

Clutch pedal position switch

CPP switch

Clutch switch

Continuous fuel injection system

CFI system

***

Continuous trap oxidizer system

CTOX system

***

Crankshaft position

CKP

***

Crankshaft position sensor

CKPS

***

Data link connector

DLC

***

Diagnostic test mode

DTM

Diagnostic mode

Diagnostic test mode selector

DTM selector

Diagnostic mode selector

Diagnostic test mode I

DTM I

Mode I

Diagnostic test mode II

DTM II

Mode II

Diagnostic trouble code

DTC

Malfunction code

Direct fuel injection system

DFI system

***

Distributor ignition system

DI system

Ignition timing control

Early fuel evaporation-mixture heater

EFE-mixture heater

Mixture heater

Early fuel evaporation system

EFE system

Mixture heater control

Electrically erasable programmable read only memory

EEPROM

***

Electronic ignition system

EI system

Ignition timing control

Engine control

EC

***

Engine control module

ECM

ECCS control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

EM

***

Engine speed

RPM

Engine speed

Erasable programmable read only memory

EPROM

***

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

GI-51

BT HA SC EL IDX

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Cont’d) NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Evaporative emission canister

EVAP canister

Canister

Evaporative emission system

EVAP system

Canister control solenoid valve

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

EGRT sensor

Exhaust gas temperature sensor

Flash electrically erasable programmable read only memory

FEEPROM

***

Flash erasable programmable read only memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Fuel pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid valve

***

PRVR control solenoid valve

Fuel trim

FT

***

Heated Oxygen sensor

HO2S

Exhaust gas sensor

Idle air control system

IAC system

Idle speed control

Idle air control valve-air regulator

IACV-air regulator

Air regulator

Idle air control valve-auxiliary air control valve

IACV-AAC valve

Auxiliary air control (AAC) valve

Idle air control valve-FICD solenoid valve

IACV-FICD solenoid valve

FICD solenoid valve

Idle air control valve-idle up control solenoid valve

IACV-idle up control solenoid valve

Idle up control solenoid valve

Idle speed control-FI pot

ISC-FI pot

FI pot

Idle speed control system

ISC system

***

Ignition control

IC

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

IA

Air

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

KS

Detonation sensor

Malfunction indicator lamp

MIL

Check engine light

Manifold absolute pressure

MAP

***

Manifold absolute pressure sensor

MAPS

***

Manifold differential pressure

MDP

***

EGR temperature sensor

GI-52

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Cont’d) NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Manifold differential pressure sensor

MDPS

***

Manifold surface temperature

MST

***

Manifold surface temperature sensor

MSTS

***

Manifold vacuum zone

MVZ

***

Manifold vacuum zone sensor

MVZS

***

Mass air flow sensor

MAFS

Air flow meter

Mixture control solenoid valve

MC solenoid valve

Air-fuel ratio control solenoid valve

Multiport fuel injection system

MFI system

Fuel injection control

Nonvolatile random access memory

NVRAM

***

On board diagnostic system

OBD system

Self-diagnosis

Open loop

OL

Open loop

Oxidation catalyst

OC

Catalyst

Oxidation catalytic converter system

OC system

***

Oxygen sensor

O2S

Exhaust gas sensor

Park position switch

***

Park switch

Park/neutral position switch

PNP switch

Park/neutral switch Inhibitor switch Neutral position switch

Periodic trap oxidizer system

PTOX system

***

Positive crankcase ventilation

PCV

Positive crankcase ventilation

Positive crankcase ventilation valve

PCV valve

PCV valve

Powertrain control module

PCM

***

Programmable read only memory

PROM

***

Pulsed secondary air injection control solenoid valve

PAIRC solenoid valve

AIV control solenoid valve

Pulsed secondary air injection system

PAIR system

Air induction valve (AIV) control

Pulsed secondary air injection valve

PAIR valve

Air induction valve

Random access memory

RAM

***

Read only memory

ROM

***

Scan tool

ST

***

Secondary air injection pump

AIR pump

***

Secondary air injection system

AIR system

***

Sequential multiport fuel injection system

SFI system

Sequential fuel injection

Service reminder indicator

SRI

***

Simultaneous multiport fuel injection system

***

Simultaneous fuel injection

Smoke puff limiter system

SPL system

***

Supercharger

SC

***

Supercharger bypass

SCB

***

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

GI-53

EL IDX

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Cont’d) NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

System readiness test

SRT

***

Thermal vacuum valve

TVV

Thermal vacuum valve

Three way catalyst

TWC

Catalyst

Three way catalytic converter system

TWC system

***

Three way + oxidation catalyst

TWC + OC

Catalyst

Three way + oxidation catalytic converter system

TWC + OC system

***

Throttle body

TB

Throttle chamber SPI body

Throttle body fuel injection system

TBI system

Fuel injection control

Throttle position

TP

Throttle position

Throttle position sensor

TPS

Throttle sensor

Throttle position switch

TP switch

Throttle switch

Torque converter clutch solenoid valve

TCC solenoid valve

Lock-up cancel solenoid Lock-up solenoid

Transmission control module

TCM

A/T control unit

Turbocharger

TC

Turbocharger

Vehicle speed sensor

VSS

Vehicle speed sensor

Volume air flow sensor

VAFS

Air flow meter

Warm up oxidation catalyst

WU-OC

Catalyst

Warm up oxidation catalytic converter sys- WU-OC system tem

***

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

GI

EM LC EC

CONTENTS PRECAUTIONS ...............................................................3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............3 PREPARATION ...............................................................4 Special Service Tools ..................................................4 Commercial Service Tool.............................................4 GENERAL MAINTENANCE ............................................5 PERIODIC MAINTENANCE ............................................7 Schedule 1...................................................................8 EMISSION CONTROL SYSTEM MAINTENANCE .........8 CHASSIS AND BODY MAINTENANCE ........................9 Schedule 2.................................................................11 EMISSION CONTROL SYSTEM MAINTENANCE .......11 CHASSIS AND BODY MAINTENANCE ......................12 RECOMMENDED FLUIDS AND LUBRICANTS...........13 Fluids and Lubricants ................................................13 SAE Viscosity Number ..............................................14 GASOLINE ENGINE OIL ..........................................14 Anti-freeze Coolant Mixture Ratio .............................15 KA24DE ENGINE MAINTENANCE ..............................................16 Checking Drive Belts .................................................16 Changing Engine Coolant..........................................17 -DRAINING ENGINE COOLANT- ..............................17 -REFILLING ENGINE COOLANT-..............................17 -FLUSHING COOLING SYSTEM- ..............................19 Checking Fuel Lines ..................................................19 Changing Fuel Filter ..................................................20 WITH CONSULT-II ..............................................20 WITHOUT CONSULT-II .......................................20 Changing Air Cleaner Filter .......................................21 Changing Engine Oil..................................................21 Changing Oil Filter.....................................................22 Changing Spark Plugs...............................................22 Checking EVAP Vapor Lines .....................................23 Changing Positive Crankcase Ventilation (PCV) Filter ...........................................................................24 SERVICE DATA AND SPECIFICATIONS (SDS) .........25

FE

Engine Maintenance ..................................................25 KA24DE ..................................................................25

CL MT

VG33E AND VG33ER ENGINE MAINTENANCE ..............................................26 Checking Drive Belts .................................................26 DRIVE BELT DEFLECTION AND TENSION ...............28 Changing Engine Coolant..........................................28 -DRAINING ENGINE COOLANT- ...............................28 -REFILLING ENGINE COOLANT- ..............................29 -FLUSHING COOLING SYSTEM- ..............................30 Checking Fuel Lines ..................................................31 Changing Fuel Filter ..................................................31 WITH CONSULT-II ..............................................31 WITHOUT CONSULT-II .......................................32 Changing Air Cleaner Filter .......................................32 VISCOUS PAPER TYPE ...........................................32 Changing Engine Oil..................................................32 Changing Oil Filter.....................................................33 Changing Spark Plugs...............................................34 Checking EVAP Vapor Lines .....................................36 SERVICE DATA AND SPECIFICATIONS (SDS) .........37 Engine Maintenance ..................................................37 VG33E AND VG33ER...............................................37 CHASSIS AND BODY MAINTENANCE .......................38 Checking Exhaust System.........................................38 Checking Clutch Fluid Level and Leaks....................38 Checking M/T Oil .......................................................38 Changing M/T Oil.......................................................38 Checking Water Entry - For 4WD models with M/T.............................................................................39 Checking A/T Fluid ....................................................39 Changing A/T Fluid ....................................................40 Checking Transfer Fluid.............................................40 Changing Transfer Fluid ............................................40 Checking Propeller Shaft...........................................41 Greasing Propeller Shaft ...........................................41 Checking Differential Gear Oil...................................41

AT TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS Changing Differential Gear Oil ..................................42 LIMITED-SLIP DIFFERENTIAL GEAR........................42 Balancing Wheels ......................................................43 Tire Rotation ..............................................................43 Checking Brake Fluid Level and Leaks.....................43 Checking Brake Lines and Cables ............................43 Checking Disc Brake .................................................43 ROTOR ...................................................................43 CALIPER .................................................................44 PAD ........................................................................44 Checking Drum Brake ...............................................44 WHEEL CYLINDER ..................................................44 DRUM .....................................................................44 LINING ....................................................................44 Checking Steering Gear and Linkage .......................44

(Cont’d) STEERING GEAR ....................................................44 STEERING LINKAGE ...............................................44

Checking Power Steering Fluid and Lines ................45 CHECKING FLUID LEVEL ........................................45 CHECKING LINES ...................................................45 Checking Axle and Suspension Parts .......................45 FRONT AND REAR AXLE AND SUSPENSION PARTS ....................................................................45 DRIVE SHAFT .........................................................46

Lubricating Locks, Hinges and Hood Latches...........47 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters...............................................48 SERVICE DATA AND SPECIFICATIONS (SDS) .........49 Chassis and Body Maintenance................................49 WHEEL BALANCE ...................................................49

MA-2

PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGMA0001

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 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), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

GI

EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

MA-3

IDX

PREPARATION Special Service Tools

Special Service Tools

NGMA0002

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description Removing oil filter a: 64.3 mm (2.531 in)

KV10115801 (J38956) Oil filter cap wrench

NT375

Commercial Service Tool Tool name (Kent-Moore No.)

Description

Belt tension gauge (BT3373-F)

Checking drive belt tension

AMA126

Filling cooling system

Coolant refill tool (J-45695)

LMA053

MA-4

NGMA0052

NGMA0003

GENERAL MAINTENANCE General maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform checks and inspections themselves or have their NISSAN dealers do them. OUTSIDE THE VEHICLE

GI

The maintenance items listed here should be performed from time to time, unless otherwise specified. Item Tires

Reference page Check the pressure at least once a month and always prior to a long distance trip with a gauge. Adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessive wear.

—

EM

Wheel nuts

When checking the tires, make sure no nuts are missing, and check for any loose nuts. Tighten if necessary.

MA-43

LC

Windshield

Clean the windshield on a regular basis. Check the windshield at least every six months for cracks or other damage. Repair as necessary.

Tire rotation

Tires should be rotated every 12,000 km (7,500 miles).

Wheel alignment and balance

If the vehicle pulls to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed.

Windshield wiper blades Doors and engine hood

Lamps

Check for cracks or wear if they do not wipe properly.

EC MA-43

FE MA-43, SU-6, “Front Wheel Alignment”

—

Check that all doors and the engine hood operate smoothly as well as the trunk lid and back hatch. Also make sure that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch keeps the hood from opening when the primary latch is released. When driving in areas using road salt or other corrosive materials, check lubrication frequently.

MA-47

Make sure that the headlamps, stop lamps, tail lamps, turn signal lamps, and other lamps are all operating properly and installed securely. Also check headlamp aim. Clean the headlamps on a regular basis.

EL-38, “Aiming Adjustment”

MT AT TF PD AX

INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Item Warning lamps and buzzers/chimes

CL

SU

Reference page Make sure that all warning lamps and buzzers/chimes are operating properly.

Windshield wiper and Check that the wipers and washer operate properly and that the wipers do washer not streak.

EL-102, “Electrical Components Inspection” —

Windshield defroster

Check that the air comes out of the defroster outlets properly and in sufficient quantity when operating the heater or air conditioner.

Steering wheel

Check that it has the specified play. Be sure to check for changes in the steering condition, such as excessive play, hard steering or strange noises.

Seats

Check seat position controls such as seat adjusters, seatback recliner, etc. to make sure they operate smoothly and that all latches lock securely in every position. Check that the head restraints move up and down smoothly and that the locks (if equipped) hold securely in all latched positions. Check that the latches lock securely for folding-down rear seatbacks.

—

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-48, RS-6, “Seat Belt Inspection”

Accelerator pedal

Check that pedal for smooth operation and make sure the pedal does not catch or require uneven effort. Keep the floor mats away from the pedal.

MA-5

BR ST

—

RS ST-6, “Checking Steering Wheel Play”

BT

FE-3, “Adjusting Accelerator Wire”

HA SC EL IDX

GENERAL MAINTENANCE Item

Reference page

Clutch pedal

Make sure the pedal operates smoothly and check that it has the proper free play.

CL-6, “Adjusting Clutch Pedal”

Brakes

Check that the brake does not pull the vehicle to one side when applied.

Brake pedal and booster

Check the pedal for smooth operation and make sure it has the proper distance under it when depressed fully. Check the brake booster function. Be sure to keep floor mats away from the pedal.

BR-11, “Removal and Installation” and BR-16, “On-vehicle Service”

Parking brake

Check that the lever has the proper travel and make sure that the vehicle is held securely on a fairly steep hill when only the parking brake is applied.

BR-27, “PARKING BRAKE CONTROL”

Automatic transmission “Park” mechanism

Check that the lock release button on the selector lever operates properly and smoothly. On a fairly steep hill check that the vehicle is held securely with the selector lever in the P position without applying any brakes.

—

—

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). Reference page Item

VG33E and VG33ER

KA24DE Windshield washer fluid

Check that there is adequate fluid in the tank.

Engine coolant level

Check the coolant level when the engine is cold.

Radiator and hoses

Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deformation, deterioration or loose connections.

— MA-17

MA-29 —

Brake and clutch fluid levels

Make sure that the brake and clutch fluid levels are between the “MAX” and “MIN” lines on the reservoirs

MA-38, 43

Battery

Check the fluid level in each cell. It should be between the “MAX” and “MIN” lines. Vehicles operated in high temperatures or under severe conditions require frequent checks of the battery fluid level.

—

Engine drive belts

Make sure that no belt is frayed, worn, cracked or oily.

MA-16

MA-26

Engine oil level

Check the level on the dipstick after parking the vehicle on a level spot and turning off the engine.

MA-21

MA-32

Power steering fluid level and lines

Check the level on the reservoir with the engine off. Check the lines for improper attachment, leaks, cracks, etc.

MA-45

Automatic transmission fluid level

Check the level on the dipstick after putting the selector lever in “P” with the engine idling.

MA-39

Exhaust system

Make sure there are no loose supports, cracks or holes. If the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble and correct it.

MA-38

The underbody is frequently exposed to corrosive substances such as those used on icy roads or to control dust. It is very important to remove these substances, otherwise rust will form on the floor pan, frame, fuel lines and around the exhaust system. At the end of winter, the underbody should be thoroughly flushed with plain water, being careful to clean those areas where mud and dirt can easily accumulate.

—

Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately.

—

Underbody

Fluid leaks

MA-6

NGMA0004

PERIODIC MAINTENANCE Two different maintenance schedules are provided, and should be used, depending upon the conditions in which the vehicle is mainly operated. After 60,000 miles (96,000 km) or 48 months, continue the periodic maintenance at the same mileage/time intervals.

Schedule 1

Follow Periodic Maintenance Schedule 1 if your driving habits frequently includes one or more of the following driving conditions: 쐌 Repeated short trips of less than 5 miles (8 km). 쐌 Repeated short trips of less than 10 miles (16 km) with outside temperatures remaining below freezing. 쐌 Operating in hot weather in stop-and-go “rush hour” traffic. 쐌 Extensive idling and/or low speed driving for long distances, such as police, taxi or door-to-door delivery use. 쐌 Driving in dusty conditions. 쐌 Driving on rough, muddy, or salt spread roads. 쐌 Towing a trailer, using a camper or a car-top carrier.

Emission Control System Maintenance

Follow Periodic Maintenance Schedule 2 if none of the driving conditions shown in Schedule 1 apply to the driving habits.

Emission Control System Maintenance

MA-11

Chassis and Body Maintenance

MA-12

GI

MA-8

EM Chassis and Body Maintenance MA-9

LC EC

Schedule 2

Maintenance for off-road driving ( only) Whenever you drive off-road through sand, mud or water, more frequent maintenance may be required of the following items: 왖 Brake pads and rotors 왖 Brake lining and drums 왖 Brake lines and hoses 왖 Wheel bearing grease and free-running hub grease 왖 Differential, transmission and transfer oil 왖 Steering linkage 왖 Propeller shaft and drive shafts 왖 Air cleaner filter 왖 Clutch housing. Refer to “Checking Water Entry — For 4WD models with M/T”, MA-39.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

MA-7

IDX

NOTE (3)

Engine coolant

MA-8 R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R*

I*

I*

[R]

[R]

EM-38

—

MA-22

MA-22

MA-21

MA-17

MA-20

MA-19

MA-23

MA-24

MA-21

MA-16

KA24DE

—

EM-82

MA-34

MA-33

MA-32

MA-28

MA-31

MA-31

MA-36

—

MA-32

MA-26

VG33E and VG33ER

Reference Section - Page or - Content Title

[ ]: At the mileage intervals only

EMISSION CONTROL SYSTEM MAINTENANCE

NOTE: (1) If operating mainly in dusty conditions, more frequent maintenance may be required. (2) When the filter becomes clogged, the vehicle speed cannot be increased as the driver wishes. In such an event, replace the filter. (3) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months. (4) If valve noises increases, inspect valve clearance. ★ Maintenance items and intervals with “*” are recommended by NISSAN for reliable vehicle operation. The owner need not perform such maintenance in order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.

Intake and Exhaust valve clearance ★

Replace every 105,000 miles (169,000 km)

R

R

Timing belt

R

R

Replace every 105,000 miles (169,000 km)

R

Engine oil filter (Use part No. 15208-31U00 or equivalent for VG engine.)

R

Spark plugs (Double PLATINUM–TIPPED type)

R

Engine oil

NOTE (4)

NOTE (2)

I*

Fuel lines

Fuel filter*

I*

EVAP vapor lines

R

NOTE (2)

Positive crankcase ventilation (PCV) filter [R]

[R]

NOTE (1)

I*

7.5 11.25 15 18.75 22.5 26.25 30 33.75 37.5 41.25 45 48.75 52.5 56.25 60 (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) (78) (84) (90) (96) 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48

Air cleaner filter

3.75 (6) 3 I*

Miles x 1,000 (km x 1,000) Months

I = Inspect. Correct or replace if necessary.

MAINTENANCE INTERVAL

Drive belts

Perform at number of miles, kilometers or months, whichever comes first.

MAINTENANCE OPERATION

Abbreviations: R = Replace.

Schedule 1

PERIODIC MAINTENANCE Schedule 1 NGMA0004S01

NGMA0004S0101

NOTE (2)

NOTE (2)

Transfer fluid & differential gear oil (exc. LSD)

Limited slip differential (LSD) gear oil

MA-9

4x2

)

NOTE (5)

NOTE (4)

NOTE (3)

3.75 (6) 3

I

L

I

I

I

7.5 (12) 6

11.25 (18) 9

R

I

I

L

I

I

I

I

I

I

I

I

15 (24) 12

I

L

I

I

I

18.75 22.5 26.25 (30) (36) (42) 15 18 21

R

I

R

I

L

I

I

I

R

I

I

I

I

30 (48) 24

I

L

I

I

I

33.75 37.5 41.25 (54) (60) (66) 27 30 33

MAINTENANCE INTERVAL

R

I

I

L

I

I

I

I

I

I

I

I

45 (72) 36

I

L

I

I

I

48.75 52.5 56.25 (78) (84) (90) 39 42 45 I

R

I

R

I

L

I

I

I

R

I

I

HA-83

MA-38

MA-45

MA-45

MA-41

MA-46

MA-43

MA-45

MA-38

MA-42

MA-40, 41

MA-39, 40

MA-43, 44

MA-43

60 (96) 48

I

Reference Section - Page or - Content Title

CHASSIS AND BODY MAINTENANCE

NOTE: (1) If towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) oil at every 30,000 miles (48,000 km) or 24 months. (2) If towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) oil (exc. LSD) at every 30,000 miles (48,000 km) or 24 months, and change LSD gear oil every 15,000 miles (24,000 km) or 12 months. (3) Refer to “Tire rotation” under the “General maintenance” heading in this section. (4) The propeller shaft should be re-greased after being immersed in water.

In-cabin microfilter

Exhaust system

Front wheel bearing grease and free-running hub grease

Front wheel bearing grease

Propeller shaft (

Drive shaft boots and propeller shaft ) (

Tire rotation

Steering gear, linkage, axle & suspension parts

Manual transmission gear oil NOTE (1)

NOTE (1)

Automatic transmission fluid

Brake pads, rotors, drums & linings

Brake lines & cables

Perform at number of miles, kilometers or months, whichever comes first.

Miles x 1,000 (km x 1,000) Months

MAINTENANCE OPERATION

Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. L = Lubricate. [ ]: At the mileage intervals only.

PERIODIC MAINTENANCE Schedule 1 (Cont’d) NGMA0004S0102

GI

EM

LC

EC

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

(5) If operating frequently in water, replace grease every 3,750 miles (6,000 km) or 3 months.

Schedule 1 (Cont’d)

PERIODIC MAINTENANCE

MA-10

MA-11 NOTE (3)

NOTE (2)

NOTE (1)

NOTE (1)

Miles x 1,000 (km x 1,000) Months

R

R

R R

15 (24) 12

7.5 (12) 6

R

R

I*

I*

[R]

[R]

I*

30 (48) 24

R

R

37.5 (60) 30

R

R

45 (72) 36

Replace every 105,000 miles (169,000 km)

Replace every 105,000 miles (169,000 km)

R

R

22.5 (36) 18

MAINTENANCE INTERVAL

R

R

52.5 (84) 42

R

R

R*

I*

I*

[R]

[R]

I*

60 (96) 48

I = Inspect. Correct or replace if necessary.

EM-38

—

MA-22

MA-22

MA-21

MA-17

MA-20

MA-19

MA-23

MA-24

MA-21

MA-16

KA24DE

—

EM-82

MA-34

MA-33

MA-32

MA-28

MA-31

MA-31

MA-36

—

MA-32

MA-26

VG33E and VG33ER

Reference Section - Page or - Content Title

[ ]: At the mileage intervals only

NOTE: (1) When the filter becomes clogged, the vehicle speed cannot be increased as the driver wishes. In such an event, replace the filter. (2) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months. (3) If valve noises increase, inspect valve clearance. ★ Maintenance items and intervals with “*” are recommended by NISSAN for reliable vehicle operation. The owner need not perform such maintenance in order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.

Intake and Exhaust valve clearance ★

Timing belt

Spark plugs (Double PLATINUM–TIPPED type)

Engine oil filter

Engine oil

Engine coolant

Fuel filter*

Fuel lines

EVAP vapor lines

Positive crankcase ventilation (PCV) filter

Air cleaner filter

Drive belts

Perform at number of miles, kilometers or months, whichever comes first.

MAINTENANCE OPERATION

Abbreviations: R = Replace.

PERIODIC MAINTENANCE Schedule 2

Schedule 2

EMISSION CONTROL SYSTEM MAINTENANCE NGMA0004S02

NGMA0004S0201

GI

EM

LC

EC

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

I

Manual transmission gear oil

MA-12 R

NOTE: (1) Refer to “Tire rotation” under the “General maintenance” heading in this section. (2) The propeller shaft should be re-greased after being immersed in water.

In-cabin microfilter

Exhaust system

R

I

L

I

I

I

R

I

I

I

I

60 (96) 48

R

R

52.5 (84) 42

R

I

L

I

I

I

I

I

I

I

45 (72) 36

I

37.5 (60) 30

HA-83

MA-38

MA-45

MA-45

MA-41

MA-46

MA-43

MA-45

MA-38

MA-42

MA-40, 41

MA-39, 40

MA-43, 44

MA-43

Reference Section - Page or - Content Title

L = Lubricate. [ ]: At the mileage interval only.

I

R

I

L

Front wheel bearing grease and free-running hub grease ( )

L

I

I

I

R

I

I

I

I

30 (48) 24

I

)

22.5 (36) 18

MAINTENANCE INTERVAL

I = Inspect. Correct or replace if necessary.

Front wheel bearing grease (4x2)

Propeller shaft (

Drive shaft boots and propeller shaft ) (

Tire rotation

NOTE (2)

I

Limited slip differential (LSD) gear oil

I

I

Transfer fluid & differential gear oil (exc. LSD)

NOTE (1)

I

Automatic transmission fluid

Steering gear, linkage, axle & suspension parts

I

15 (24) 12

Brake pads, rotors, drums & linings

7.5 (12) 6 I

Miles x 1,000 (km x 1,000) Months

Brake lines & cables

Perform at number of miles, kilometers or months, whichever comes first.

MAINTENANCE OPERATION

Abbreviations: R = Replace.

Schedule 2 (Cont’d)

PERIODIC MAINTENANCE

CHASSIS AND BODY MAINTENANCE NGMA0004S0202

NGMA0005

RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants

Fluids and Lubricants

NGMA0005S01

KA24DE

GI Capacity (Approximate) KA24DE

Recommended Fluids/Lubricants US measure Imp measure

Liter

With oil filter

3-3/4 qt

3-1/8 qt

3.5

Without oil filter

3-1/2 qt

2-7/8 qt

3.3

Dry engine (Engine overhaul)

4-3/8 qt

3-5/8 qt

4.1

MT

7-3/4 qt

6-3/8 qt

7.3

AT

7-1/2 qt

6-1/4 qt

7.1

Mix 50% genuine NISSAN anti-freeze coolant or equivalent and 50% demineralized water or distilled water.

4-1/4 pt

3-1/2 pt

2.0

API GL-4, Viscosity SAE 75W-85

Drain and refill Engine oil

Cooling system (With reservoir)

Manual transmission gear oil (FS5W71C)

Differential carrier gear oil

C200

Power steering fluid

쐌 API Certification Mark*1 쐌 API grade SG/SH, Energy Conserving I & II or API grade SJ, Energy Conserving*1 쐌 ILSAC grade GF-I & GF-II*1

3-1/8 pt

2-5/8 pt

1.5

Standard differential gear: API GL-5 Viscosity SAE 80W-90*3 Limited-slip differential (LSD) gear: Use only LSD gear oil API GL-5 Viscosity SAE 80W-90*3 approved for NISSAN LSD*4.

30.4-33.8 fl oz

31.7-35.2 fl oz

0.9-1.0

Genuine NISSAN PSF II or equivalent*5

Brake and clutch fluid

—

—

—

Genuine NISSAN Brake Fluid*2 or equivalent DOT 3 (U.S. FMVSS No. 116)

Multi-purpose grease

—

—

—

NLGI No. 2 (Lithium soap base)

*1: For further details, see “SAE Viscosity Number”. *2: Available in mainland U.S.A. through your NISSAN dealer. *3: For hot climates, viscosity SAE 90 is suitable for ambient temperatures above 0°C (32°F). *4: Contact a NISSAN dealer for a list of approved oils. *5: Genuine NISSAN PSF, Canada NISSAN Automatic Transmission Fluid, DEXRONTMIII, MERCONTM, or equivalent ATF may also be used.

Capacity (Approximate) VG33E and VG33ER

Recommended Fluids/Lubricants US measure Imp measure

Engine oil

3-1/2 qt

2-7/8 qt

3.3

Without oil filter

3-1/8 qt

2-5/8 qt

3.0

4 qt

3-3/8 qt

3.8

11-5/8 qt

9-5/8 qt

10.95

5-7/8 pt

4-7/8 pt

2.8

Cooling system (With reservoir)

Transfer fluid (TX10A)

Liter

With oil filter

Dry engine (Engine overhaul)

Manual transmission gear oil (FS5R30A)

LC EC FE CL MT AT TF PD AX SU

VG33E and VG33ER

Drain and refill

EM

2WD

BR

쐌 API Certification Mark*1 쐌 API grade SG/SH, Energy Conserving I & II or API grade SJ, Energy Conserving*1 쐌 ILSAC grade GF-I & GF-II*1

ST

Mix 50% genuine NISSAN anti-freeze coolant or equivalent and 50% demineralized water or distilled water.

BT

RS

HA API GL-4, viscosity SAE 75W-85

4WD

10-3/4 pt

2-3/8 qt

9 pt

2 qt

MA-13

5.1

2.2

NISSAN Matic ’D’ (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid*2 or API GL-4 Viscosity SAE 75W-85 or 75W-90.

SC EL IDX

RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants (Cont’d) Capacity (Approximate) VG33E and VG33ER

Recommended Fluids/Lubricants US measure Imp measure

Liter Standard differential gear: API GL-5 Viscosity SAE 80W-90*4. Limited-slip differential (LSD) gear: Use only LSD gear oil API GL-5 Viscosity SAE 80W-90*4 approved for NISSAN LSD*5.

Front (4WD)

3-3/4 pt

3-1/8 pt

1.75

Rear

5-7/8 pt

4-7/8 pt

2.8

2WD

8-3/4

7-1/4

8.3

4WD

9 qt

7-1/2 qt

8.5

33.8-37.2 fl oz

35.2-38.7 fl oz

1.0-1.1

Brake and clutch fluid

—

—

—

Genuine NISSAN Brake Fluid*3 or equivalent DOT 3 (U.S. FMVSS No. 116)

Propeller shaft grease

—

—

—

NLGI No. 2 (Molybdenum disulphide lithium soap base)

Multi-purpose grease

—

—

—

NLGI No. 2 (Lithium soap base)

Free-running hub grease (Auto-lock)

—

—

—

Genuine NISSAN grease or equivalent

Differential carrier gear oil

Automatic transmission fluid

Power steering fluid

NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid*2 Genuine NISSAN PSF II or equivalent*6

*1: For further details, see “SAE Viscosity Number”. *2: DEXRON IIITM, MERCONTM or equivalent may also be used. Outside the continental United States and Alaska contact a NISSAN dealership for more information regarding suitable fluids, including recommended brand(s) of DEXRONTMIII, MERCONTM Automatic Transmission Fluid. *3: Available in mainland U.S.A. through your NISSAN dealer. *4: For hot climates, viscosity SAE 90 is suitable for ambient temperatures above 0°C (32°F). *5: Contact a NISSAN dealer for a list of approved oils. *6: Genuine NISSAN PSF, Canada NISSAN Automatic Transmission Fluid, DEXRONTMIII, MERCONTM, or equivalent ATF may also be used.

SAE Viscosity Number GASOLINE ENGINE OIL

NGMA0005S02 NGMA0005S0201

SAE 5W-30 viscosity oil is preferred for all temperatures. SAE 10W-30 and 10W-40 viscosity oil may be used if the ambient temperature is above −18°C (0°F).

AMA156

MA-14

RECOMMENDED FLUIDS AND LUBRICANTS Anti-freeze Coolant Mixture Ratio

Anti-freeze Coolant Mixture Ratio

NGMA0005S03

The engine cooling system is filled at the factory with a high-quality, year-round, anti-freeze coolant solution. The anti-freeze solution contains rust and corrosion inhibitors. Therefore, additional cooling system additives are not necessary. CAUTION: When adding or replacing coolant, be sure to use only genuine NISSAN anti-freeze coolant or equivalent with the proper mixture. Outside temperature down to: °C

°F

Genuine NISSAN anti-freeze coolant or equivalent

-35

-30

50%

GI

EM

Demineralized water or distilled water

LC

50%

EC

Other types of coolant solutions may damage the engine cooling system.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

MA-15

IDX

ENGINE MAINTENANCE

KA24DE

Checking Drive Belts

Checking Drive Belts

NGMA0056

AMA150

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. Check belt tension using belt tension gauge (BT3373-F or equivalent). Inspect drive belt deflection or tension when engine is cold. 쐌 Adjust if belt deflections exceed the limit or if belt tension is not within specifications. 쐌 Drive belt tension can be checked at other points on the belt.

MA-16

ENGINE MAINTENANCE

KA24DE Checking Drive Belts (Cont’d)

DRIVE BELT DEFLECTION AND TENSION Deflection adjustment

Unit: mm (in)

Tension adjustment

Used belt

*1 Unit: N (kg, lb)

GI

Used belt New belt

New belt

Limit

After adjustment

Generator

17 (0.67)

10 - 12 (0.39 0.47)

8 - 10 (0.31 0.39)

222.4 (22.7, 50)

355.8 - 444.8 489.3 - 578.2 (36.3 - 45.4, 80 - (49.9 - 59.0, 110 100) - 130)

Air conditioner compressor

16 (0.63)

10 - 12 (0.39 0.47)

8 - 10 (0.31 0.39)

200.2 (20.4, 45)

355.8 - 444.8 489.3 - 578.2 (36.3 - 45.4, 80 - (49.9 - 59.0, 110 100) - 130)

LC

Power steering oil pump

17 (0.67)

10 - 13 (0.39 0.51)

8 - 10 (0.31 0.39)

222.4 (22.7, 50)

355.8 - 444.8 489.3 - 578.2 (36.3 - 45.4, 80 - (49.9 - 59.0, 110 100) - 130)

EC

Applied pushing force

Limit

After adjustment

98 N (10 kg, 22 lb)

EM

FE

—

*1: If belt tension gauge cannot be installed at check point shown, check belt tension at a different location on the belt.

CL MT

Changing Engine Coolant

NGMA0057

WARNING: To avoid being scalded, never change the coolant when the engine is hot.

—DRAINING ENGINE COOLANT— 1. a. LMA048

b.

AT TF

NGMA0057S01

Set air conditioner system as follows to prevent coolant from remaining in the system. Turn ignition switch ON and set temperature control lever all the way to hot position for the highest temperature position. Wait 10 seconds before turning ignition switch OFF.

2.

Open drain plug at the bottom of radiator, and remove radiator cap. Be careful not to allow coolant to contact drive belts. When draining all of the coolant in the system, also perform the following two steps. 1) Remove cylinder block drain plug and air relief plug.

PD AX SU BR ST RS

SMA919C

2)

Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated flush engine cooling system, “Refer to FLUSHING COOLING SYSTEM”, MA-19.

—REFILLING ENGINE COOLANT— 1. 쐌 쐌

BT HA

NGMA0057S02

Install the radiator drain plug. Install the reservoir tank and cylinder block drain plug, if removed for a total system drain or for engine removal or repair. The radiator must be completely empty of coolant and water. Apply sealant to the threads of the cylinder block drain plugs. Use Genuine High Performance Thread Sealant or equivalent.

SC EL

SMA580C

MA-17

IDX

ENGINE MAINTENANCE

KA24DE

Changing Engine Coolant (Cont’d)

2. 3.

Refer to “Recommended Chemical Products and Sealants”, GI-50. Radiator drain plug: 7.8 - 11.8 N쐌m (0.8 - 1.2 kg-m, 69 104 in-lb) Cylinder block drain plug: 34 - 44 N쐌m (3.5 - 4.5 kg-m, 25 - 33 ft-lb) Air relief plug: 7 - 8 N쐌m (0.7 - 0.8 kg-m, 61- 69 in-lb) If disconnected, reattach the upper radiator hose at the engine side. Set the vehicle heater controls to the full HOT and heater ON position. Turn the vehicle ignition ON with the engine OFF as necessary to activate the heater mode.

4.

LMA054

Install the Tool by installing the radiator cap adapter onto the radiator neck opening. Then attache the gauge body assembly with the refill tube and the venturi assembly to the radiator cap adapter. 5. Insert the refill hose into the coolant mixture container that is placed at floor level. Make sure the ball valve is in the closed position. 쐌 Use Genuine NISSAN Anti-Freeze Coolant or equivalent, mixed 50/50 with distilled water or demineralized water. Refer to “Anti-freeze Coolant Mixture Ratio”, MA-15. Engine coolant capacity (without reservoir tank) MT: 6.5
(6 7/8 US qt) AT: 6.3
(6 5/8 US qt) Reservoir tank: 0.8
(7/8 US qt) 6. Install an air hose to the venturi assembly; the air pressure must be with specification. Compressed air supply pressure 5.7 - 8.5 kPa (5.6 - 8.4 kg/cm2, 80 - 120 psi) CAUTION: The compressed air supply must be equipped with an air dryer. 7. The vacuum gauge will begin to rise and there will be an audible hissing noise. During this process, open the ball valve on the refill hose slightly. Coolant will be visible rising in the refill hose. Once the refill hose is full of coolant, close the ball valve. This will purge any air trapped in the refill hose.

MA-18

ENGINE MAINTENANCE

KA24DE Changing Engine Coolant (Cont’d)

8.

LMA055

Continue to draw the vacuum until the gauge reaches 28 inches of vacuum. The gauge may not reach 28 inches in high altitude locations; refer to the vacuum specifications based on the altitude above sea level. Altitude above sea level

Vacuum gauge reading

0 - 100 m (328 ft)

28 inches of vacuum

300 m (984 ft)

27 inches of vacuum

500 m (1,641 ft)

26 inches of vacuum

1,000 m (3,281 ft)

24 - 25 inches of vacuum

GI

EM LC

9.

When the vacuum gauge has reached the specified amount, disconnect the air hose and wait 20 seconds to see if the system loses any vacuum. If the vacuum level drops , perform any necessary repairs to the system and repeat steps 6 - 8 to bring the vacuum to the specified amount. Recheck for any leaks. 10. Place the coolant container (with the refill hose inserted) at the same level as the top of the radiator. Then open the ball valve on the refill hose so the coolant will be drawn up to fill the cooling system. The cooling system is full when the vacuum gauge reads zero. CAUTION: Do not allow the coolant container to get too low when filling , to avoid air from being drawn into the cooling system. 11. Remove the Tool from the radiator neck opening. 12. Fill the cooling system reservoir tank to the specified level. Run the engine to warm up the cooling system and top up the system as necessary before installing the radiator cap.

—FLUSHING COOLING SYSTEM— 1. 2.

3. 4. 5. 6. 7.

NGMA0057S03

Open air relief plug. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. Repeat steps 1 through 6 until clear water begins to drain from radiator.

EC FE CL MT AT TF PD AX SU BR ST RS

Checking Fuel Lines

NGMA0058

Inspect fuel lines and tank for improper attachment, leaks, cracks, damage, chafing and deterioration. If necessary, repair or replace.

BT HA SC EL

SMA215C

MA-19

IDX

ENGINE MAINTENANCE

KA24DE

Changing Fuel Filter

Changing Fuel Filter

NGMA0059

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 the screw does not contact adjacent parts. WARNING: Before removing fuel filter, release fuel pressure from fuel line. AMA123

WITH CONSULT-II 1. 2. 3. 4.

5. 6. 7. 쐌 쐌

NGMA0059S01

Start engine. Perform “FUEL PRES RELEASE” in “WORK SUPPORT” mode to release fuel pressure to zero. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. Turn ignition switch “OFF”.

Remove the fuel filter shield. Loosen fuel hose clamps. Replace fuel filter. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. Properly tighten fuel hose clamps. Refer to “Checking Fuel Lines”, MA-19.

AMA151

WITHOUT CONSULT-II 1. 2. 3. 4.

NGMA0059S02

Remove fuel pump fuse. For correct fuse location, refer to label on fuse block cover. Start engine. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. Turn ignition switch “OFF” and install fuel pump fuse.

SMA869C

5. 6. 7. 쐌 쐌

Remove the fuel filter shield. Loosen fuel hose clamps. Replace fuel filter. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. Properly tighten fuel hose clamps. Refer to “Checking Fuel Lines”, MA-19.

AMA151

MA-20

ENGINE MAINTENANCE

KA24DE Changing Air Cleaner Filter

Changing Air Cleaner Filter

NGMA0060

The viscous paper type filter does not need cleaning between renewals.

GI

EM LC

SMA243C

Changing Engine Oil

AMA113

NGMA0061

WARNING: 쐌 Be careful not to burn yourself, as the engine oil is hot. 쐌 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. Remove drain plug and oil filler cap. 3. Drain oil and refill with new engine oil. Oil specification and viscosity: 쐌 API Certification Mark 쐌 API grade SG/SH, Energy Conserving I & II or API grade SJ, Energy Conserving 쐌 ILSAC grade GF-I & GF-II 쐌 Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13. Oil capacity (Approximately):

EC FE CL MT AT TF PD

Unit:
(US qt, Imp qt) with oil filter change

3.5 (3-3/4, 3-1/8)

without oil filter change

3.3 (3-1/2, 2-7/8)

AX

Drain and refill Dry engine (engine overhaul)

4.1 (4-3/8, 3-5/8)

SU

CAUTION: 쐌 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) 쐌 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.

BR

4. 5.

BT

6.

Check oil level. Start engine and check area around drain plug and oil filter for oil leakage. Run engine for a few minutes, then turn it off. After several minutes, check oil level.

ST RS

HA SC EL

SMA885B

MA-21

IDX

ENGINE MAINTENANCE

KA24DE

Changing Oil Filter

Changing Oil Filter

NGMA0062

1. Remove oil filter with Tool. 쐌 a: 64.3 mm (2.531 in) WARNING: Be careful not to burn yourself. Engine and engine oil are hot. The filter is a full-flow cartridge type and is provided with a relief valve.

2.

Clean oil filter mounting surface on cylinder block. Coat rubber seal of new oil filter with engine oil.

SMA010

3.

Screw in the oil filter until a slight resistance is felt, then tighten additionally more than 2/3 of a turn. 4. Add engine oil. Refer to “Changing Engine Oil”, MA-21. 쐌 Clean excess oil from engine.

SMA229B

Changing Spark Plugs 1.

Disconnect ignition wires from spark plugs at boot. Do not pull on the wire.

SMA356CA

MA-22

NGMA0063

ENGINE MAINTENANCE

KA24DE Changing Spark Plugs (Cont’d)

2. Remove spark plugs with spark plug wrench. Spark plug: Make

SMA581C

NGK - Double Platinum-tipped

Standard type

PFR5G-11

Cold type

PFR6G-11

Use standard type spark plug under normal conditions. The cold type spark plug is suitable when spark knock occurs with the standard spark plug under conditions such as: 쐌 extended highway driving 쐌 frequent high engine revolution 쐌 Do not use a wire brush for cleaning. 쐌 If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (6 kg/cm2, 85 psi) Cleaning time: Less than 20 seconds

GI

EM LC EC FE CL MT

SMA673B

쐌

3.

Checking and adjusting plug gap is not required between change intervals. Spark plug (Double Platinum-tipped type) Gap (Nominal): 1.1 mm (0.043 in) Install spark plugs. Reconnect ignition wires according to numbers indicated on them. Spark plug: : 20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

AT TF PD AX

SMA806C

Checking EVAP Vapor Lines 1.

2.

NGMA0064

Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections, chafing and deterioration. Inspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc. Refer to EC-40, “EVAPORATIVE EMISSION SYSTEM”.

SU BR ST RS BT HA SC EL

AMA116

MA-23

IDX

ENGINE MAINTENANCE

KA24DE

Changing Positive Crankcase Ventilation (PCV) Filter

Changing Positive Crankcase Ventilation (PCV) Filter

NGMA0065

Remove air cleaner cover and take out PCV filter located inside air cleaner cover. Then install new PCV filter.

MA-24

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE Engine Maintenance

Engine Maintenance KA24DE Drive Belt Deflection and Tension Deflection adjustment

NGMA0066

Unit: mm (in)

Tension adjustment

Used belt

*1 Unit: N (kg, lb)

Used belt New belt

Limit

After adjustment

Generator

17 (0.67)

10 - 12 (0.39 0.47)

Air conditioner compressor

16 (0.63)

Power steering oil pump

17 (0.67)

Applied pushing force

GI

NGMA0066S01

New belt Limit

After adjustment

8 - 10 (0.31 - 0.39)

222.4 (22.7, 50)

355.8-444.8 (36.345.4, 80-100)

489.3-578.2 (49.959.0, 110-130)

10 - 12 (0.39 0.47)

8 - 10 (0.31 - 0.39)

200.2 (20.4, 45)

355.8-444.8 (36.345.4, 80-100)

489.3-578.2 (49.959.0, 110-130)

10 - 13 (0.39 0.51)

8 - 10 (0.31 - 0.39)

222.4 (22.7, 50)

355.8-444.8 (36.345.4, 80-100)

489.3-578.2 (49.959.0, 110-130)

98 N (10 kg, 22 lb)

EM

—

LC EC FE

*1: If belt tension gauge cannot be installed at check point shown, check belt tension at a different location on the belt.

Spark Plug

NGMA0066S02

Make

CL

NGK—Double Platinum-tipped

Hot type

—

Standard type

PFR5G-11

Cold type

PFR6G-11

Gap (nominal)

MT AT

1.1 mm (0.043 in)

TF PD AX SU BR ST RS BT HA SC EL

MA-25

IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Checking Drive Belts

Checking Drive Belts

NGMA0016

VG33E

AMA152

MA-26

ENGINE MAINTENANCE

VG33E AND VG33ER Checking Drive Belts (Cont’d)

VG33ER

GI

EM LC EC FE CL MT AT WMA040

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. Check belt tension using belt tension gauge (BT3373-F or equivalent). Inspect drive belt deflection or tension when engine is cold. 쐌 Adjust if belt deflections exceed the limit or if belt tension is not within specifications. 쐌 Drive belt tension can be checked at other points on the belt.

TF PD AX SU BR ST RS BT HA SC EL

MA-27

IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Checking Drive Belts (Cont’d)

DRIVE BELT DEFLECTION AND TENSION Deflection adjustment

NGMA0016S01

Unit: mm (in)

Tension adjustment

Used belt

*1 Unit: N (kg, lb)

Used belt New belt

Limit

After adjustment

Generator

11 (0.43)

7 - 8 (0.24 0.31)

Air conditioner compressor VG33E

18 (0.71)

Air conditioner compressor and SuperchargerVG33ER Power steering oil pump Applied pushing force

New belt Limit

After adjustment

6 - 7 (0.24 0.28)

226 (23, 51)

554.1 - 642.4 (56.5 - 65.5, 124.6 - 144.4)

671.8 - 760.0 (68.5 - 77.5, 151.0 - 170.9)

12 - 13 (0.47 0.51)

10.5 - 11.5 (0.413 - 0.453)

196 (20, 44)

495.3 - 583.5 (50.5 - 59.5, 111.4 - 131.2)

603.1 - 691.4 (61.5 -70.5, 135.6 - 155.5)

16.5 (0.65)

9.5 - 10.5 (0.374 - 0.413)

8.5 - 9.5 (0.33 0.37)

294 (30, 66)

15 (0.59)

9.5 - 10.5 (0.374 - 0.413)

8 - 9 (0.31 0.35)

275 (28, 62)

730 - 818 (75.5 - 838 - 926 (85.5 83.5, 166.5 94.5, 188.5 208.4) 184.1) 554.1 - 642.4 (56.5 - 65.5, 124.6 - 144.4)

98 N (10 kg, 22 lb)

671.8 - 760.0 (68.5 - 77.5, 151.0 - 170.9)

—

*1: If belt tension gauge cannot be installed at check point shown, check belt tension at a different location on the belt.

Changing Engine Coolant

NGMA0017

WARNING: To avoid the danger of being scalded, never change the coolant when the engine is hot.

—DRAINING ENGINE COOLANT— 1. a. LMA048

b. 2.

NGMA0017S01

Set air conditioning system as follows to prevent coolant from remaining in the system. Turn ignition switch “ON” and set temperature controller to maximum hot position. Wait 10 seconds before turning ignition switch “OFF”. Open radiator drain plug at the bottom of radiator and remove radiator cap.

쐌 Be careful not to allow coolant to contact drive belts. When draining all of the coolant in the system, also perform the two following steps.

SMA858C

MA-28

ENGINE MAINTENANCE

VG33E AND VG33ER Changing Engine Coolant (Cont’d)

1) 2)

Remove cylinder block drain plugs and air relief plug. Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated flush engine cooling system. Refer to “FLUSHING COOLING SYSTEM”, MA-30.

—REFILLING ENGINE COOLANT— 1.

SMA952C

쐌 쐌

2. 3. SMA860C

GI

NGMA0017S02

Install the radiator drain plug. Install the reservoir tank and cylinder block drain plug, if removed for a total system drain or for engine removal or repair. The radiator must be completely empty of coolant and water. Apply sealant to the threads of the cylinder block drain plugs. Use Genuine High Performance Thread Sealant or equivalent. Refer to “Recommended Chemical Products and Sealants”, GI-50. Radiator drain plug: 7.8 - 11.8 N쐌m (0.8 - 1.2 kg-m, 69 104 in-lb) Cylinder block drain plug: 34 - 44 N쐌m (3.5 - 4.5 kg-m, 25 - 33 ft-lb) Air relief plug: 7 - 8 N쐌m (0.7 - 0.8 kg-m, 61- 69 in-lb) If disconnected, reattach the upper radiator hose at the engine side. Set the vehicle heater controls to the full HOT and heater ON position. Turn the vehicle ignition ON with the engine OFF as necessary to activate the heater mode.

EM LC EC FE CL MT AT TF PD AX

4.

LMA054

Install the Tool by installing the radiator cap adapter onto the radiator neck opening. Then attache the gauge body assembly with the refill tube and the venturi assembly to the radiator cap adapter. 5. Insert the refill hose into the coolant mixture container that is placed at floor level. Make sure the ball valve is in the closed position. 쐌 Use Genuine NISSAN Anti-Freeze Coolant or equivalent, mixed 50/50 with distilled water or demineralized water. Refer to “Anti-freeze Coolant Mixture Ratio”, MA-15. Engine coolant capacity (without reservoir tank) 10.15
(10 3/4 US qt) Reservoir tank: 0.8
(7/8 US qt) 6. Install an air hose to the venturi assembly; the air pressure must be with specification. Compressed air supply pressure 5.7 - 8.5 kPa (5.6 - 8.4 kg/cm2, 80 - 120 psi) CAUTION: The compressed air supply must be equipped with an air dryer. 7. The vacuum gauge will begin to rise and there will be an audible hissing noise. During this process, open the ball valve

MA-29

SU BR ST RS BT HA SC EL IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Changing Engine Coolant (Cont’d)

on the refill hose slightly. Coolant will be visible rising in the refill hose. Once the refill hose is full of coolant, close the ball valve. This will purge any air trapped in the refill hose.

8.

LMA055

Continue to draw the vacuum until the gauge reaches 28 inches of vacuum. The gauge may not reach 28 inches in high altitude locations; refer to the vacuum specifications based on the altitude above sea level. Altitude above sea level

Vacuum gauge reading

0 - 100 m (328 ft)

28 inches of vacuum

300 m (984 ft)

27 inches of vacuum

500 m (1,641 ft)

26 inches of vacuum

1,000 m (3,281 ft)

24 - 25 inches of vacuum

9.

When the vacuum gauge has reached the specified amount, disconnect the air hose and wait 20 seconds to see if the system loses any vacuum. If the vacuum level drops , perform any necessary repairs to the system and repeat steps 6 - 8 to bring the vacuum to the specified amount. Recheck for any leaks. 10. Place the coolant container (with the refill hose inserted) at the same level as the top of the radiator. Then open the ball valve on the refill hose so the coolant will be drawn up to fill the cooling system. The cooling system is full when the vacuum gauge reads zero. CAUTION: Do not allow the coolant container to get too low when filling , to avoid air from being drawn into the cooling system. 11. Remove the Tool from the radiator neck opening. 12. Fill the cooling system reservoir tank to the specified level. Run the engine to warm up the cooling system and top up the system as necessary before installing the radiator cap.

—FLUSHING COOLING SYSTEM— 1.

Open air relief plug.

SMA860C

MA-30

NGMA0017S04

ENGINE MAINTENANCE

VG33E AND VG33ER Changing Engine Coolant (Cont’d)

2.

3. 4. 5. 6. 7.

Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain the water. Repeat steps 1 through 6 until clear water begins to drain from radiator.

GI

EM LC

SMA858C

Checking Fuel Lines

NGMA0018

Inspect fuel lines and tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. If necessary, repair or replace faulty parts.

EC FE CL MT

SMA803A

Changing Fuel Filter

NGMA0019

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.

AT TF PD AX

AMA123

WARNING: Before removing fuel filter, release fuel pressure from fuel line.

WITH CONSULT-II 1. 2. 3. 4.

NGMA0019S01

SU

Start engine. Perform “FUEL PRES RELEASE” in “WORK SUPPORT” mode to release fuel pressure to zero. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. Turn ignition switch “OFF”.

BR

Remove the fuel filter shield. Loosen fuel hose clamps. Replace fuel filter. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. Properly tighten fuel hose clamps. Refer to “Checking Fuel Lines”, MA-31.

BT

ST RS

PEF823K

5. 6. 7. 쐌 쐌

HA SC EL

AMA151

MA-31

IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Changing Fuel Filter (Cont’d)

WITHOUT CONSULT-II 1. 2. 3. 4.

NGMA0019S02

Remove fuel pump fuse. Start engine. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. Turn ignition switch “OFF” and install fuel pump fuse.

SMA869C

5. 6. 7. 쐌 쐌

Remove the fuel filter shield Loosen fuel hose clamps. Replace fuel filter. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. Properly tighten fuel hose clamps. Refer to “Checking Fuel Lines”, MA-31.

AMA151

Changing Air Cleaner Filter VISCOUS PAPER TYPE

NGMA0020 NGMA0020S01

The viscous paper type filter does not need cleaning between replacement intervals.

WMA041

Changing Engine Oil

SMA862C

NGMA0021

WARNING: 쐌 Be careful not to burn yourself, as the engine oil is hot. 쐌 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 and wait for more than 10 minutes. 3. Remove drain plug and oil filler cap. 4. Drain oil and refill with new engine oil. Oil specification and viscosity 쐌 API SG/SH and Energy Conserving I & II or API grade SJ, Energy Conserving 쐌 API Certification Mark 쐌 ILSAC grade GF-I & GF-II 쐌 See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13.

MA-32

ENGINE MAINTENANCE

VG33E AND VG33ER Changing Engine Oil (Cont’d)

Refill oil capacity (Approximately) : Unit:
(US qt, Imp qt)

GI

Drain and refill with oil filter change

3.3 (3-1/2, 2-7/8)

without oil filter change

3.0 (3-1/8, 2-5/8)

Dry engine (engine overhaul)

3.8 (4, 3-3/8)

EM CAUTION: 쐌 Be sure to clean drain plug and install with new washer. Oil pan drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) 쐌 The refill capacity depends on the oil temperature and drain time; use the “Refill oil capacity” values as a reference and be certain to check with the dipstick when changing the oil.

LC EC FE CL MT

5. 6. 7.

Warm up engine and check area around drain plug and oil filter for oil leakage. Stop engine and wait for more than 10 minutes. Check oil level.

AT TF PD AX

SMA878C

Changing Oil Filter

NGMA0022

1. Remove oil filter with Tool. WARNING: Be careful not to burn yourself, as the engine and engine oil are hot. The filter is a full-flow cartridge type and is provided with a relief valve.

SU BR ST RS

SMA863C

2.

Clean oil filter mounting surface on cylinder block. Coat rubber seal of new oil filter with engine oil.

BT HA SC EL

SMA010

MA-33

IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Changing 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-32. 쐌 Clean excess oil from engine.

SMA702C

Changing Spark Plugs 1. 2. 쐌

NGMA0023

Disconnect ignition wires from spark plugs at boot. Do not pull on the wire. Remove spark plugs with 16 mm (0.63 in) spark plug wrench. For VG33ER engine only; to remove the No. 2, and 4 spark plugs, the following components must be removed:

ADI1076

a) b) c)

Disconnect the accelerator cable from the throttle body. Disconnect the ASCD cable from the throttle body. Remove air inlet tube bracket from air inlet tube (with cables attached) and position aside.

d) 쐌 쐌

Remove the air inlet duct. Disconnect the PCV hoses. Disconnect the resonator hose.

LEM105

LEM110

MA-34

ENGINE MAINTENANCE

VG33E AND VG33ER Changing Spark Plugs (Cont’d)

e)

Remove the air inlet tube upper and lower supports.

GI

EM LC

LEM107

f)

Remove the air inlet tube bolts, nuts, and studs. Position the air inlet tube aside. 쐌 Disconnect the evaporative emission vacuum hose. 쐌 Disconnect the brake booster vacuum hose. 쐌 Disconnect the TPS sensor electrical connector. 쐌 Disconnect the TPS switch electrical connector. 3. Check type and gap of new spark plug. Spark plug (VG33E): Description LEM108

NGK (Double Platinum Tipped)

Hot type

PFR4G-11

Standard type

PFR5G-11

Cold type

PFR6G-11

Spark Plug Gap (nominal)

1.1 mm (0.043 in)

Spark plug (VG33ER): Description

FE CL MT AT TF PD

NGK (Double Platinum Tipped)

Hot type

PFR5G-11

Standard type

PFR6G-11

Cold type

PFR7G-11

Spark Plug Gap (nominal)

EC

AX SU

1.1 mm (0.043 in)

Use standard type spark plug under normal conditions. The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions such as: 쐌 frequent engine starts 쐌 low ambient temperatures The cold type spark plug is suitable when spark knock occurs with the standard type spark plug under conditions such as: 쐌 extended highway driving 쐌 frequent high engine revolution

BR ST RS BT HA SC EL

MA-35

IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Changing Spark Plugs (Cont’d)

쐌 쐌

Do not use a wire brush for cleaning. If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (6 kg/cm2, 85 psi) Cleaning time: Less than 20 seconds

쐌

Checking and adjusting plug gap is not required between spark plug change intervals.

SMA773C

SMA806C

When installing ignition wires to No. 2 and 4 cylinders, securely fit each ignition wire mounting hole onto the ignition wire fixing pin. Spark plug: : 20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

SMA213C

Checking EVAP Vapor Lines 1.

NGMA0024

Visually inspect EVAP vapor lines for improper attachment, cracks, damage, loose connections, chafing or deterioration. 2. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, etc. Refer to EC-626, “EVAPORATIVE EMISSION SYSTEM”.

AMA145

MA-36

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Engine Maintenance

Engine Maintenance VG33E AND VG33ER Drive Belt Deflection and Tension Deflection adjustment

NGMA0054

Unit: mm (in)

Tension adjustment

Used belt

*1 Unit: N (kg, lb)

Used belt New belt

Limit

Generator

Air conditioner compressor (VG33E) Air conditioner compressor and supercharger (VG33ER) Power steering oil pump

11 (0.43)

After adjustment

7 - 8 (0.24 - 0.31)

New belt Limit

6 - 7 (0.24 - 0.28)

EM

226 (23, 51)

495.3 - 583.5 (50.5 603.1 - 691.4 (61.5 - 59.5, 111.4 - 70.5, 135.6 131.2) 155.5)

10.5 - 11.5 (0.413 0.435)

196 (20, 44)

16.5 (0.65)

9.5 - 10.5 (0.374 0.413)

8.5 - 9.5 (0.33 0.39)

294 (30, 66)

15 (0.59)

9.5 - 10.5 (0.374 0.413)

8 - 9 (0.31 - 0.35)

275 (28, 62)

Applied pushing force

After adjustment 554.1 - 642.4 (56.5 671.8 - 760.0 (68.5 - 65.5, 124.6 - 77.5, 151.0 144.4) 170.9)

12 - 13 (0.47 0.51)

18 (0.71)

GI

NGMA0054S01

730 - 818 (75.5 83.5, 166.5 184.1)

838 - 926 (85.5 94.5, 188.5 208.4)

554.1 - 642.4 (56.5 671.8 - 760.0 (68.5 - 65.5, (124.6 - 77.5, 151.0 144.4) 170.9)

98 N (10 kg, 22 lb)

LC EC FE CL MT

—

*1: If belt tension gauge cannot be installed at check point shown, check belt tension at a different location on the belt.

AT

Spark Plug NGK - Double Platinum-tipped

NGMA0054S02

VG33E

VG33ER

Hot type

PFR4G-11

PFR5G-11

Standard type

PFR5G-11

PFR6G-11

Cold type

PFR6G-11

PFR7G-11

Gap (nominal)

1.1 mm (0.043 in)

TF PD AX SU BR ST RS BT HA SC EL

MA-37

IDX

CHASSIS AND BODY MAINTENANCE Checking Exhaust System

Checking Exhaust System

NGMA0025

Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration.

SMA211A

Checking Clutch Fluid Level and Leaks

NGMA0026

If fluid level is extremely low, check clutch system for leaks.

SMA956C

Checking M/T Oil

NGMA0027

Check for oil leakage and oil level. Never start engine while checking oil level. Filler plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

SMA103

Changing M/T Oil 1. 2.

NGMA0028

Drain oil from drain plug and refill with new gear oil. Check oil level. Oil grade and viscosity: API GL-4. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13. Oil capacity: FS5W71C 2WD 2.0
(4-1/4 US pt, 3-1/2 Imp pt) FS5R30A 2WD 2.8
(5-7/8 US pt, 4-7/8 Imp pt) 4WD 5.1
(10-3/4 US pt, 9 Imp pt) Drain plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

MA-38

CHASSIS AND BODY MAINTENANCE Checking Water Entry — For 4WD models with M/T

Checking Water Entry — For 4WD models with M/T

NGMA0029

Check water entry in the clutch housing by removing the sealing grommet, whenever driving in deep water or mud.

GI

EM LC

SMA369B

Checking A/T Fluid 1. 2. 3. a. b.

LMA052

c. d. e. f. Do 4. 5.

NGMA0030

Warm up engine. Check for fluid leakage. Before driving, fluid level can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on dipstick. Park vehicle on level surface and set parking brake. Start engine and move selector lever through each gear position. Leave selector lever in “P” position. Check fluid level with engine idling. Remove dipstick and note reading. If level is at low side of either range, and fluid to the charging pipe. Re-insert dipstick into charging pipe as far as it will go. Remove dipstick and note reading. If reading is at low side of range, add fluid to the charging pipe. not overfill. Drive vehicle for approximately 5 minutes in urban areas. Re-check fluid level at fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on dipstick.

EC FE CL MT AT TF PD AX

6. 쐌 쐌

Check fluid condition. If fluid is very dark or smells burned, refer to AT-62, “FLUID CONDITION CHECK”. Flush cooling system after repair of A/T. If A/T fluid contains frictional material (clutches, bands, etc.), replace radiator and flush cooler line using cleaning solvent and compressed air after repair of A/T. Refer to LC-14 (KA24DE), LC-32 (VG33E and VG33ER), “REMOVAL AND INSTALLATION”.

SU BR ST RS

SMA853B

BT HA SC EL

MA-39

IDX

CHASSIS AND BODY MAINTENANCE Changing A/T Fluid

Changing A/T Fluid 1. 2. 3.

SMA515C

4. 5.

=NGMA0031

Warm up A/T fluid. Stop engine. Drain A/T fluid from drain plug and refill with new A/T fluid. Always refill same volume with drained fluid. Fluid grade: NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13. Fluid capacity (With torque converter): VG33E and VG33ER 2WD 8.3
(8-3/4 US qt, 7-1/4 Imp qt) 4WD 8.5
(9 US qt, 7-1/2 Imp qt) Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) Run engine at idle speed for five minutes. Check fluid level and condition. Refer to “Checking A/T Fluid”, MA-39. If fluid is still dirty, repeat steps 2 through 5.

Checking Transfer Fluid

NGMA0032

Check for fluid leakage and fluid level. A/T fluid is used for the transfer in the factory. Never start engine while checking fluid level. Filler plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

SMA439B

Changing Transfer Fluid

SMA444B

NGMA0033

When changing transfer fluid completely, A/T fluid may be used. Fluid grade: NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid or API GL-4. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13. Fluid capacity: 2.2
(2-3/8 US qt, 2 Imp qt) Drain plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

MA-40

CHASSIS AND BODY MAINTENANCE Checking Propeller Shaft

Checking Propeller Shaft

NGMA0034

Check propeller shaft for damage, looseness or grease leakage.

GI

EM LC

WMA042

EC FE CL MT

WMA043

Greasing Propeller Shaft

NGMA0035

Apply specified grease to nipples provided on propeller shaft. Grease grade: Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13.

AT TF PD AX

SMA873C

Checking Differential Gear Oil Check for oil leakage and oil level. Filler plug: Front – R200A : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear – H233B : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear – C200 : 39 - 59 N·m (4 - 6 kg-m, 29 - 43 ft-lb)

NGMA0036

SU BR ST RS

SMA440B

BT HA SC EL

MA-41

IDX

CHASSIS AND BODY MAINTENANCE Changing Differential Gear Oil

Changing Differential Gear Oil 1. 2.

SMA632C

SMA631C

LIMITED-SLIP DIFFERENTIAL GEAR 쐌 쐌 1. 2. 3.

NGMA0037

Drain oil from drain plug and refill with new gear oil. Check oil level. Oil grade and viscosity: See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13, 14. Oil capacity: Front — R200A 1.75
(3-3/4 US pt, 3-1/8 Imp pt) Rear — H233B 2.8
(5-7/8 US pt, 4-7/8 Imp pt) Rear — C200 1.3
(2-3/4 US pt, 2-1/4 Imp pt) Filler plug: Front — R200A : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear — H233B : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear — C200 : 39 - 59 N·m (4 - 6 kg-m, 29 - 43 ft-lb) Drain plug: Front — R200A : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear — H233B : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear — C200 : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb)

NGMA0037S01

Use only approved limited-slip differential gear oil. Limited-slip differential identification. Lift both rear wheels off the ground. Turn one rear wheel by hand. If both rear wheels turn in the same direction simultaneously, vehicle is equipped with limited-slip differential.

MA-42

CHASSIS AND BODY MAINTENANCE Balancing Wheels

Balancing Wheels

=NGMA0038

Adjust wheel balance using the road wheel center. Wheel balance (Maximum allowable unbalance): Refer to “WHEEL BALANCE”, MA-49.

GI

EM LC

Tire Rotation 쐌 쐌

NGMA0039

After rotating the tires, adjust the tire pressure. Retighten the wheel nuts when the vehicle has been driven for 600 miles (1000 km) (also in cases of a flat tire, etc.) Wheel nuts: : 118 - 147 N·m (12 - 15 kg-m, 87 - 108 ft-lb)

EC FE CL MT

AMA159

Checking Brake Fluid Level and Leaks 쐌 쐌 쐌

NGMA0040

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. If the brake warning lamp comes on, check brake fluid level switch and parking brake switch.

AT TF PD AX

SBR451D

Checking Brake Lines and Cables

NGMA0041

CAUTION: If leakage occurs around joints, retighten or, if necessary, replace damaged parts. 1. Check brake lines (tubes and hoses) for cracks, deterioration and other damage. Replace any damaged parts. 2. Check for oil leakage by fully depressing brake pedal while engine is running.

SU BR ST RS

SBR389C

Checking Disc Brake ROTOR Check condition, wear and damage. Standard thickness: 28 mm (1.10 in) Minimum thickness: 26 mm (1.024 in)

NGMA0042

BT

NGMA0042S01

HA SC EL

SMA260A

MA-43

IDX

CHASSIS AND BODY MAINTENANCE Checking Disc Brake (Cont’d)

CALIPER

NGMA0042S02

Check for leakage.

SMA922A

PAD

NGMA0042S03

Check wear or damage. Standard thickness: 10 mm (0.39 in) Minimum thickness: 2.0 mm (0.079 in)

LMA051

Checking Drum Brake WHEEL CYLINDER

NGMA0043 NGMA0043S01

Check for leakage.

DRUM

NGMA0043S02

Check condition and inner surface. Standard inner diameter: 295.0 mm (11.61 in) Drum repair limit (Inner diameter): 296.5 mm (11.67 in) SMA848B

LINING

NGMA0043S03

Check wear or damage. Standard thickness: 5.8 mm (0228 in) Lining wear limit (Minimum thickness): 1.5 mm (0.059 in)

SMA849B

Checking Steering Gear and Linkage STEERING GEAR 쐌 쐌

NGMA0044S01

Check steering gear housing for looseness, damage and grease leakage. Check connection with steering column for looseness.

STEERING LINKAGE 쐌

NGMA0044

NGMA0044S02

Check ball joint, dust cover and other component parts for looseness, wear, damage and grease leakage.

AMA144

MA-44

CHASSIS AND BODY MAINTENANCE Checking Power Steering Fluid and Lines

Checking Power Steering Fluid and Lines CHECKING FLUID LEVEL 쐌 쐌

AMA155

NGMA0045 NGMA0045S01

Check fluid level with engine off. Check fluid level on reservoir. Use “HOT” range at fluid temperatures of 50 to 80°C (122 to 176°F). Use “COLD” range at fluid temperatures of 0 to 30°C (32 to 86°F). CAUTION: 쐌 Do not overfill. 쐌 Recommended fluid is Genuine NISSAN PSF II, Canada NISSAN Automatic Transmission Fluid, DEXRONTMIII, MERCONTM, or equivalent ATF may also be used. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13.

GI

EM LC EC FE CL MT

CHECKING LINES 쐌

NGMA0045S02

Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

AT TF PD AX

AST255

Checking Axle and Suspension Parts

NGMA0067

FRONT AND REAR AXLE AND SUSPENSION PARTS NGMA0067S01 Check front and rear axle and suspension parts for excessive play, cracks, wear or other damage.

SU BR ST RS

쐌 쐌 쐌

Shake each wheel to check for excessive play. Rotate each wheel to check for abnormal noise. Check axle and suspension nuts and bolts for looseness.

BT HA SC EL

SMA525A

MA-45

IDX

CHASSIS AND BODY MAINTENANCE Checking Axle and Suspension Parts (Cont’d)

쐌 쐌

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.

ASU018

DRIVE SHAFT

NGMA0067S02

Check boot and drive shaft for cracks, wear, damage, and grease leakage.

SFA901

MA-46

CHASSIS AND BODY MAINTENANCE Lubricating Locks, Hinges and Hood Latches

Lubricating Locks, Hinges and Hood Latches

NGMA0046

GI

EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA AMA153

SC EL

MA-47

IDX

CHASSIS AND BODY MAINTENANCE Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters

Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters

NGMA0047

WMA034

MA-48

SERVICE DATA AND SPECIFICATIONS (SDS) Chassis and Body Maintenance

Chassis and Body Maintenance WHEEL BALANCE

NGMA0050

Dynamic (At rim flange)

g (oz)

GI

10 (0.35) (one side)

Maximum allowable unbalance Static

g (oz)

20 (0.71)

EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

MA-49

IDX

NOTES

ENGINE MECHANICAL SECTION

EM

GI MA

LC EC

CONTENTS KA24DE PRECAUTIONS ...............................................................4 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............4 Parts Requiring Angular Tightening.............................4 Liquid Gasket Application Procedure ..........................5 PREPARATION ...............................................................6 Special Service Tools ..................................................6 Commercial Service Tools ...........................................8 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................10 NVH Troubleshooting Chart - Engine Noise .............11 OUTER COMPONENT PARTS .....................................12 Removal and Installation ...........................................12 MEASUREMENT OF COMPRESSION PRESSURE ....15 OIL PAN.........................................................................16 Components...............................................................16 Removal.....................................................................16 Installation..................................................................17 TIMING CHAIN ..............................................................18 Components...............................................................18 LIQUID GASKET APPLICATION PLACES..................19 Removal.....................................................................20 UPPER TIMING CHAIN ............................................20 IDLER SPROCKET ..................................................21 LOWER TIMING CHAIN ...........................................21 Inspection...................................................................22 Installation..................................................................23 LOWER TIMING CHAIN ...........................................23 IDLER SPROCKET ..................................................24 UPPER TIMING CHAIN ............................................24 OIL SEAL.......................................................................26 Replacement..............................................................26 VALVE OIL SEAL .....................................................26 OIL SEAL INSTALLING DIRECTION .........................26 FRONT OIL SEAL ....................................................26 REAR OIL SEAL ......................................................27 CYLINDER HEAD..........................................................29 Components...............................................................29

Removal.....................................................................30 Installation..................................................................31 Disassembly...............................................................31 Inspection...................................................................31 CYLINDER HEAD DISTORTION ...............................31 CAMSHAFT VISUAL CHECK ....................................32 CAMSHAFT RUNOUT ..............................................32 CAMSHAFT CAM HEIGHT .......................................32 CAMSHAFT JOURNAL CLEARANCE ........................32 CAMSHAFT END PLAY............................................33 CAMSHAFT SPROCKET RUNOUT ...........................33 VALVE GUIDE CLEARANCE ....................................33 VALVE GUIDE REPLACEMENT ................................34 VALVE SEATS .........................................................35 REPLACING VALVE SEAT FOR SERVICE PARTS ....35 VALVE DIMENSIONS ...............................................36 VALVE SPRING .......................................................37 VALVE LIFTER AND VALVE SHIM ............................37 Assembly ...................................................................38 Valve Clearance.........................................................38 CHECKING .............................................................38 ADJUSTING ............................................................39 ENGINE ASSEMBLY.....................................................41 Removal and Installation ...........................................41 REMOVAL ...............................................................42 INSTALLATION........................................................43 CYLINDER BLOCK .......................................................44 Components...............................................................44 Removal and Installation ...........................................45 Disassembly...............................................................45 PISTON AND CRANKSHAFT ....................................45 Inspection...................................................................45 PISTON AND PISTON PIN CLEARANCE ..................45 PISTON RING SIDE CLEARANCE ............................46 PISTON RING END GAP..........................................46 CONNECTING ROD BEND AND TORSION ...............46 CYLINDER BLOCK DISTORTION AND WEAR ...........47 PISTON-TO-BORE CLEARANCE ..............................47 CRANKSHAFT.........................................................48 BEARING CLEARANCE ...........................................49

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS CONNECTING ROD BUSHING CLEARANCE (SMALL END) ..........................................................51 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) ..........................................51 FLYWHEEL RUNOUT ..............................................52

Assembly ...................................................................52 PISTON ..................................................................52 CRANKSHAFT.........................................................53 REPLACING PILOT BUSHING ..................................54 SERVICE DATA AND SPECIFICATIONS (SDS) .........55 General Specifications...............................................55 COMPRESSION PRESSURE ...................................55 Cylinder Head ............................................................55 Valve ..........................................................................56 VALVE ....................................................................56 VALVE SPRING .......................................................56 VALVE GUIDE .........................................................57 VALVE LIFTER ........................................................57 VALVE CLEARANCE ADJUSTMENT .........................57 AVAILABLE SHIMS ..................................................58 VALVE SEAT ...........................................................59 Cylinder Block............................................................60 Camshaft and Camshaft Bearing ..............................61 Piston, Piston Ring and Piston Pin ...........................62 PISTON ..................................................................62 PISTON PIN ............................................................62 PISTON RING .........................................................62 Connecting Rod .........................................................63 Crankshaft..................................................................63 Bearing Clearance .....................................................64 Available Main Bearing..............................................64 STANDARD .............................................................64 UNDERSIZE (SERVICE) ..........................................64 Available Connecting Rod Bearing............................64 STANDARD .............................................................64 UNDERSIZE (SERVICE) ..........................................64 Miscellaneous Components.......................................65 VG33E AND VG33ER PRECAUTIONS .............................................................66 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″.............66 Parts Requiring Angular Tightening...........................66 Liquid Gasket Application Procedure ........................67 PREPARATION .............................................................68 Special Service Tools ................................................68 Commercial Service Tools .........................................70 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................72 NVH Troubleshooting Chart - Engine Noise .............73 OUTER COMPONENT PARTS .....................................74 Removal and Installation ...........................................74 MEASUREMENT OF COMPRESSION PRESSURE ....77

(Cont’d)

OIL PAN.........................................................................79 Removal.....................................................................79 Installation..................................................................80 TIMING BELT ................................................................82 Components...............................................................82 Removal.....................................................................83 Inspection...................................................................84 BELT TENSIONER AND TENSIONER SPRING ..........85 Installation..................................................................85 Tension Adjustment....................................................86 AFTER BELT REPLACEMENT..................................86 AFTER ENGINE OVERHAUL OR ENGINE REASSEMBLY (WITH ROCKER COVERS REMOVED) .............................................................87

OIL SEAL.......................................................................90 Replacement..............................................................90 VALVE OIL SEAL .....................................................90 OIL SEAL INSTALLING DIRECTION .........................90 CAMSHAFT OIL SEAL .............................................91 FRONT OIL SEAL ....................................................91 REAR OIL SEAL ......................................................91 CYLINDER HEAD..........................................................92 Components...............................................................92 Removal.....................................................................93 Disassembly...............................................................95 Inspection...................................................................96 CYLINDER HEAD DISTORTION ...............................96 CAMSHAFT VISUAL CHECK ....................................96 CAMSHAFT RUNOUT ..............................................96 CAMSHAFT CAM HEIGHT .......................................96 CAMSHAFT JOURNAL CLEARANCE ........................96 CAMSHAFT END PLAY............................................97 CAMSHAFT SPROCKET RUNOUT ...........................97 VALVE GUIDE CLEARANCE ....................................97 VALVE GUIDE REPLACEMENT ................................98 VALVE SEATS .........................................................99 REPLACING VALVE SEAT FOR SERVICE PARTS ..100 VALVE DIMENSIONS .............................................100 VALVE SPRING .....................................................101 ROCKER SHAFT AND ROCKER ARM ....................102 HYDRAULIC VALVE LIFTER ..................................102 Assembly .................................................................102 Installation................................................................103 SUPERCHARGER .......................................................108 Components.............................................................108 Removal...................................................................109 Inspection.................................................................110 SUPERCHARGER FLANGE ...................................110 ROTOR SYSTEM ..................................................110 SUPERCHARGER BYPASS VALVE ACTUATOR ..... 111 Installation................................................................ 111 ENGINE ASSEMBLY...................................................112 Removal and Installation .........................................112 REMOVAL .............................................................113 CYLINDER BLOCK .....................................................115

EM-2

CONTENTS Components.............................................................115 Removal and Installation .........................................116 Disassembly.............................................................116 PISTON AND CRANKSHAFT ..................................116 Inspection.................................................................117 PISTON AND PISTON PIN CLEARANCE ................117 PISTON RING SIDE CLEARANCE ..........................117 PISTON RING END GAP........................................118 CONNECTING ROD BEND AND TORSION .............118 CYLINDER BLOCK DISTORTION AND WEAR .........118 PISTON-TO-BORE CLEARANCE ............................119 CRANKSHAFT.......................................................120 BEARING CLEARANCE .........................................121 CONNECTING ROD BUSHING CLEARANCE (SMALL END) ........................................................123 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) ........................................124 FLYWHEEL/DRIVE PLATE RUNOUT ......................124

Assembly .................................................................124 PISTON ................................................................124 CRANKSHAFT.......................................................125 REPLACING PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T) ................................................126

SERVICE DATA AND SPECIFICATIONS (SDS) .......127 General Specifications.............................................127 Cylinder Head ..........................................................128 Valve ........................................................................128

(Cont’d) VALVE ..................................................................128 VALVE SPRING .....................................................129 HYDRAULIC VALVE LIFTER ..................................129 VALVE GUIDE .......................................................129 ROCKER SHAFT AND ROCKER ARM ....................129

Valve Seat................................................................130 INTAKE VALVE SEAT ............................................130 EXHAUST VALVE SEAT.........................................131 Camshaft and Camshaft Bearing ............................132 Cylinder Block..........................................................133 Piston, Piston Ring and Piston Pin .........................134 AVAILABLE PISTON ..............................................134 PISTON RING .......................................................134 PISTON PIN ..........................................................135 Connecting Rod .......................................................135 Crankshaft................................................................135 Available Main Bearing............................................136 NO. 1 MAIN BEARING ...........................................136 NO. 2 AND 3 MAIN BEARING.................................136 NO. 4 MAIN BEARING ...........................................136 UNDER SIZE .........................................................136 Available Connecting Rod Bearing..........................137 CONNECTING ROD BEARING UNDERSIZE ...........137 Miscellaneous Components.....................................137 BEARING CLEARANCE .........................................137

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EM-3

IDX

PRECAUTIONS

KA24DE

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGEM0085

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 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), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

Parts Requiring Angular Tightening 쐌 a) b) 쐌 쐌 쐌

NGEM0086

Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Connecting rod cap nuts Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.

EM-4

PRECAUTIONS

KA24DE Liquid Gasket Application Procedure

Liquid Gasket Application Procedure 1)

2) 쐌 쐌 SEM371C

3) 4) 5)

NGEM0087

Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also completely clean any oil stains from these portions. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”.) Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) dia. (for oil pan). Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) dia. (in areas except oil pan). Apply liquid gasket to inner surface around hole perimeter area (unless otherwise specified). Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant.

GI MA

LC EC FE CL MT

AEM080

AT TF PD AX SU BR ST RS BT HA SC EL

EM-5

IDX

PREPARATION

KA24DE

Special Service Tools

Special Service Tools

NGEM0100

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description Disassembling and assembling

ST0501S000 ( — ) Engine stand assembly 1 ST05011000 ( — ) Engine stand 2 ST05012000 ( — ) Base NT042

KV10105001 ( — ) Engine attachment

NT031

KV101092S0 (J26336-B) Valve spring compressor 1 KV10109210 ( — ) Compressor 2 KV100109220 ( — ) Adapter

Disassembling and assembling valve components

NT021

Tightening bearing cap, cylinder head bolts, etc.

KV10112100 (BT8653-A) Angle wrench

NT014

Installing valve oil seal a: 25 (0.98) dia. b: 14.4 (0.567) dia. c: 11.8 (0.465) dia. d: 10 (0.39) dia. e: 11 (0.43) f: 9 (0.35)

KV10116300 (J-38955) Valve oil seal drift

NT602

EM-6

PREPARATION

KA24DE Special Service Tools (Cont’d)

Tool number (Kent-Moore No.) Tool name KV10110300 ( — ) Piston pin press stand assembly 1 KV10110310 ( — ) Cap 2 KV10110330 ( — ) Spacer 3 ST13030020 ( — ) Press stand 4 ST13030030 ( — ) Spring 5 KV10110340 ( — ) Drift 6 KV10110320 ( — ) Center shaft

Description

GI Disassembling and assembling piston with connecting rod

MA

LC EC FE NT036

CL MT Installing piston assembly into cylinder bore

EM03470000 (J8037) Piston ring compressor

AT TF NT044

Removing valve oil seal

(J36467) Valve oil seal remover

PD AX

NT034

Removing crankshaft pilot bushing

ST16610001 (J23907) Pilot bushing puller

BR ST

NT045

Removing oil pan

KV10111100 (J37228) Seal cutter

RS BT

NT046

WS39930000 ( — Tube presser

SU

Pressing the tube of liquid gasket

HA

)

SC NT052

EL

EM-7

IDX

PREPARATION

KA24DE

Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name KV101151S0 (J38972) Lifter stopper set 1 KV10115110 (J38972-1) Camshaft pliers 2 KV10115120 (J38972-2) Lifter stopper

Description Changing valve lifter shims

NT041

Loosening or tightening heated oxygen sensor For 22 mm (0.87 in) hexagon nut

KV10117100 (J36471-A) Front heated oxygen sensor wrench

NT379

Commercial Service Tools Tool name (Kent Moore No.)

NGEM0101

Description Removing and installing spark plug

Spark plug wrench

NT047

Pulley holder

Holding camshaft pulley while tightening or loosening camshaft bolt

NT035

Finishing valve seat dimensions

Valve seat cutter set

NT048

Removing and installing piston ring

Piston ring expander

NT030

Valve guide drift

Removing and installing valve guide Intake & Exhaust: a = 10.5 mm (0.413 in) dia. b = 6.6 mm (0.260 in) dia. NT015

EM-8

PREPARATION

KA24DE Commercial Service Tools (Cont’d)

Tool name (Kent Moore No.)

Description

GI Reaming valve guide 1 or hole for oversize valve guide 2 Intake: d1 = 7.0 mm (0.276 in) dia. d2 = 11.2 mm (0.441 in) dia. Exhaust: d1 = 8.0 mm (0.315 in) dia. d2 = 12.2 mm (0.480 in) dia.

Valve guide reamer

NT016

Front oil seal drift

Installing front oil seal a: 52 mm (2.05 in) dia. b: 44 mm (1.73 in) dia.

MA

LC EC

NT049

FE Installing rear oil seal a: 46 mm (1.81 in) b: 110 mm (4.33 in) c: 84 mm (3.31 in) d: 96 mm (3.78 in)

Rear oil seal drift

CL MT AT

NT719

a: 18 mm (0.71 in) b: 12 mm (0.47 in)

a: (J-43897-18) b: (J-43897-12) Thread repair tool for oxygen sensor

TF PD AX

AEM488

For preventing corrosion, seizing, and galling on high temperature applications.

Anti-seize thread compound

SU BR ST RS

AEM489

BT HA SC EL

EM-9

IDX

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NGEM0046

KA24DE

AEM466

EM-10

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

KA24DE

NVH Troubleshooting Chart — Engine Noise

NVH Troubleshooting Chart — Engine Noise

NGEM0046S01

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 the engine. 4. Check the specified noise source. If necessary, repair or replace these parts.

GI MA

Operating condition of engine Location of noise

Top of engine Rocker cover Cylinder head

Type of noise

When revving

While driving

Source of noise

Check item

Reference page

C

A

—

A

B

—

Tappet noise Valve clearance

EM-38

Rattle

C

A

—

A

B

C

Camshaft bearing noise

Camshaft journal clearance Camshaft runout

EM-32

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

A

Piston slap noise

Piston ring side clearance Piston ring end gap Connecting rod bend and EM-47, 46 torsion Piston-to-bore clearance Connecting rod bearing clearance (Big end) Connecting rod bushing clearance (Small end)

Slap or rap

—

A

A

—

—

—

B

B

B

B

—

B

C

B

B

B

Knock

A

B

—

A

B

C

Crankshaft runout Main bearing Main bearing oil clearnoise ance

EM-48

B

Timing chain and chain Timing chain cracks and tensioner wear noise

EM-22

C

Other drive belts (Sticking or slipping)

Drive belt deflection

—

B

B

Squeaking or fizzing

A

Creaking

A

B

A

B

A

B

Other drive belts (Slipping)

Idler pulley bearing operation

Squall creak

A

B

—

B

A

B

Water pump noise

Water pump operation

A: Closely related

B: Related

B

—

B

—

C: Sometimes related —: Not related

FE

MT

A

A

EC

EM-45, 51

Knock

A

LC

CL

Connecting rod-bearing noise

Front of engine Tapping Timing chain or ticking cover

Front of engine

When idling

Ticking or clicking

Slap or knock

Crankshaft pulley Cylinder block (upper side of engine) Oil pan

Before After When warm- warm- startup up ing

EM-50, 51

AT TF PD AX SU BR

MA-16, “Checking Drive Belts”

LC-12, “Water Pump Inspection”

ST RS BT HA SC EL

EM-11

IDX

OUTER COMPONENT PARTS

KA24DE

Removal and Installation

Removal and Installation

NGEM0047

WEM132

EM-12

OUTER COMPONENT PARTS

KA24DE Removal and Installation (Cont’d)

GI MA

LC EC FE CL MT AT WEM073

1. 2. 3.

Spark plug Ignition wires Camshaft position sensor built into distributor

4. 5. 6.

EGR tube Exhaust manifold Heated oxygen sensor 1 (front)

7. 8.

Exhaust manifold cover TWC (manifold)

TF PD AX SU BR ST RS BT HA SC EL

EM-13

IDX

OUTER COMPONENT PARTS

KA24DE

Removal and Installation (Cont’d)

AEM467

EM-14

MEASUREMENT OF COMPRESSION PRESSURE 1. 2. 3.

SEM486D

NGEM0048

KA24DE

Warm up engine. Turn ignition switch OFF. Release fuel pressure. Refer to EC-57, “Fuel Pressure Release”. 4. Remove all spark plugs. 쐌 Clean area around plug with compressed air before removing the spark plug. 5. Disconnect camshaft position sensor harness connector at the distributor. 6. Remove fuel injector fuse 3 on FUSE BLOCK (J/B) behind the instrument lower panel driver’s side. 7. Attach a compression tester to No. 1 cylinder. 8. Depress accelerator pedal fully to keep throttle valve wide open. 9. Crank engine and record highest gauge indication. 10. Repeat the measurement on each cylinder as shown above. 쐌 Always use a fully-charged battery to obtain specified engine speed. Compression pressure: kPa (kg/cm2, psi)/300 rpm Standard 1,226 (12.5, 178) Minimum 1,030 (10.5, 149) Difference limit between cylinders 98 (1.0, 14) 11. If 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. 쐌 If adding oil improves cylinder compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. 쐌 If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. Refer to “VALVE”, EM-56 and “VALVE SEAT”, EM-59. If valve or valve seat is damaged excessively, replace it. 쐌 If compression in any two cylinders 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. 12. Reinstall spark plugs, fuel injector fuse, fuel pump fuse, and reconnect camshaft position sensor harness connector at the distributor. 13. Erase the DTC stored in the ECM. CAUTION: Always erase the DTC after checking compression. Refer to EC-86, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EM-15

IDX

OIL PAN

KA24DE

Components

Components

NGEM0049

WEM133

Removal

NGEM0050

1. 2. 3. 4.

Raise vehicle and support it with safety stands. Remove engine under cover. Drain engine oil. Remove front suspension member.

5.

Remove oil pan bolts.

6. a. 쐌 쐌

Remove oil pan. Insert Tool between cylinder block and oil pan. Be careful not to damage aluminum mating surface. Do not insert screwdriver, or oil pan flange will be damaged. Slide Tool by tapping on the side of the Tool with a hammer. Pull out oil pan from front side.

AEM497

b. 7.

SEM365E

EM-16

OIL PAN

KA24DE Installation

Installation 1. 쐌

NGEM0051

Use a scraper to remove old liquid gasket from mating surface of oil pan. Also remove traces of liquid gasket from mating surface of cylinder block.

GI MA

LC

AEM299

2. 쐌 쐌 쐌

Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”. Apply to groove on mating surface. Allow 7 mm (0.28 in) clearance around bolt hole.

EC FE CL MT

AEM300

AT TF PD AX SEM015E

쐌 쐌

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.

SU BR ST RS

AEM301

3. 쐌 쐌 4.

Install oil pan. Tighten oil pan bolts in numerical order. : 6.4 - 7.5 N·m (0.65 - 0.76 kg-m, 56 - 66 in-lb) Wait at least 30 minutes before refilling engine oil. Install parts in reverse order of removal.

BT HA SC EL

AEM498

EM-17

IDX

TIMING CHAIN

KA24DE

Components

Components

NGEM0052

WEM134

1. 2. 3. 4. 5. 6.

Upper timing chain tensioner Cam sprocket Upper timing chain Water pump Water pump pulley Crankshaft pulley

7. 8. 9. 10. 11. 12.

Front oil seal Front cover Camshaft sprocket cover Oil slinger Oil pump drive gear Lower timing chain

EM-18

13. 14. 15. 16. 17.

Crankshaft sprocket Chain guide Idler sprocket Chain tension arm Lower timing chain tensioner

TIMING CHAIN

KA24DE Components (Cont’d)

GI MA

LC EC FE

LIQUID GASKET APPLICATION PLACES

WEM135

CL

NGEM0052S01

MT AT TF PD AX SU BR ST RS BT HA

AEM479

SC EL

EM-19

IDX

TIMING CHAIN

KA24DE

Removal

Removal

NGEM0053

CAUTION: 쐌 After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. 쐌 When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new engine oil. 쐌 Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets and crankshaft pulley. 쐌 Do not spill engine coolant on drive belts.

UPPER TIMING CHAIN

NGEM0053S01

1. 2.

Remove the air cleaner assembly. Remove the spark plug wires.

3. 4.

Set No.1 piston at TDC on its compression stroke. Remove vacuum hoses, electrical harness connectors, and harness clamps. Remove the power steering belt. Remove the power steering pump and position it to one side. Remove the idler pulley and bracket as well.

5. 6.

WEM067

7. 쐌

Remove the rocker cover. Loosen in numerical order as shown to remove the rocker cover bolts.

8.

Remove the camshaft sprocket cover.

AEM356

AEM374

EM-20

TIMING CHAIN

KA24DE Removal (Cont’d)

9.

Wipe off the links of the timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the cam sprockets and idler sprocket. 10. Remove cam sprocket bolts, cam sprockets and upper timing chain.

GI MA

LC

JEM547G

IDLER SPROCKET

NGEM0053S03

1.

Remove upper timing chain. Refer to “UPPER TIMING CHAIN”, EM-20. 2. Support lower timing chain by using a suitable tool to prevent chain tensioner spring from coming out. NOTE: This step is only to be applied when the lower cover is not being removed. 3. Remove the idler sprocket.

EC

LOWER TIMING CHAIN

MT

1.

2. 3. 쐌 쐌 쐌 쐌 4. AEM480

5. 6.

NGEM0053S02

Drain coolant by removing the cylinder block drain plug and opening the radiator drain cock. Refer to MA-17, “Changing Engine Coolant”. Drain engine oil from drain plug of oil pan. Remove the following parts. Alternator drive belt. A/C compressor drive belt. Cooling fan with coupling. Radiator shroud. Remove A/C compressor and position it to the side. Remove the idler pulley and bracket as well. Set No. 1 piston to TDC on its compression stroke. Remove the distributor.

FE CL

AT TF PD AX SU BR ST RS

WEM067

BT HA SC EL

EM-21

IDX

TIMING CHAIN

KA24DE

Removal (Cont’d)

7. 8.

Remove the crankshaft pulley with suitable puller. Remove oil pan. Refer to “Removal”, EM-16. 9. Remove the oil pump and distributor drive shaft, then the oil pickup strainer. 10. Remove the front cover. CAUTION: Be careful not to tear or damage the cylinder head gasket.

AEM354

11. Remove the following parts. 쐌 Lower timing chain tensioner (Push piston and insert a suitable pin into pin hole.) 쐌 Chain tension arm 쐌 Lower timing chain guide 12. Remove the upper timing chain and idler sprocket. Refer to “UPPER TIMING CHAIN”, EM-20 and “IDLER SPROCKET”, EM-21.

SEM796E

13. Wipe off the links of the timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the crankshaft sprocket and idler sprocket. 14. Remove the lower timing chain and sprocket.

AEM482

Inspection

NGEM0054

Check for cracks and excessive wear at roller links. Replace chain if necessary.

AEM403

EM-22

TIMING CHAIN

KA24DE Installation

Installation LOWER TIMING CHAIN

NGEM0055 NGEM0055S01

1. 쐌

SEM205C

Install crankshaft sprocket. Make sure that mating marks of crankshaft sprocket face front of engine. 2. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process. CAUTION: Be careful not to tear or damage the cylinder head gasket. 3. Install chain guide and chain tension arm. 4. Install lower chain tensioner and remove the pin securing the piston into the tensioner body.

GI MA

LC EC FE CL MT

5. 쐌

SEM715A

Front cover installation: Using a scraper or other suitable tool remove all traces of liquid gasket from the cylinder block and front cover mating surfaces. 쐌 Install new crankshaft seal in front cover. 쐌 Apply a continuous bead of RTV sealant to the front cover. Refer to “LIQUID GASKET APPLICATION PLACES”, EM-19. NOTE: Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”. 쐌 Be sure to install new front oil seal. Refer to “FRONT OIL SEAL”, EM-26. 쐌 Also place RTV sealant on the head gasket surface. 쐌 Install the front cover to the engine. 6. Install oil strainer and oil pan. Refer to “Installation”, EM-17.

AT TF PD AX SU BR ST RS

SEM292D

AEM391

7. Install the oil pump and distributor drive shaft. NOTE: Make sure the flat side of the distributor drive shaft is facing the engine. Failure to do so will result in the distributor being out of time. 8. Install the following parts: 쐌 Crankshaft pulley. 쐌 A/C compressor and idler pulley bracket. 쐌 Radiator shroud and cooling fan with coupling. 쐌 A/C compressor, alternator and power steering pump drive belts.

EM-23

BT HA SC EL IDX

TIMING CHAIN

KA24DE

Installation (Cont’d)

쐌

Air duct.

IDLER SPROCKET 1. 2.

UPPER TIMING CHAIN 1.

NGEM0055S03

Install lower timing chain. Refer to “LOWER TIMING CHAIN”, EM-23. Install idler sprocket and bolt.

NGEM0055S02

Install lower timing chain and idler sprocket. Refer to “LOWER TIMING CHAIN”, EM-23 and “IDLER SPROCKET”, EM-24.

SEM548G

2.

SEM549G

Install upper timing chain and sprockets, referring to the painted marks made during removal. 3. Install chain tensioner. Remove the pin holding the tensioner piston in the bore of the tensioner. 4. Install camshaft sprocket cover: 쐌 Use a scraper to remove all traces of liquid gasket from mating surfaces of the engine block and camshaft sprocket cover. 쐌 Apply a continuous bead of RTV sealant to the cover. Refer to “LIQUID GASKET APPLICATION PLACES”, EM-19. 쐌 Also place RTV sealant on the head gasket surface. NOTE: Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”. CAUTION: 쐌 Be careful not to tear or damage the cylinder head gasket. 쐌 Be careful upper timing chain does not slip or jump when installing camshaft sprocket cover. 5. Install rocker cover gasket to rocker cover. 쐌 Apply a continuous bead of RTV sealant to the cylinder head camshaft sprocket cover. Refer to “LIQUID GASKET APPLICATION PLACES”, EM-19.

JEM547G

6.

Install rocker cover. Tighten bolts in numerical order. : 8 - 11 N·m (0.8 - 1.1 kg-m, 69 - 95 in-lb).

AEM357

EM-24

TIMING CHAIN

KA24DE Installation (Cont’d)

7. 8.

Install distributor, aligning as shown. Install vacuum hoses, electrical harnesses, connectors, and harness clamps.

GI MA

LC

WEM067

EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EM-25

IDX

OIL SEAL

KA24DE

Replacement

Replacement VALVE OIL SEAL

NGEM0056 NGEM0056S01

1. 2. 3.

Remove rocker cover. Remove camshaft. Refer to “TIMING CHAIN”, EM-18. Remove valve spring and valve oil seal with Tool or a suitable tool. Piston concerned should be set at TDC to prevent valve from falling.

4.

Apply engine oil to new valve oil seal and install it with Tool.

SEM289D

SEM290D

OIL SEAL INSTALLING DIRECTION 쐌

NGEM0056S02

Install new oil seal in the direction shown.

SEM715A

FRONT OIL SEAL 1. 2. 쐌

Remove radiator shroud and crankshaft pulley. Remove front oil seal Be careful not to scratch front cover.

AEM385

EM-26

NGEM0056S03

OIL SEAL

KA24DE Replacement (Cont’d)

3.

Apply engine oil to new oil seal and install it using a suitable tool.

GI MA

LC

SEM292D

REAR OIL SEAL 1. 2. 3. 쐌

NGEM0056S04

Remove flywheel. Remove rear oil seal retainer. Remove rear oil seal from retainer. Be careful not to scratch rear oil seal retainer.

EC FE CL MT

SEM895A

4. 쐌

Apply engine oil to new oil seal and install it using suitable tool. Install new oil seal in the direction shown.

AT TF PD AX

SEM715A

SU BR ST RS SEM897A

5. a. 쐌

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.

BT HA SC EL

SEM896A

EM-27

IDX

OIL SEAL

KA24DE

Replacement (Cont’d)

b. 쐌 쐌

Apply a continuous bead of liquid gasket to mating surface of rear oil seal retainer. Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”. Apply around inner side of bolt holes.

AEM404

EM-28

CYLINDER HEAD

KA24DE Components

Components

NGEM0057

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST WEM136

1. 2. 3. 4. 5. 6.

Oil filler cap Rocker cover Camshaft bracket Intake camshaft Exhaust camshaft Shim

7. 8. 9. 10. 11.

Valve lifter Valve cotter Spring retainer Valve spring Spring seat

12. 13. 14. 15. 16.

Valve oil seal Intake valve Exhaust valve Cylinder head Cylinder head bolt

RS BT HA SC EL

EM-29

IDX

CYLINDER HEAD

KA24DE

Removal

Removal

NGEM0058

CAUTION: 쐌 When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. 쐌 Apply new engine oil to threads and seat surfaces when installing cylinder head, camshaft sprocket, crankshaft pulley, and camshaft bracket. 쐌 Attach tags to valve lifters so as not to mix them up. 쐌 1) 쐌 쐌

Before removing camshaft and idler sprockets, apply paint marks to them for retiming. Remove upper timing chain and idler sprocket. Refer to “UPPER TIMING CHAIN”, EM-20 and “IDLER SPROCKET”, EM-21. For retiming during cylinder head removal/installation, apply paint marks to camshaft sprockets, upper timing chain, lower timing chain, and idler sprocket.

2) 쐌

Remove camshaft brackets and camshafts. Mark these parts’ original positions for reassembly.

3) 쐌

Remove cylinder head bolts in numerical order. Removing bolts in incorrect order could result in a warped or cracked cylinder head. Loosen cylinder head bolts in two or three steps. Remove cylinder head and cylinder head gasket.

AEM352

쐌 4)

SEM274D

EM-30

CYLINDER HEAD

KA24DE Installation

Installation 1) a) b) c) d) e) SEM275D

2) a) 쐌 b) c)

SEM276D

쐌 3) 쐌

NGEM0083

Tighten cylinder head bolts in numerical order using the following procedure: Tighten all bolts to 29 N·m (3.0 kg-m, 22 ft-lb). Tighten all bolts to 79 N·m (8.1 kg-m, 59 ft-lb). Loosen all bolts completely. Tighten all bolts to 25 to 34 N·m (2.5 to 3.5 kg-m, 18 to 25 ftlb). Turn all bolts 86 to 91 degrees clockwise. If angle wrench is not available, mark all cylinder head bolts on the side facing engine front. Then turn each cylinder head bolts 86 to 91 degrees clockwise. Install camshafts and camshaft brackets in the order shown using the following procedure: Set camshafts and camshaft brackets. Dowel pins of both intake and exhaust camshafts should be at 12 o’clock positions when installing the camshafts. Tighten all bolts to 2 N·m (0.2 kg-m, 17 in-lb). Tighten all bolts to 9.0 to 11.8 N·m (0.92 to 1.2 kg-m, 79.9 to 104.2 in-lb). Apply new engine oil to bolt threads and seat surfaces. Install upper timing chain and idler sprocket. Refer to “UPPER TIMING CHAIN”, EM-24 and “IDLER SPROCKET”, EM-24.

GI MA

LC EC FE CL MT AT TF PD AX

AEM352

Disassembly 1. 2. 3.

NGEM0059

Remove intake manifold and exhaust manifold. Refer to “Removal and Installation”, EM-12. Remove valve components. Remove valve oil seal with a suitable tool.

SU BR ST RS

SEM692D

Inspection CYLINDER HEAD DISTORTION

NGEM0060

BT

NGEM0060S01

Clean surface of cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of cylinder head surface. Check along six positions shown in the figure. Head surface flatness: Standard Less than 0.03 mm (0.0012 in) Limit 0.1 mm (0.004 in)

HA SC EL

SEM294D

EM-31

IDX

CYLINDER HEAD

KA24DE

Inspection (Cont’d)

If beyond the specified limit, replace it or resurface it. Resurfacing limit: The limit of cylinder head resurfacing is determined by the cylinder block resurfacing. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit: 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: 126.3 - 126.5 mm (4.972 - 4.980 in)

CAMSHAFT VISUAL CHECK

NGEM0060S02

Check camshaft for scratches, seizure and wear.

CAMSHAFT RUNOUT 1.

2.

NGEM0060S03

Measure camshaft runout at the center journal. Runout (Total indicator reading): Standard: Less than 0.02 mm (0.0008 in) Limit: 0.04 mm (0.0016 in) If it exceeds the limit, replace camshaft.

SEM926C

CAMSHAFT CAM HEIGHT 1.

2.

NGEM0060S04

Measure camshaft cam height. Standard cam height: Intake 41.755 - 41.945 mm (1.644 - 1.651 in) Exhaust 41.815 - 42.005 mm (1.646 - 1.654 in) Cam height wear limit: Intake & Exhaust 0.2 mm (0.008 in) If wear is beyond the limit, replace camshaft.

SEM549A

CAMSHAFT JOURNAL CLEARANCE 1. 2.

NGEM0060S05

Install camshaft bracket and tighten bolts to the specified torque. Measure inner diameter of camshaft bearing. Standard inner diameter: No. 1 to No. 5 journals 28.000 - 28.025 mm (1.1024 - 1.1033 in)

SEM295D

EM-32

CYLINDER HEAD

KA24DE Inspection (Cont’d)

3.

4.

Measure outer diameter of camshaft journal. Standard outer diameter: No. 1 to No. 5 journals 27.935 - 27.955 mm (1.0998 - 1.1006 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance: Standard 0.045 - 0.090 mm (0.0018 - 0.0035 in) Limit 0.12 mm (0.0047 in)

GI MA

LC

SEM012A

CAMSHAFT END PLAY 1. 2.

3. SEM296D

4.

NGEM0060S06

Install camshaft in cylinder head. Measure camshaft end play. Camshaft end play: Standard 0.070 - 0.148 mm (0.0028 - 0.0058 in) Limit 0.2 mm (0.008 in) If end play exceeds the limit, replace camshaft and remeasure camshaft end play. If end play still exceeds the limit after replacing camshaft, replace cylinder head.

EC FE CL MT AT TF PD AX

CAMSHAFT SPROCKET RUNOUT 1. 2.

3.

NGEM0060S07

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.

SU BR ST RS

AEM328

VALVE GUIDE CLEARANCE 1.

NGEM0060S08

Measure valve deflection as shown in figure. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (Dial gauge reading): Intake & Exhaust 0.2 mm (0.008 in)

BT HA SC EL

SEM297D

EM-33

IDX

CYLINDER HEAD

KA24DE

Inspection (Cont’d)

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 = Valve guide inner diameter - Valve stem diameter: Unit: mm (in) 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)

c. 쐌

If it exceeds the limit, replace valve and remeasure clearance. If clearance still exceeds the limit after replacing valve, replace the valve guide.

SEM298D

VALVE GUIDE REPLACEMENT

NGEM0060S09

1.

To remove valve guide, heat cylinder head to 120 to 140°C (248 to 284°F) by soaking in heated oil.

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.

3.

Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake & Exhaust 11.175 - 11.196 mm (0.4400 - 0.4408 in)

SEM008A

SEM299D

SEM300D

EM-34

CYLINDER HEAD

KA24DE Inspection (Cont’d)

4.

Heat cylinder head to 120 to 140°C (248 to 284°F) and press service valve guide onto cylinder head. Projection “L”: 13.3 - 13.9 mm (0.524 - 0.547 in)

GI MA

LC

SEM301D

5.

Ream valve guide. Finished size: Intake & Exhaust 7.000 - 7.018 mm (0.2756 - 0.2763 in)

EC FE CL MT

SEM300D

VALVE SEATS

NGEM0060S10

Check valve seats for pitting at contact surface. Resurface or replace if excessively worn. 쐌 Before repairing valve seats, check valve and valve guide for wear. If they have worn, replace them. Then correct valve seat. 쐌 Use both hands to cut uniformly.

AT TF PD AX

SEM302D

REPLACING VALVE SEAT FOR SERVICE PARTS 1.

SEM795A

NGEM0060S11

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 38.000 - 38.016 mm (1.4961 - 1.4967 in) Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in) Use the valve guide center for reaming to ensure valve seat will have the correct fit.

SU BR ST RS BT HA SC EL

EM-35

IDX

CYLINDER HEAD

KA24DE

Inspection (Cont’d)

3. 4.

Heat cylinder head to 120 to 140°C (248 to 284°F). Press fit valve seat until it seats on the bottom.

5.

Cut or grind valve seat using suitable tool to the specified dimensions. Refer to “VALVE”, EM-56 After cutting, lap valve seat with abrasive compound. Check valve seating condition. Seat face angle “α”: 45°15′ - 45°45′ deg. Contacting width “W”: Intake 1.48 - 1.63 mm (0.0583 - 0.0642 in) Exhaust 1.8 - 2.0 mm (0.071 - 0.079 in)

SEM008A

6. 7.

SEM892B

8.

Use a depth gauge to measure the distance 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 adjust it. If it is longer, replace the valve seat with a new one. Valve seat resurface limit “L”: Intake 42.02 - 42.52 mm (1.6543 - 1.6740 in) Exhaust 42.03 - 42.53 mm (1.6547 - 1.6744 in)

SEM621F

VALVE DIMENSIONS

NGEM0060S12

Check dimensions of each valve. Refer to “Valve”, EM-56. 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-36

CYLINDER HEAD

KA24DE Inspection (Cont’d)

VALVE SPRING Squareness 1.

2.

NGEM0060S13 NGEM0060S1301

Measure dimension “S”. Out-of-square “S”: Less than 2.2 mm (0.087 in) If it exceeds the limit, replace spring.

GI MA

LC

SEM288A

Pressure

NGEM0060S1302

Check valve spring pressure at specified spring height. Pressure: N (kg, lb) at height mm (in) Standard 418.0 (42.6, 93.9) at 29.17 (1.1484) Limit 393.0 (40.1, 88.4) at 29.17 (1.1484) If not within specification, replace spring.

EC FE CL MT

EM113

VALVE LIFTER AND VALVE SHIM 1.

NGEM0060S14

Visually check contact and sliding surfaces for wear and scratches.

AT TF PD AX

AEM499

2.

Check diameter of valve lifter and valve lifter guide bore. Valve lifter outer diameter: 33.960 - 33.975 mm (1.3370 - 1.3376 in)

SU BR ST RS

AEM502

Lifter guide bore diameter: 34.000 - 34.021 mm (1.3386 - 1.3394 in) Valve lifter to valve lifter guide clearance: 0.025 - 0.061 mm (0.0010 - 0.0024 in) If it exceeds the standard diameter or clearance, replace valve lifter or cylinder head.

BT HA SC EL

SEM303D

EM-37

IDX

CYLINDER HEAD

KA24DE

Assembly

Assembly 1. 쐌 쐌 쐌 쐌

NGEM0061

Install valve component parts. Always use new valve oil seal. Refer to “Replacement”, EM-26. Before installing valve oil seal, install valve spring seat. Install outer valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side. After installing valve component parts, tap valve stem tip with plastic hammer to assure a proper fit.

SEM638B

Valve Clearance CHECKING

NGEM0062 NGEM0062S01

Check valve clearance while engine is warm but not running. 1. Remove rocker cover and all spark plugs. 2. Set No. 1 cylinder at TDC on its compression stroke. 쐌 Align pointer with TDC mark on crankshaft pulley. 쐌 Check that valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight. If not, turn crankshaft one revolution (360°) and align as above. WEM068

3.

Check only those valves shown in the figure.

4.

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 (Hot): Intake 0.31 - 0.39 mm (0.012 - 0.015 in) Exhaust 0.39 - 0.47 mm (0.015 - 0.019 in)

AEM382

쐌

SEM304D

5. 6. 쐌 7. 쐌 쐌

Turn crankshaft one revolution (360°) and align mark on crankshaft pulley with pointer. Check 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

AEM383

EM-38

CYLINDER HEAD

KA24DE Valve Clearance (Cont’d)

ADJUSTING

SEM515EA

NGEM0062S02

Adjust valve clearance while engine is cold. 1. Turn crankshaft to position cam lobe on camshaft of valve that must be adjusted upward. 2. Place Tool (A) around camshaft as shown in figure. 3. Rotate Tool (A) so that lifter is pushed down. Before placing Tool (A), rotate notch toward center of cylinder head (See figure.), to simplify shim removal later. CAUTION: Be careful not to damage cam surface with Tool (A). Place Tool (B) between camshaft and the edge of the valve lifter to retain valve lifter. CAUTION: 쐌 Tool (B) must be placed as close to camshaft bracket as possible. 쐌 Be careful not to damage cam surface with Tool (B). 5. Remove Tool (A).

GI MA

LC

4.

EC FE CL MT

SEM516EA

6.

Rotate adjusting shim until hole is visible. Blow air into the hole to separate adjusting shim from valve lifter.

AT TF PD AX

AEM447

7.

Remove adjusting shim using a small screwdriver and a magnetic finger.

SU BR ST RS

SEM517EA

8. a. b.

Determine replacement adjusting shim size as follows. Using a micrometer 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 Intake & Exhaust: N = R + [M − 0.37 mm (0.0146 in)]

BT HA SC EL

SEM145D

EM-39

IDX

CYLINDER HEAD

KA24DE

Valve Clearance (Cont’d)

c.

Shims are available in thicknesses from 1.96 mm (0.0772 in) to 2.68 mm (0.1055 in), in steps of 0.02 mm (0.0008 in). Select new shim with thickness as close as possible to calculated value. Refer to “AVAILABLE SHIMS”, EM-58.

SEM308D

9. 쐌 10. 11. 12. 13.

Install new shim using a suitable tool. Install with the surface on which the thickness is stamped facing down. Place Tool (A) as mentioned in steps 2 and 3. Remove Tool (B). Remove Tool (A). Recheck valve clearance. Refer to “CHECKING”, EM-38.

SEM518EA

EM-40

ENGINE ASSEMBLY

KA24DE Removal and Installation

Removal and Installation

NGEM0063

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST WEM055

WARNING: 쐌 Position vehicle on a flat and solid surface. 쐌 Place chocks at front and back of rear wheels. 쐌 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. 쐌 Before disconnecting fuel hose, release fuel pressure. Refer to EC-57, “Fuel Pressure Release”. 쐌 Be sure to hoist engine and transmission in a safe manner. 쐌 For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG.

EM-41

RS BT HA SC EL IDX

ENGINE ASSEMBLY

KA24DE

Removal and Installation (Cont’d)

CAUTION: 쐌 When lifting engine, be sure to clear surrounding parts. Take special care near accelerator wire casing, brake lines and brake master cylinder. 쐌 In hoisting the engine, always use engine slingers in a safe manner. 쐌 Before separating engine and transmission, remove the crankshaft position sensor (OBD) from the assembly. 쐌 Always take extra care not to damage edge of crankshaft position sensor (OBD) or ring gear teeth.

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

12. 13.

NGEM0063S01

Drain coolant from engine block and radiator. Refer to MA-17, “Changing Engine Coolant”. Release fuel pressure. Refer to EC-57, “Fuel Pressure Release”. Remove negative battery cable. Remove hood. Refer to BT-12, “Removal and Installation”. Remove air cleaner. Remove power steering drive belt, generator drive belt and A/C compressor drive belt. Remove radiator. Refer to LC-14, “Radiator”. Remove exhaust manifold heat shield. Disconnect exhaust system at rear of TWC (manifold). Remove A/C compressor from bracket. Refer to HA-70, “Compressor Mounting”. Disconnect accelerator wire, ASCD wire (if equipped), vacuum hoses, electrical connectors, heater hoses and vacuum booster hose. Remove four power steering pump bolts. Remove transmission. Refer to MT-9, “Removal”.

EM-42

ENGINE ASSEMBLY

KA24DE Removal and Installation (Cont’d)

GI MA

LC EC FE CL MT AT WEM063

14. Install engine slingers and connect engine lift. 15. Remove LH and RH engine mounts. 16. Remove engine.

INSTALLATION 쐌

Install in reverse order of removal.

TF PD

NGEM0063S02

AX SU BR ST RS BT HA SC EL

EM-43

IDX

CYLINDER BLOCK

KA24DE

Components

Components

NGEM0064

WEM137

EM-44

CYLINDER BLOCK

KA24DE Removal and Installation

Removal and Installation

NGEM0065

CAUTION: 쐌 When installing sliding parts (bearings, pistons, etc.), lubricate contacting surfaces with new engine oil. 쐌 Place removed parts such as bearings and bearing caps in their proper order and direction. 쐌 When installing connecting rod nuts and main bearing cap bolts, apply new engine oil to threads and seating surfaces. 쐌 Do not allow any magnetic materials to contact the ring gear teeth of flywheel or drive plate.

Disassembly PISTON AND CRANKSHAFT

MA

LC

NGEM0066 NGEM0066S01

1. 2. 3. 4. 5. 6. 7.

Place engine on a work stand. Drain coolant and oil. Remove oil pan. Remove timing chain. Refer to “Removal”, EM-20. Remove water pump. Remove cylinder head. Remove pistons with connecting rods.

8. 쐌

Remove bearing caps and crankshaft. Before removing bearing caps, measure crankshaft end play. Refer to “CRANKSHAFT”, EM-53. Bolts should be loosened in two or three steps.

EC FE CL MT

SEM744

쐌

GI

AT TF PD AX

EEM118

Inspection PISTON AND PISTON PIN CLEARANCE 1.

NGEM0067

SU

NGEM0067S01

Measure inner diameter of piston pin hole “dp”. Standard diameter “dp”: 20.993 - 21.005 mm (0.8265 - 0.8270 in)

BR ST RS

AEM023

2.

3.

Measure outer diameter of piston pin “Dp”. Standard diameter “Dp”: 20.989 - 21.001 mm (0.8263 - 0.8268 in) Calculate piston pin clearance. dp − Dp = −0.002 - 0.01 mm (−0.0001 - 0.0004 in) If it exceeds the above value, replace piston assembly with pin.

BT HA SC EL

AEM024

EM-45

IDX

CYLINDER BLOCK

KA24DE

Inspection (Cont’d)

PISTON RING SIDE CLEARANCE

NGEM0067S02

Side clearance: Top ring 0.04 - 0.08 mm (0.0016 - 0.0031 in) 2nd ring 0.03 - 0.07 mm (0.0012 - 0.0028 in) Max. limit of side clearance: 0.1 mm (0.004 in) If out of specification, replace piston ring. If clearance exceeds maximum limit with new ring, replace piston. SEM249CA

PISTON RING END GAP

SEM250C

NGEM0067S03

End gap: Top ring 0.28 - 0.52 mm (0.0110 - 0.0205 in) 2nd ring 0.45 - 0.69 mm (0.0177 - 0.0272 in) Oil ring 0.20 - 0.69 mm (0.0079 - 0.0272 in) Max. limit of ring gap: Refer to “PISTON RING”, EM-62. 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 “PISTON RING”, EM-62. 쐌 When replacing the piston, check cylinder block surface for scratches or seizure. If scratches or seizure are found, hone or replace the cylinder block.

CONNECTING ROD BEND AND TORSION 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. SEM038F

SEM003F

EM-46

NGEM0067S04

CYLINDER BLOCK

KA24DE Inspection (Cont’d)

CYLINDER BLOCK DISTORTION AND WEAR

NGEM0067S05

1.

Clean upper face 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. Limit: 0.1 mm (0.004 in) 2. If out of specification, resurface it. The limit for cylinder block resurfacing is determined by 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: 246.95 - 247.05 mm (9.7224 - 9.7264 in) 3. If necessary, replace cylinder block.

MA

LC EC FE CL MT

SEM255CB

PISTON-TO-BORE CLEARANCE 1.

SEM040

GI

2.

NGEM0067S06

Using a bore gauge, measure cylinder bore for wear, out-ofround and taper. Standard inner diameter: Refer to “Cylinder Block”, EM-60. Wear limit: 0.2 mm (0.008 in) Out-of-round (X − Y) standard: 0.015 mm (0.0006 in) Taper (A − B) standard: 0.010 mm (0.0004 in) If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Check for scratches and seizure. If seizure is found, hone it.

AT TF PD AX SU BR ST RS

쐌

If cylinder block and piston are replaced, match piston grade with grade number on cylinder block upper surface.

BT HA SC EL

SEM257C

EM-47

IDX

CYLINDER BLOCK

KA24DE

Inspection (Cont’d)

3.

SEM258C

Measure piston skirt diameter. Piston diameter “A”: Refer to “PISTON”, EM-62. Measuring point “a” (Distance from the top): Approximately 48 mm (1.89 in) 4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance “B”: 0.020 - 0.040 mm (0.0008 - 0.0016 in) 5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to “Piston, Piston Ring and Piston Pin”, EM-62. 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. 쐌 When any cylinder needs boring, all other cylinders must also be bored. 쐌 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. 쐌 Measurement should be done after cylinder bore cools down.

CRANKSHAFT 1. 2.

SEM316A

NGEM0067S07

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): Main journal Less than 0.01 mm (0.0004 in) Crank pin Less than 0.005 mm (0.0002 in) Taper (A − B): Main journal Less than 0.01 mm (0.0004 in) Crank pin Less than 0.005 mm (0.0002 in)

EM-48

CYLINDER BLOCK

KA24DE Inspection (Cont’d)

3.

Measure crankshaft runout. Runout (Total indicator reading): Less than 0.10 mm (0.0039 in)

GI MA

LC

SEM254C

BEARING CLEARANCE 쐌

NGEM0067S08

Use Method A or Method B. Method A is preferred because it is more accurate. Method A (Using bore gauge and micrometer)

Main bearing 1.

EC FE

NGEM0067S0801

Set main bearings in their proper positions on cylinder block and main bearing cap.

CL MT

SEM448C

2. 쐌 3.

Install main bearing cap to cylinder block. Tighten all bolts in correct order in two or three stages. Refer to “Components”, EM-44 and “CRANKSHAFT”, EM-53. Measure inner diameter “A” of each main bearing.

AT TF PD AX

EEM119

4. 5.

6. 7.

Measure outer diameter “Dm” of each crankshaft main journal. Calculate main bearing clearance. Main bearing clearance = A − Dm Standard: 0.020 - 0.047 mm (0.0008 - 0.0019 in) Limit: 0.1 mm (0.004 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.

SU BR ST RS

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) Grind crankshaft to use with available service parts. Refer to “Crankshaft”, EM-63 and “Available Main Bearing”, EM-64.

BT HA SC EL

SEM964

EM-49

IDX

CYLINDER BLOCK

KA24DE

Inspection (Cont’d)

8.

a.

If crankshaft is reused, measure main bearing clearance and select thickness of main bearing. If crankshaft or cylinder block 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.

EEM120

b.

c.

Grade number of each crankshaft main journal is punched on crankshaft. These numbers are punched in either Arabic or Roman numerals. Select main bearing with suitable thickness according to the following example or table. For example: Main journal grade number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 + 2 = 3 (Yellow) Main bearing grade number and identification color: Main journal grade number

SEM272C

Crankshaft journal grade number

0

1

2

0

0 (Black)

1 (Brown)

2 (Green)

1 or I

1 (Brown)

2 (Green)

3 (Yellow)

2 or II

2 (Green)

3 (Yellow)

4 (Blue)

Connecting Rod Bearing (Big End)

NGEM0067S0802

1. 2. 쐌 3.

Install connecting rod bearing to connecting rod and cap. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. Measure inner diameter “C” of each bearing.

4. 5.

Measure outer diameter “Dp” of each crankshaft pin journal. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C − Dp: Standard 0.010 - 0.035 mm (0.0004 - 0.0014 in) Limit 0.09 mm (0.0035 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.

AEM027

6. 7. AEM028

EM-50

CYLINDER BLOCK

KA24DE Inspection (Cont’d)

Refer to step 5 of “BEARING CLEARANCE”, EM-49.

GI MA

LC 8.

If crankshaft 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. Crank pin grade number

Connecting rod bearing grade number

0

0

1 or I

1

2 or II

2

EC FE CL MT

SEM567B

Method B (Using plastigage) CAUTION: 쐌 Do not turn crankshaft or connecting rod while plastigage is being inserted. 쐌 When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. Then if excessive bearing clearance exists, use a thicker main bearing or undersized bearing so that the specified bearing clearance is obtained.

AT TF PD AX

EM142

CONNECTING ROD BUSHING CLEARANCE (SMALL SU END) NGEM0067S09 1. 2. 3.

AEM332

Measure inner diameter “C” of bushing. Measure outer diameter “Dp” of piston pin. Calculate connecting rod bushing clearance. C − Dp = 0.005 - 0.017 mm (0.0002 - 0.0007 in) (Standard) 0.023 mm (0.0009 in) (Limit) If out of specification, replace connecting rod assembly and/or piston set with pin.

BR ST RS

REPLACEMENT OF CONNECTING ROD BUSHING BT (SMALL END) NGEM0067S10 1.

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 until 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)

HA SC EL

SEM062A

EM-51

IDX

CYLINDER BLOCK

KA24DE

Inspection (Cont’d)

FLYWHEEL RUNOUT

NGEM0067S11

Runout (Total indicator reading): Flywheel Less than 0.15 mm (0.006 in) CAUTION: 쐌 Be careful not to damage the ring gear teeth. 쐌 Do not allow any magnetic materials to contact the ring gear teeth. 쐌 Do not resurface the flywheel. Replace as necessary. AEM100

Assembly PISTON 1. 쐌 쐌 쐌

NGEM0068 NGEM0068S01

Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, piston pin and connecting rod. 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.

SEM262C

SEM215E

2. Set piston rings as shown. CAUTION: 쐌 When piston rings are not replaced, make sure that piston rings are mounted in their original positions. 쐌 When piston rings are being replaced and no punchmark is present, piston rings can be mounted with either side up.

LEM069

3.

Align piston rings so that end gaps are positioned as shown.

SEM160B

EM-52

CYLINDER BLOCK

KA24DE Assembly (Cont’d)

CRANKSHAFT 1. 쐌 쐌

NGEM0068S02

Set main bearings in their proper positions on cylinder block and main bearing caps. Confirm that correct main bearings are used. Refer to “Bearing Clearance”, EM-49. Apply new engine oil to bearing surfaces.

GI MA

LC

SEM448C

2. 쐌 쐌 쐌 쐌 EEM121

Install crankshaft and main bearing caps and tighten bolts to the specified torque. Refer to “Components”, EM-44. Apply new engine oil to the bolt threads and seat surface. Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction. 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.

Measure crankshaft end play. Crankshaft end play: Standard 0.05 - 0.18 mm (0.0020 - 0.0071 in) Limit 0.3 mm (0.012 in) If beyond the limit, replace No. 3 bearing with a new one.

EC FE CL MT

3.

AT TF PD AX

EEM122

4. 쐌 쐌 쐌

Install connecting rod bearings in connecting rods and connecting rod caps. Confirm that correct bearings are used. Refer to “Connecting Rod Bearing (Big End)”, EM-50. Install bearings so that oil hole in connecting rod aligns with oil hole of bearing. Apply new engine oil to bearing surfaces, bolt threads and seating surfaces.

SU BR ST RS

SEM159B

5. a. 쐌 쐌 쐌 쐌

Install pistons with connecting rods. Install them into corresponding cylinders with Tool. Arrange so that front mark on piston head faces toward front of engine. Make sure connecting rod does not scratch cylinder wall. Make sure connecting rod bolts do not scratch crankshaft journals. Apply new engine oil to piston rings and sliding surface of piston.

BT HA SC EL

SEM269C

EM-53

IDX

CYLINDER BLOCK

KA24DE

Assembly (Cont’d)

b.

Install connecting rod bearing caps. Tighten connecting rod bearing cap nuts using the following procedure. Connecting rod bearing nut: (1) Tighten to 14 - 16 N·m (1.4 - 1.6 kg-m, 10 - 12 ft-lb). (2) Tighten nuts 60 to 65 degrees clockwise with an angle wrench. If an angle wrench is not available, tighten them to 38 - 44 N·m (3.9 - 4.5 kg-m, 28 - 33 ft-lb).

EEM123

6.

Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.2 - 0.4 mm (0.008 - 0.016 in) Limit 0.6 mm (0.024 in) If beyond the limit, replace connecting rod and/or crankshaft.

EEM124

REPLACING PILOT BUSHING 1.

Remove pilot bushing.

2.

Install pilot bushing.

SEM916AA

SEM275GA

EM-54

NGEM0068S03

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE General Specifications

General Specifications

NGEM0069

Cylinder arrangement

GI

In-line 4 2,389 cm3 (145.78 cu in)

Displacement Bore and stroke

MA

89 x 96 mm (3.50 x 3.78 in)

Valve arrangement

DOHC

Firing order

1-3-4-2 Compression

2

Oil

1

Number of piston rings Number of main bearings

LC

5

Compression ratio

EC

9.2

COMPRESSION PRESSURE

NGEM0069S01

Unit: kPa (kg/cm2, psi)/300 rpm Standard

1,226 (12.5, 178)

Minimum

1,030 (10.5, 149)

Differential limit between cylinders

FE CL

98 (1.0, 14)

MT

Cylinder Head

NGEM0070

Unit: mm (in)

AT Standard

Limit

TF PD

Head surface distortion

Less than 0.03 (0.0012)

0.1 (0.004)

AX

SEM519E

SU BR ST RS BT HA SC EL

EM-55

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE

Valve

Valve

NGEM0071

VALVE

NGEM0071S01

Unit: mm (in)

SEM188

Intake

36.5 - 36.7 (1.437 - 1.445)

Exhaust

31.2 - 31.4 (1.228 - 1.236)

Valve head diameter “D” Intake

101.17 - 101.47 (3.9831 - 3.9949)

Valve length “L” Exhaust

98.67 - 98.97 (3.8846 - 3.8964)

Intake

6.965 - 6.980 (0.2742 - 0.2748)

Exhaust

6.945 - 6.960 (0.2734 - 0.2740)

Valve stem diameter “d” Valve seat angle “α”

Intake & Exhaust

45°15′ - 45°45′

Intake

0.95 - 1.25 (0.0374 - 0.0492)

Exhaust

1.15 - 1.45 (0.0453 - 0.0571)

Valve margin “T” Valve margin “T” limit

More than 0.5 (0.020)

Valve stem end surface grinding limit

Less than 0.2 (0.008)

VALVE SPRING Free height

NGEM0071S02

mm (in)

Pressure N (kg, lb) at height mm (in) Out-of-square

50.3 (1.9831) Standard

418.0 (42.6, 93.9) at 29.17 (1.1484)

Limit

393.0 (40.1, 88.4) at 29.17 (1.1484)

mm (in)

Less than 2.2 (0.087)

EM-56

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE Valve (Cont’d)

VALVE GUIDE

NGEM0071S03

Unit: mm (in)

GI MA

LC SEM301D

Valve guide Outer diameter Valve guide Inner diameter (Finished size) Cylinder head valve guide hole diameter

Standard

Service

Intake

11.023 - 11.034 (0.4340 - 0.4344)

11.223 - 11.234 (0.4418 - 0.4423)

Exhaust

11.023 - 11.034 (0.4340 - 0.4344)

11.223 - 11.234 (0.4418 - 0.4423)

Intake

7.000 - 7.018 (0.2756 - 0.2763)

Exhaust

7.000 - 7.018 (0.2756 - 0.2763)

FE CL

Intake

10.975 - 10.996 (0.4321 - 0.4329)

11.175 - 11.196 (0.4400 - 0.4408)

Exhaust

10.975 - 10.996 (0.4321 - 0.4329)

11.175 - 11.196 (0.4400 - 0.4408)

Interference fit of valve guide

EC

MT AT

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)

TF

Stem to guide clearance

PD

Valve deflection limit

0.2 (0.008)

Projection length “L”

13.3 - 13.9 (0.524 - 0.547)

AX

VALVE LIFTER

NGEM0071S04

Unit: mm (in) Valve lifter outer diameter

33.960 - 33.975 (1.3370 - 1.3376)

Lifter guide inner diameter

34.000 - 34.021 (1.3386 - 1.3394)

Clearance between lifter and filter guide

SU BR

0.025 - 0.061 (0.0010 - 0.0024)

VALVE CLEARANCE ADJUSTMENT

NGEM0071S05

Unit: mm (in) Intake

0.31 - 0.39 (0.012 - 0.015)

Exhaust

0.39 - 0.47 (0.015 - 0.019)

Valve clearance (Hot)

ST RS BT HA SC EL

EM-57

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE

Valve (Cont’d)

AVAILABLE SHIMS

NGEM0071S06

Thickness mm (in)

Identification mark

Thickness mm (in)

Identification mark

—

—

1.90 (0.0748)

190

1.92 (0.0756)

192

1.94 (0.0764)

194

1.96 (0.0772)

196

1.98 (0.0780)

198

2.00 (0.0787)

200

2.02 (0.0795)

202

2.04 (0.0803)

204

2.06 (0.0811)

206

2.08 (0.819)

208

2.10 (0.0827)

210

2.12 (0.0835)

212

2.14 (0.0843)

214

2.16 (0.0850)

216

2.18 (0.0858)

218

2.20 (0.0866)

220

2.22 (0.0874)

222

2.24 (0.0882)

224

2.26 (0.0890)

226

2.28 (0.0898)

228

2.30 (0.0906)

230

2.32 (0.0913)

232

2.34 (0.0921)

234

2.36 (0.0929)

236

2.38 (0.0937)

238

2.40 (0.0945)

240

2.42 (0.0953)

242

2.44 (0.0961)

244

2.46 (0.0969)

246

2.48 (0.0976)

248

2.50 (0.0984)

250

2.52 (0.0992)

252

2.54 (0.1000)

254

2.56 (0.1008)

256

2.58 (0.1016)

258

2.60 (0.1024)

260

2.62 (0.1031)

262

2.64 (0.1039)

264

2.66 (0.1047)

266

2.68 (0.1055

268

—

—

SEM308D

EM-58

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE Valve (Cont’d)

VALVE SEAT

NGEM0071S07

Unit: mm (in)

GI MA

LC EC FE CL MT AT TF AEM456

PD AX SU BR SEM621F

Standard

Service

Intake

37.500 - 37.516 (1.4764 - 1.4770)

38.000 - 38.016 (1.4961 - 1.4967)

Exhaust

32.200 - 32.216 (1.2677 - 1.2683)

32.700 - 32.716 (1.2874 - 1.2880)

Cylinder head seat recess diameter (D) Intake

0.064 - 0.096 (0.0025 - 0.0038)

Exhaust

0.064 - 0.096 (0.0025 - 0.0038)

Valve seat interference fit Intake

37.580 - 37.596 (1.4795 - 1.4802)

38.080 - 38.096 (1.4992 - 1.4998)

Exhaust

32.280 - 32.296 (1.2709 - 1.2715)

32.780 - 32.796 (1.2905 - 1.2912)

Valve seat outer diameter (d) Intake

6.1 - 6.3 (0.240 - 0.248)

Exhaust

6.1 - 6.3 (0.240 - 0.248)

Depth (H) Intake

5.8 - 6.0 (0.228 - 0.236) 5.9 - 6.0 (0.232 - 0.236)

5.3 - 5.5 (0.209 - 0.217)

Exhaust

5.9 - 6.0 (0.232 - 0.236)

5.32 - 5.42 (0.209 - 0.213)

Height (h1)

EM-59

ST RS BT HA SC EL IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE

Valve (Cont’d) Intake

0.24 - 0.64 (0.0094 - 0.0252) 0.34 - 0.64 (0.0134 - 0.0252)

Exhaust

0.43 - 0.73 (0.0169 - 0.0287)

Height (h2)

Intake

42.02 - 42.52

Exhaust

42.03 - 42.53

Depth (L)

Cylinder Block

NGEM0072

Unit: mm (in)

SEM400E

Distortion

Inner diameter Cylinder bore

Standard

Limit

—

0.1 (0.004)

Grade 1

89.000 - 89.010 (3.5039 - 3.5043)

Grade 2

89.010 - 89.020 (3.5043 - 3.5047)

Grade 3

89.020 - 89.030 (3.5047 - 3.5051)

0.2 (0.008)*

Out-of-round (X − Y)

Less than 0.015 (0.0006)

—

Taper (A − B)

Less than 0.010 (0.0004)

—

Less than 0.03 (0.0012)

0.2 (0.008)

0.020 - 0.040 (0.0008 - 0.0016)

—

246.95 - 247.05 (9.7224 - 9.7264)

0.2 (0.008)**

Difference in inner diameter between cylinders Piston-to-cylinder clearance Cylinder block height (From crankshaft center)

* Wear limit ** Total amount of cylinder head resurfacing and cylinder block resurfacing

EM-60

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE

Camshaft and Camshaft Bearing

Camshaft and Camshaft Bearing

NGEM0073

Unit: mm (in)

GI MA

LC

SEM568A

EM120

Standard

Limit

Intake

41.755 - 41.945 (1.644 - 1.651)

—

Exhaust

41.815 - 42.005 (1.646 - 1.654)

—

—

0.2 (0.008)

0.045 - 0.090 (0.0018 - 0.0035)

0.12 (0.0047)

EC FE

Cam height (A) Wear limit of cam height Camshaft journal to bearing clearance Inner diameter of camshaft bearing

#1 to #5 journals

28.000 - 28.025 (1.1024 - 1.1033)

—

Outer diameter of camshaft journal (D)

#1 to #5 journals

27.935 - 27.955 (1.0998 - 1.1006)

—

Less than 0.02 (0.0008)

0.04 (0.0016)

0.070 - 0.148 (0.0028 - 0.0058)

0.2 (0.008)

a

224

—

b

224

—

c

−1

—

d

45

—

e

7

—

f

37

—

Camshaft runout* Camshaft end play

Valve timing (Degree on crankshaft)

CL MT AT TF PD AX SU

* Total indicator reading

BR ST RS BT HA SC EL

EM-61

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE

Piston, Piston Ring and Piston Pin

Piston, Piston Ring and Piston Pin

NGEM0074

PISTON

NGEM0074S01

Unit: mm (in)

SEM804E

Standard Piston skirt diameter (A)

Grade No. 1

88.970 - 88.980 (3.5027 - 3.5031)

Grade No. 2

88.980 - 88.990 (3.5031 - 3.5035)

Grade No. 3

88.990 - 89.000 (3.5035 - 3.5039)

0.5 (0.020)

89.470 - 89.500 (3.5224 - 3.5236)

1.0 (0.039)

89.970 - 90.000 (3.5421 - 3.5433)

Service (Oversize) Dimension (a)

Approximately 48 (1.89)

Piston pin hole diameter (d)

20.993 - 21.005 (0.8265 - 0.8270)

Piston-to-cylinder bore clearance

0.020 - 0.040 (0.0008 - 0.0016)

PISTON PIN

NGEM0074S02

Unit: mm (in) Standard

Limit

Piston pin outer diameter

20.989 - 21.001 (0.8263 - 0.8268)

—

Interference fit of piston pin to piston pin hole

−0.002 to 0.01 (−0.0001 to 0.0004)

—

Piston pin to connecting rod bearing clearance

0.005 - 0.017 (0.0002 - 0.0007)

0.023 (0.0009)

PISTON RING

NGEM0074S03

Unit: mm (in)

Side clearance

Ring gap

Standard

Limit

Top

0.040 - 0.080 (0.0016 - 0.0031)

0.1 (0.004)

2nd

0.030 - 0.070 (0.0012 - 0.0028)

0.1 (0.004)

Oil

0.065 - 0.135 (0.0026 - 0.0053)

__

Top

0.28 - 0.52 (0.0110 - 0.0205)

1.0 (0.039)

2nd

0.45 - 0.69 (0.0177 - 0.0272)

1.0 (0.039)

Oil (rail ring)

0.20 - 0.69 (0.0079 - 0.0272)

1.0 (0.039)

EM-62

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE Connecting Rod

Connecting Rod

NGEM0075

Unit: mm (in)

GI MA

LC SEM570A

Standard

Limit

164.95 - 165.05 (6.4941 - 6.4980)

—

Bend [per 100 mm (3.94 in)]

—

0.15 (0.0059)

Torsion [per 100 mm (3.94 in)]

—

0.30 (0.0118)

Connecting rod small end inner diameter (d)*

23.970 - 24.000 (0.9437 - 0.9449)

—

Piston pin bushing inner diameter

21.000 - 21.012 (0.8268 - 0.8272)

—

Connecting rod big end inner diameter (D)*

53.000 - 53.013 (2.0866 - 2.0871)

—

0.2 - 0.4 (0.008 - 0.016)

0.6 (0.024)

Center distance (S)

Side clearance

EC FE CL MT AT

* Without bearing

Crankshaft

TF NGEM0076

Unit: mm (in)

PD AX SU BR SEM394

Main journal diameter (Dm)

Pin journal diameter (Dp)

EM715

Grade No. 0

59.967 - 59.975 (2.3609 - 2.3612)

Grade No. 1

59.959 - 59.967 (2.3606 - 2.3609)

Grade No. 2

59.951 - 59.959 (2.3603 - 2.3606)

Grade No. 0

49.968 - 49.974 (1.9672 - 1.9675)

Grade No. 1

49.962 - 49.968 (1.9670 - 1.9672)

Grade No. 2

49.956 - 49.962 (1.9668 - 1.9670)

Center distance (r)

ST RS BT HA

47.95 - 48.05 (1.8878 - 1.8917) Standard

Limit

Journal

—

0.01 (0.0004)

Pin

—

0.005 (0.0002)

SC

Taper of journal and pin [A - B]

EM-63

EL IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE

Crankshaft (Cont’d) Journal

—

0.01 (0.0004)

Pin

—

0.005 (0.0002)

Runout [TIR]*

—

0.10 (0.0039)

Free end play

0.05 - 0.18 (0.0020 - 0.0071)

0.3 (0.012)

Out-of-round of journal and pin [X - Y]

Fillet roil

More than 0.1 (0.004)

* Total indicator reading

Bearing Clearance

NGEM0077

Unit: mm (in) Standard

Limit

Main bearing clearance

0.020 - 0.047 (0.0008 - 0.0019)

0.1 (0.004)

Connecting rod bearing clearance

0.010 - 0.035 (0.0004 - 0.0014)

0.09 (0.0035)

Available Main Bearing

NGEM0078

STANDARD

NGEM0078S01

Unit: mm (in) Grade number

Thickness

Identification color

0

1.821 - 1.825 (0.0717 - 0.0719)

Black

1

1.825 - 1.829 (0.0719 - 0.0720)

Brown

2

1.829 - 1.833 (0.0720 - 0.0722)

Green

3

1.833 - 1.837 (0.0722 - 0.0723)

Yellow

4

1.837 - 1.841 (0.0723 - 0.0725)

Blue

UNDERSIZE (SERVICE)

NGEM0078S02

Unit: mm (in)

0.25 (0.0098)

Thickness

Main journal diameter “Dm”

1.952 - 1.960 (0.0769 - 0.0772)

Grind so that bearing clearance is the specified value.

Available Connecting Rod Bearing STANDARD

NGEM0079 NGEM0079S01

Unit: mm (in) Grade number

Thickness

Identification color

0

1.505 - 1.508 (0.0593 - 0.0594)

—

1

1.508 - 1.511 (0.0594 - 0.0595)

Brown

2

1.511 - 1.514 (0.0595 - 0.0596)

Green

UNDERSIZE (SERVICE)

NGEM0079S02

Unit: mm (in) Thickness 0.08 (0.0031)

1.540 - 1.548 (0.0606 - 0.0609)

0.12 (0.0047)

1.560 - 1.568 (0.0614 - 0.0617)

0.25 (0.0098)

1.625 - 1.633 (0.0640 - 0.0643)

EM-64

Crank pin journal diameter “Dp”

Grind so that bearing clearance is the specified value.

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE

Miscellaneous Components

Miscellaneous Components

NGEM0080

Unit: mm (in) Camshaft sprocket runout Flywheel runout

[TIR]*

Less than 0.15 (0.0059)

[TIR]*

Less than 0.15 (0.006)

GI MA

* Total indicator reading

LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EM-65

IDX

PRECAUTIONS

VG33E AND VG33ER

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGEM0090

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 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), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

Parts Requiring Angular Tightening 쐌 a) b) 쐌 쐌 쐌

NGEM0091

Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Connecting rod cap nuts Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.

EM-66

PRECAUTIONS

VG33E AND VG33ER Liquid Gasket Application Procedure

Liquid Gasket Application Procedure 1)

2) 쐌 쐌 SEM371C

3) 4) 5)

NGEM0092

Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also completely clean any oil stains from these portions. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”.) Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) dia. (for oil pan). Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) dia. (in areas except oil pan). Apply liquid gasket to inner surface around hole perimeter area (unless otherwise specified). Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant.

GI MA

LC EC FE CL MT

AEM080

AT TF PD AX SU BR ST RS BT HA SC EL

EM-67

IDX

PREPARATION

VG33E AND VG33ER

Special Service Tools

Special Service Tools

NGEM0102

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description Disassembling and assembling

ST0501S000 ( — ) Engine stand assembly 1 ST05011000 ( — ) Engine stand 2 ST05012000 ( — ) Base NT042

KV10106500 ( — ) Engine stand shaft

NT028

KV10110001 ( — ) Engine sub-attachment

NT032

ST10120000 (J24239-01) Cylinder head bolt wrench

Loosening and tightening cylinder head bolt a: 13 mm (0.51 in) dia. b: 12 mm (0.47 in) c: 10 mm (0.39 in)

NT583

Tightening bearing cap, cylinder head bolts, etc.

KV10112100 (BT8653-A) Angle wrench

NT014

Disassembling and assembling valve components

KV10110600 (J33986) Valve spring compressor

NT033

Installing valve oil seal

KV10107501 ( — ) Valve oil seal drift NT025

EM-68

PREPARATION

VG33E AND VG33ER Special Service Tools (Cont’d)

Tool number (Kent-Moore No.) Tool name KV10110300 ( — ) Piston pin press stand assembly 1 KV10110310 ( — ) Cap 2 KV10110330 ( — ) Spacer 3 ST13030020 ( — ) Press stand 4 ST13030030 ( — ) Spring 5 KV10110340 ( — ) Drift 6 KV10110320 ( — ) Center shaft

Description

GI Disassembling and assembling piston with connecting rod

MA

LC EC FE NT036

CL MT Installing piston assembly into cylinder bore

EM03470000 (J8037) Piston ring compressor

AT TF NT044

Removing crankshaft pilot bushing

ST16610001 (J23907) Pilot bushing puller

PD AX

NT045

Removing oil pan

KV10111100 (J37228) Seal cutter

BR ST

NT046

WS39930000 ( — Tube presser

SU

Pressing the tube of liquid gasket )

RS BT

NT052

Loosening or tightening heated oxygen sensor For 22 mm (0.87 in) hexagon nut

KV10117100 (J36471-A) Front heated oxygen sensor wrench

HA SC EL

NT379

EM-69

IDX

PREPARATION

VG33E AND VG33ER

Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

KV10114400 (J38365) Heated oxygen sensor wrench

Loosening or tightening rear heated oxygen sensor (For right bank) a: 22 mm (0.87 in)

NT636

Commercial Service Tools Tool name (Kent Moore No.)

NGEM0103

Description Removing and installing spark plug

Spark plug wrench

NT047

Holding camshaft pulley while tightening or loosening camshaft bolt

Pulley holder

NT035

Finishing valve seat dimensions

Valve seat cutter set

NT048

Removing and installing piston ring

Piston ring expander

NT030

Valve guide drift

Removing and installing valve guide Intake & Exhaust: a = 10.5 mm (0.413 in) dia. b = 6.6 mm (0.260 in) dia. NT015

Reaming valve guide 1 or hole for oversize valve guide 2 Intake: d1 = 7.0 mm (0.276 in) dia. d2 = 11.2 mm (0.441 in) dia. Exhaust: d1 = 8.0 mm (0.315 in) dia. d2 = 12.2 mm (0.480 in) dia.

Valve guide reamer

NT016

EM-70

PREPARATION

VG33E AND VG33ER Commercial Service Tools (Cont’d)

Tool name (Kent Moore No.)

Description

GI Installing camshaft oil seal a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia. c: 75 mm (2.95 in)

Camshaft oil seal drift

MA

NT613

Installing front oil seal a: 52 mm (2.05 in) dia. b: 44 mm (1.73 in) dia.

Front oil seal drift

LC EC

NT049

Installing rear oil seal a: 46 mm (1.81 in) b: 110 mm (4.33 in) c: 84 mm (3.31 in) d: 96 mm (3.78 in)

Rear oil seal drift

FE CL MT

NT719

a: 18 mm (0.71 in) b: 12 mm (0.47 in)

a: (J-43897-18) b: (J-43897-12) Thread repair tool for oxygen sensor

AT TF PD AX

AEM488

For preventing corrosion, seizing, and galling on high temperature applications.

Anti-seize thread compound

SU BR ST

AEM489

RS BT HA SC EL

EM-71

IDX

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING VG33E AND VG33ER

NGEM0039

WEM111

EM-72

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING VG33E AND VG33ER NVH Troubleshooting Chart — Engine Noise

NVH Troubleshooting Chart — Engine Noise

NGEM0039S01

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.

GI MA

Top of engine Rocker cover Cylinder head

Rattle

C

A

—

A

B

Slap or knock

—

A

—

B

B

A

A

A

—

B

—

—

C

A

B

B

B

B

B

Source of noise

While driving

When racing

C

Camshaft journal clearance Camshaft runout

EM-96, EM-96

CL

—

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

EM-117, EM-123

MT

A

Piston slap noise

Piston-to-bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion

EM-119, EM-117, EM-118, EM-118

B

Connecting rod bearing noise

Connecting rod bushing clearance (Small end) Connecting rod bearing clearance (Big end)

EM-123, EM-123

Main bearing oil clearance Crankshaft runout

EM-121, EM-120

Loose timing belt Belt contacting case

EM-82

A

B

C

Main bearing noise

Whine or hissing

C

A

—

A

A

—

Timing belt noise (too tight)

Squeaking or fizzing

Creaking

Squall Creak

A: Closely related

A

A

A

B: Related

B

B

B

—

A

—

C

B

B

B

A

—

A

A

C: Sometimes related

EC

Camshaft bearing noise

—

—

Step 19 in “Installation”, EM-103

LC

C

B

B

Reference page

Hydraulic valve lifter

A

A

Check item

Tappet noise

—

Knock

Clatter

Front of engine

When idling

Ticking or clicking

Crankshaft pul- Slap or rap ley Cylinder block (Side of Knock engine) Oil pan

Timing belt cover

When starting

Type of noise

After warm-up

Location of noise

Before warm-up

Operating condition of engine

—

Timing belt noise (too loose)

C

Other drive belts (Sticking or slipping)

B

Other drive belts (Slipping)

B

AT TF PD AX SU BR

Drive belts deflection

MA-26, “Checking Drive Belts”

ST RS

Idler pulley bearing operation

Water pump Water pump operation noise

—: Not related

FE

BT LC-30, “Water Pump Inspection”

HA SC EL

EM-73

IDX

OUTER COMPONENT PARTS

VG33E AND VG33ER

Removal and Installation

Removal and Installation

NGEM0005

VG33E, VG33ER

WEM138

EM-74

OUTER COMPONENT PARTS

VG33E AND VG33ER Removal and Installation (Cont’d)

VG33ER

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEM139

EM-75

EL IDX

OUTER COMPONENT PARTS

VG33E AND VG33ER

Removal and Installation (Cont’d)

VG33E, VG33ER

WEM140

EM-76

MEASUREMENT OF COMPRESSION PRESSURE 1. 2. 3. 4. 쐌 5. 6.

NGEM0006

VG33E AND VG33ER

Warm up engine. Turn ignition switch OFF. Release fuel pressure. Refer to EC-644, “Fuel Pressure Release”. Remove all spark plugs. Clean area around plug with compressed air before removing the spark plugs. Disconnect camshaft position sensor harness connector at the distributor. Remove fuel injector fuse 3 on FUSE BLOCK (J/B) behind the instrument lower panel. Refer to “FUSE BLOCK — JUNCTION BOX (J/B)”.

GI MA

LC EC FE CL MT

7. 8. 9. 10. 쐌

SEM814C

11. 쐌

SEM387C

쐌

쐌

12.

13.

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 on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine speed. Compression pressure: kPa (kg/cm2, psi)/300 rpm Standard 1,196 (12.2, 173) Minimum 883 (9.0, 128) Difference limit between cylinders 98 (1.0, 14) If cylinder compression in one or more cylinders is low, pour a small amount of engine oil into cylinders through spark plug holes and retest compression. If adding oil improves cylinder compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. Refer to “Valve Seat”, EM-130. If valve or valve seat is damaged excessively, replace them. 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. Reinstall spark plugs, fuel injector fuse, fuel pump fuse, and reconnect camshaft position sensor harness connector at the distributor. Erase the DTC stored in the ECM.

EM-77

AT TF PD AX SU BR ST RS BT HA SC EL IDX

MEASUREMENT OF COMPRESSION PRESSURE

VG33E AND VG33ER

CAUTION: Always erase the DTC after checking compression. Refer to EC-673, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.

EM-78

OIL PAN

VG33E AND VG33ER Removal

Removal

NGEM0007

WARNING: 쐌 Place vehicle on a flat and solid surface. 쐌 Place chocks at front and rear of rear wheels. 쐌 You should not remove oil pan until exhaust system and cooling system have completely cooled off. Otherwise, you may burn yourself and/or fire may break out in the fuel line. 쐌 When removing front and/or rear engine mounting bolts or nuts, lift engine slightly to ensure safety. CAUTION: 쐌 In lifting engine, be careful not to hit against adjacent parts, especially against accelerator wire casing end, brake tube and brake master cylinder. 쐌 For tightening torque, refer to AT-271, “Removal”; MT-41, “REMOVAL AND INSTALLATION”; and PD-8, “Removal and Installation”. 1. Remove undercover. 2. Drain engine oil. 3. Remove stabilizer bracket bolts (RH & LH). 4. Remove front propeller shaft from front differential carrier. 5. Remove front drive shaft fixing bolts (RH & LH). 6. Remove front differential carrier bleeder hose. 7. Remove front suspension crossmember. 8. Remove differential front mounting bolts (RH & LH) and rear mounting bolts. 9. Remove front differential carrier. 10. Remove front differential carrier mounting bracket. 11. Remove starter motor. 12. Remove transmission to rear engine mounting bracket nuts (RH & LH). 13. Remove engine mounting bolts or nuts (RH & LH). 14. Remove power steering mounting brackets (RH & LH). 15. Lift up engine. If necessary, disconnect exhaust tube. 16. Remove relay rod. It is not necessary to disconnect pitman arm.

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST RS

17. Remove oil pan bolts in numerical order.

BT HA SC EL

SEM308F

EM-79

IDX

OIL PAN

VG33E AND VG33ER

Removal (Cont’d)

18. Remove oil pan. a. Insert Tool between cylinder block and oil pan. 쐌 Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating face will be damaged. 쐌 Do not insert screwdriver, or oil pan flange will be deformed. b. Slide Tool by tapping its side with a hammer, and remove oil pan. SEM365E

Installation 1. 쐌

NGEM0008

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

2.

Apply sealant to oil pump gasket and rear oil seal retainer gasket.

3.

Apply a continuous bead of liquid gasket to mating surface of oil pan. (Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”.)

SEM894B

쐌

SEM351B

EM-80

OIL PAN

VG33E AND VG33ER Installation (Cont’d)

쐌 4. 쐌 5. 쐌 쐌

Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide. Apply liquid gasket to inner sealing surface as shown in figure. Attaching should be done within 5 minutes after coating. Install oil pan. Install bolts/nuts in the reverse order of removal. Wait at least 30 minutes before refilling engine oil.

GI MA

LC

SEM015E

EC FE CL MT

AEM080

AT TF PD AX SU BR ST RS BT HA SC EL

EM-81

IDX

TIMING BELT

VG33E AND VG33ER

Components

Components

NGEM0009

CAUTION: 쐌 Do not bend or twist timing belt. 쐌 After removing timing belt, do not turn crankshaft and camshaft separately because valves will strike piston heads. 쐌 Make sure that timing belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and free from oil and water. 쐌 Installation should be carried out when engine is cold.

SEM311FA

EM-82

TIMING BELT

VG33E AND VG33ER Removal

Removal 1. 2.

3. 4. 5. 쐌 쐌 쐌 쐌 6. 7.

NGEM0010

Remove engine under cover. Drain engine coolant from radiator. Refer to MA-28, “DRAINING ENGINE COOLANT”. Be careful not to spill coolant on drive belts. Remove radiator. Refer to LC-32, “REMOVAL AND INSTALLATION”. Remove engine cooling fan and water pump pulley. Remove the following belts. Power steering pump drive belt Compressor drive belt Alternator drive belt Supercharger (if equipped). Refer to “Removal”, EM-109. Remove all spark plugs. Remove distributor protector.

GI MA

LC EC FE CL MT

8. Remove compressor drive belt idler bracket. 9. Remove fresh-air intake tube for rocker cover. 10. Remove water hose for thermostat housing.

AT TF PD AX SU BR ST RS

AEM223

11. Set No. 1 piston at TDC on its compression stroke by rotating crankshaft. 12. Remove crankshaft pulley bolt. 13. Remove crankshaft pulley using a suitable puller. 14. Remove front upper and lower belt covers.

BT HA SC EL

SEM347F

EM-83

IDX

TIMING BELT

VG33E AND VG33ER

Removal (Cont’d)

쐌 쐌 쐌

Align punchmark on LH camshaft sprocket with punchmark on timing belt rear cover. Align punchmark on crankshaft sprocket with alignment mark on oil pump housing. Temporarily install crankshaft pulley bolt on crankshaft so the crankshaft can be rotated.

SEM394CA

15. Loosen timing belt tensioner nut, rotate tensioner, then remove timing belt.

SEM240A

Inspection

NGEM0011

Visually check the condition of timing belt. Replace if any abnormality is found. Item to check

Problem

Cause 쐌 Camshaft jamming 쐌 Distributor jamming 쐌 Damaged camshaft/crankshaft oil seal

Tooth is broken/tooth root is cracked.

SEM394A

쐌 Tensioner jamming 쐌 Overheated engine 쐌 Interference with belt cover

Back surface is cracked/worn.

SEM395A

EM-84

TIMING BELT

VG33E AND VG33ER Inspection (Cont’d)

Item to check

Problem

Cause 쐌 Improper installation of belt 쐌 Malfunctioning crankshaft pulley plate/timing belt plate

Side surface is worn.

GI MA

SEM396A

쐌 Belt corners are worn and round. 쐌 Wicks are frayed and coming out. 쐌 쐌 쐌 쐌 쐌

Teeth are worn.

Poor belt cover sealing Coolant leakage at water pump Camshaft not functioning properly Distributor not functioning properly Excessive belt tension

LC EC

SEM397A

FE

쐌 Canvas on tooth face is worn down. 쐌 Canvas on tooth is fluffy, rubber layer is worn down and faded white, or weft is worn down and invisible. Oil/Coolant or water is stuck to belt.

CL 쐌 Poor oil sealing of each oil seal 쐌 Coolant leakage at water pump 쐌 Poor belt cover sealing

—

BELT TENSIONER AND TENSIONER SPRING 1. 2.

MT NGEM0011S01

Check belt tensioner for smooth turning. Check condition of tensioner spring.

AT TF PD AX

SEM558

Installation 1.

NGEM0012

Confirm that No. 1 piston is set at TDC on its compression stroke.

SU BR ST RS

SEM510EA

2. Install tensioner and tensioner spring. Once stud is removed, apply locking sealant to threads of stud on cylinder block side before installing.

BT HA SC EL

SEM243A

EM-85

IDX

TIMING BELT

VG33E AND VG33ER

Installation (Cont’d)

3.

Turn tensioner fully outward with hexagon wrench, and temporarily tighten lock nut.

SEM829A

4. 1)

Set timing belt when engine is cold. Align white lines on timing belt with punchmarks on camshaft sprockets and crankshaft sprocket. 2) Point arrow on timing belt toward front belt cover. Number of teeth (reference): Number of timing belt teeth Number of teeth between timing marks

133

Between LH and RH camshaft sprockets

40

Between LH camshaft sprocket and crankshaft timing sprocket

43

SEM511EA

5.

Install the remaining parts in the reverse order of removal.

Tension Adjustment AFTER BELT REPLACEMENT

NGEM0040 NGEM0040S01

If the timing belt was replaced (or to adjust tension on a used belt), follow the steps below. 1. Loosen tensioner lock nut, then turn tensioner clockwise and counterclockwise with hexagon wrench at least 2 times.

AEM440

EM-86

TIMING BELT

VG33E AND VG33ER Tension Adjustment (Cont’d)

2. 3. 4.

5.

SEM744DA

Tighten tensioner lock nut. Turn crankshaft clockwise at least 2 times, then slowly set No. 1 piston at TDC on its compression stroke. Measure deflection of timing belt midway between camshaft pulleys while pushing with 98 N (10 kg, 22 lb) force. Belt deflection when engine is cold (Reference value): 13 - 15 mm (0.51 - 0.59 in)/98 N (10 kg, 22 lb) If belt deflection is not within specification, return to step 1 and repeat procedure.

GI MA

AFTER ENGINE OVERHAUL OR ENGINE REASSEMBLY LC (WITH ROCKER COVERS REMOVED) NGEM0040S02 If the engine was overhauled or previously disassembled (i.e. intake manifold and/or cylinder head were removed), follow the steps below. 1. Loosen rocker shaft bolts to relieve belt tension caused by the cam shafts.

EC FE CL MT

2. 3.

4.

Loosen tensioner lock nut, keeping tensioner steady with hexagon wrench. Turn tensioner 70 to 80 degrees clockwise with hexagon wrench to release belt tension, and temporarily tighten lock nut. Turn crankshaft clockwise at least two times, then slowly set No. 1 piston at TDC on its compression stroke.

AT TF PD AX

SEM886B

5.

6.

Push middle of timing belt between RH camshaft sprocket and tensioner pulley with force of 98 N (10 kg, 22 lb) to apply tensions on part A and part B. Loosen tensioner lock nut, keeping tensioner steady with hexagon wrench.

SU BR ST RS

AEM446

7.

Set feeler gauge as shown in figure which is 0.5 mm (0.0206 in) thick and 12.7 mm (0.500 in) wide.

BT HA SC EL

SEM240E

EM-87

IDX

TIMING BELT

VG33E AND VG33ER

Tension Adjustment (Cont’d)

8.

Turn crankshaft clockwise until feeler gauge is positioned as shown in figure. 쐌 Timing belt will move about 2.5 teeth. 9. Tighten tensioner lock nut, keeping tensioner steady with hexagon wrench. 10. Turn crankshaft clockwise or counterclockwise, and remove feeler gauge. 11. Turn crankshaft clockwise at least two times, then slowly set No. 1 piston at TDC on its compression stroke. SEM889BA

12. Measure deflection of timing belt midway between camshaft pulleys while pushing with 98 N (10 kg, 22 lb) force. Belt deflection when engine is cold (Reference value): 13 - 15 mm (0.51 - 0.59 in)/98 N (10 kg, 22 lb) 13. If belt deflection is not within specification, return to step 1 and repeat procedure. 14. Install lower and upper belt covers. 15. Install the remaining components in the reverse order of removal. SEM744DA

EM-88

TIMING BELT

VG33E AND VG33ER Tension Adjustment (Cont’d)

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST SEM313F

RS BT HA SC EL

EM-89

IDX

OIL SEAL

VG33E AND VG33ER

Replacement

Replacement VALVE OIL SEAL 1. 2. 3. 쐌 쐌 SEM257A

쐌

NGEM0013 NGEM0013S01

Remove rocker cover. Remove rocker shaft assembly and valve lifters with valve lifter guide. Remove valve springs and valve oil seal. Piston concerned should be set at TDC to prevent valve from falling. When removing intake side valve oil seal, use Tool or suitable tool. When removing exhaust side valve oil seal, pull it out with suitable tool.

SEM285A

4. 쐌 쐌 쐌

Apply engine oil to new valve oil seal and install it. Before installing valve oil seal, install inner valve spring seat. When installing intake side valve oil seal, use Tool. When installing exhaust side valve oil seal, set it by hand.

SEM493F

OIL SEAL INSTALLING DIRECTION Install oil seal in direction shown.

SEM715A

EM-90

NGEM0013S02

OIL SEAL

VG33E AND VG33ER Replacement (Cont’d)

CAMSHAFT OIL SEAL 1. 2. 3. 4. Be 5.

NGEM0013S03

Remove timing belt. Remove camshaft sprocket. Remove camshaft. Remove camshaft oil seal. careful not to scratch camshaft. Apply engine oil to new camshaft oil seal.

GI MA

LC

SEM284A

FRONT OIL SEAL 1. 2. 3. 4.

NGEM0013S04

Remove timing belt and crankshaft sprocket. Remove oil pump assembly. Remove front oil seal from oil pump body. Apply engine oil to new oil seal and install it using suitable tool.

EC FE CL MT

SEM241E

REAR OIL SEAL 1. 2. 3. 쐌 4. 5. 쐌

NGEM0013S05

Remove drive plate. Remove rear oil seal retainer. Remove rear oil seal from retainer. Be careful not to scratch rear oil seal retainer. Apply engine oil to new oil seal and install it using suitable tool. Install rear oil seal retainer with a new gasket to cylinder block. Always use a new oil seal retainer to cylinder block gasket.

AT TF PD AX

SEM242E

SU BR ST RS BT HA SC EL

EM-91

IDX

CYLINDER HEAD

VG33E AND VG33ER

Components

Components

NGEM0014

WEM155

EM-92

CYLINDER HEAD

VG33E AND VG33ER Removal

Removal 1. 2.

NGEM0015

Release fuel pressure. Refer to EC-644, “Fuel Pressure Release”. Remove timing belt. Refer to “Components”, EM-82.

GI MA

LC 3. 4.

SMA207CB

SMA208CA

5. 6. a. 쐌 쐌 쐌 쐌 쐌 b. c. d. e. 쐌 쐌 f. g. h. i. j.

Drain coolant by removing drain plugs from both sides of cylinder block. Separate ASCD and accelerator control wire from intake manifold collector (VG33E only). Remove intake manifold collector from engine (VG33E only). The following parts must be disconnected. Harness connectors for: IACV-AAC valve Throttle position sensor Throttle position switch Distributor (ignition coil) Distributor Water hoses from collector Heater hoses PCV hose from RH/LH rocker cover Vacuum hoses for: Brake master cylinder Pressure regulator Purge hose from purge control valve Spark plug wires Distributor assembly 3 left/right bank injector connectors Ground harness

EC FE CL MT AT TF PD AX SU BR ST RS

7. 8. 9.

Remove fuel feed and fuel return hoses from injector fuel tube assembly. Disconnect the right injector harness connectors. Remove injector fuel tube assembly.

BT HA SC EL

SEM817C

EM-93

IDX

CYLINDER HEAD

VG33E AND VG33ER

Removal (Cont’d)

10. Remove intake manifold from engine. The following parts should be disconnected to remove intake manifold. a. Engine coolant temperature switch harness connector b. Thermal transmitter harness connector c. Water hose from thermostat housing

SEM034E

11. Remove both camshaft sprockets. 12. Remove rear timing belt cover. 13. Remove distributor and ignition wires. After pulling out distributor from cylinder head, do not rotate distributor rotor. 14. Remove harness clamp from RH rocker cover. 15. Remove exhaust tube from exhaust manifold.

SEM819C

16. Remove compressor and generator. 17. Remove power steering pump. 18. Remove the compressor, generator and power steering pump brackets.

AEM416

19. Loosen and remove the bolts from both rocker covers in the order shown. Remove both rocker covers.

SEM317F

20. Remove cylinder head with exhaust manifold. 쐌 A warped or cracked cylinder head could result from removing in incorrect order. 쐌 Cylinder head bolts should be loosened in two or three steps.

SEM926AA

EM-94

CYLINDER HEAD

VG33E AND VG33ER Disassembly

Disassembly

NGEM0016

CAUTION: 쐌 When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces. 쐌 When tightening cylinder head bolts and rocker shaft bolts, apply new engine oil to thread portions and seat surfaces of bolts.

GI MA

LC 쐌

쐌 쐌

If hydraulic valve lifter is kept on its side, there is a risk of air entering it. After removal, always set hydraulic valve lifter straight up, or when laying it on its side, have it soak in new engine oil. Do not disassemble hydraulic valve lifter. Attach tags to valve lifters so as not to mix them up.

EC FE CL MT

SEM870BA

1.

Remove exhaust manifolds from cylinder head.

AT TF PD AX LEM080

2. Remove rocker shafts with rocker arms. Bolts should be loosened in two or three steps. 3. Remove hydraulic valve lifters and lifter guide. 쐌 Hold hydraulic valve lifters with wire so that they will not drop from lifter guide. 4. Remove oil seal and camshaft. 쐌 Before removing camshaft, measure camshaft end play.

SU BR ST RS

SEM304A

5. 6.

Remove valve components with Tool. Remove valve oil seals with Tool or suitable tool.

BT HA SC EL

SEM257A

EM-95

IDX

CYLINDER HEAD

VG33E AND VG33ER

Inspection

Inspection CYLINDER HEAD DISTORTION

SEM868A

NGEM0017 NGEM0017S01

Head surface flatness: Less than 0.1 mm (0.004 in) If beyond the specified limit, resurface it or replace it. Resurfacing limit: The resurfacing 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: 106.8 - 107.2 mm (4.205 - 4.220 in)

CAMSHAFT VISUAL CHECK

NGEM0017S02

Check camshaft for scratches, seizure and wear.

CAMSHAFT RUNOUT 1.

2.

NGEM0017S03

Measure camshaft runout at the center journal. Runout (Total indicator reading): Limit 0.1 mm (0.004 in) If it exceeds the limit, replace camshaft.

SEM758A

CAMSHAFT CAM HEIGHT 1.

2.

NGEM0017S04

Measure camshaft cam height. Standard cam height: Intake and exhaust: 38.943 - 39.133 mm (1.5332 - 1.5407 in) Cam wear limit: 0.15 mm (0.0059 in) If wear is beyond the limit, replace camshaft.

SEM549A

CAMSHAFT JOURNAL CLEARANCE 1.

Measure outer diameter of camshaft journal. Standard outer diameter: A 46.920 - 46.940 mm (1.8472 - 1.8480 in) B 42.420 - 42.440 mm (1.6701 - 1.6709 in) C 47.920 - 47.940 mm (1.8866 - 1.8874 in)

SEM893BA

EM-96

NGEM0017S05

CYLINDER HEAD

VG33E AND VG33ER Inspection (Cont’d)

2.

3.

Measure inner diameter of camshaft bearing. Standard inner diameter: A 47.000 - 47.025 mm (1.8504 - 1.8514 in) B 42.500 - 42.525 mm (1.6732 - 1.6742 in) C 48.000 - 48.025 mm (1.8898 - 1.8907 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance limit: 0.15 mm (0.0059 in)

GI MA

LC

SEM879A

CAMSHAFT END PLAY 1. 2.

NGEM0017S06

Install camshaft and locate plate in cylinder head. Measure camshaft end play. Camshaft end play: Standard: 0.03 - 0.06 mm (0.0012 - 0.0024 in)

EC FE CL MT

SEM392E

3.

If it is out of the specified range, select thickness of camshaft locate plate to obtain standard specified end play. Example: When camshaft end play is 0.08 mm (0.0031 in) with camshaft locate plate 1, replace camshaft locate plate 1 with camshaft locate plate 4 to set the end play at 0.04 mm (0.0016 in).

AT TF PD AX

WEM081

CAMSHAFT SPROCKET RUNOUT 1. 2.

3.

NGEM0017S07

Install sprocket on camshaft. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace camshaft sprocket.

SU BR ST RS

SEM872B

VALVE GUIDE CLEARANCE 1.

NGEM0017S08

Measure valve deflection in a right-angled direction with camshaft. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (Dial gauge reading): 0.20 mm (0.0079 in)

BT HA SC EL

SEM263A

EM-97

IDX

CYLINDER HEAD

VG33E AND VG33ER

Inspection (Cont’d)

2. a. b.

c.

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: Intake: 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust: 0.030 - 0.049 mm (0.0012 - 0.0019 in) Limit: 0.10 mm (0.0039 in) If it exceeds the limit, replace valve or valve guide.

SEM751A

VALVE GUIDE REPLACEMENT

NGEM0017S09

1.

To remove valve guide, heat cylinder head to 150 to 160°C (302 to 320°F) by soaking in heated oil.

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.

3.

Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake: 11.175 - 11.196 mm (0.4400 - 0.4408 in) Exhaust: 12.175 - 12.196 mm (0.4793 - 0.4802 in)

SEM008A

SEM264A

SEM088C

EM-98

CYLINDER HEAD

VG33E AND VG33ER Inspection (Cont’d)

4.

5.

SEM089C

Heat cylinder head to 150 to 160°C (302 to 320°F) and press service valve guide onto cylinder head. Projection “L”: 13.2 - 13.4 mm (0.520 - 0.528 in) Ream valve guide. Finished size: Intake: 7.000 - 7.018 mm (0.2756 - 0.2763 in) Exhaust: 8.000 - 8.011 mm (0.3150 - 0.3154 in)

VALVE SEATS

GI MA

LC

NGEM0017S10

Check valve seats for any evidence of pitting at valve contact surface, and reseat or replace if it has worn out excessively. 쐌 Before repairing valve seats, check valve and valve guide for wear. If they have worn, replace them. Then correct valve seat. 쐌 Use both hands to cut uniformly.

EC FE CL MT

SEM090C

AT TF PD AX SU BR ST RS BT HA SC EL

EM-99

IDX

CYLINDER HEAD

VG33E AND VG33ER

Inspection (Cont’d)

REPLACING VALVE SEAT FOR SERVICE PARTS =NGEM0017S11 1.

SEM795A

Bore out old seat until it collapses. The machine depth stop should be set so that boring cannot continue beyond the bottom face of the seat recess in cylinder head. 2. Ream cylinder head recess. Reaming bore for service valve seat: Oversize [0.5 mm (0.020 in)]: Intake: 44.500 - 44.516 mm (1.7520 - 1.7526 in) Exhaust: 37.500 - 37.516 mm (1.4764 - 1.4770 in) Reaming should be done in circles concentric to the valve guide center so that valve seat will have the correct fit. 3. Heat cylinder head to 150 to 160°C (302 to 320°F) by soaking in heated oil. 4. Press fit valve seat until it seats on the bottom.

5. 6. 7.

Cut or grind valve seat using suitable tool at the specified dimensions as shown. Refer to “VALVE”, EM-128. After cutting, lap valve seat with abrasive compound. Check valve seating condition.

Seat face angle “α” Contacting width “W”

degree mm (in)

Intake

Exhaust

45

45

1.75 (0.0689)

1.7 (0.067)

SEM892B

8.

Use a depth gauge to measure the distance 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 adjust it. If it is longer, replace the valve seat with a new one. Intake: 44.7 - 44.9 mm (1.760 - 1.768 in) Exhaust: 45.4 - 45.6 mm (1.787 - 1.795 in)

SEM621F

VALVE DIMENSIONS

NGEM0017S12

Check dimensions in each valve. Refer to “VALVE”, EM-128. 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-100

CYLINDER HEAD

VG33E AND VG33ER Inspection (Cont’d)

VALVE SPRING Squareness 1.

SEM207E

2.

NGEM0017S13 NGEM0017S1301

Measure “S” dimension. Out-of-square (if equipped with two springs): Outer: Less than 2.2 mm (0.087 in) Inner: Less than 1.9 mm (0.075 in) Out-of-square (if equipped with one spring): Single: Less than 2.0 mm (0.079 in) If it exceeds the limit, replace spring.

GI MA

LC EC FE CL MT

Pressure

EM113

NGEM0017S1302

Check valve spring pressure. Standard pressure (if equipped with two springs): N (kg, lb) at height mm (in) Outer: 523.7 (53.4, 117.7) at 30.0 (1.181) Inner: 255.0 (26.0, 57.3) at 25.0 (0.984) Standard pressure (if equipped with one spring) N (kg, lb) at height mm (in) Single: 770 – 837 (78.5 – 85.4, 173.1 – 188.2) at 30.0 (1.181) Limit pressure (if equipped with two springs): N (kg, lb) at height mm (in) Outer: More than 228.5 (23.3, 51.4) at 25.0 (0.984) Inner: More than 225.6 (23.0, 50.7) at 25.0 (0.984) Limit pressure (if equipped with one spring): N (kg, lb) at height mm (in) Single: More than 733 (74.8, 164.8) at 30.0 (1.181) If not within specification, replace spring.

AT TF PD AX SU BR ST RS BT HA SC EL

EM-101

IDX

CYLINDER HEAD

VG33E AND VG33ER

Inspection (Cont’d)

ROCKER SHAFT AND ROCKER ARM

NGEM0017S14

1. 2.

Check rocker shafts for scratches, seizure and wear. Check outer diameter of rocker shaft. Diameter: 17.979 - 18.000 mm (0.7078 - 0.7087 in)

3.

Check inner diameter of rocker arm. Diameter: 18.007 - 18.028 mm (0.7089 - 0.7098 in) Rocker arm to shaft clearance: 0.007 - 0.049 mm (0.0003 - 0.0019 in) Keep rocker arm with hydraulic valve lifter standing to prevent air from entering hydraulic valve lifter when checking.

SEM761A

쐌

SEM762A

HYDRAULIC VALVE LIFTER

NGEM0017S15

1. 2.

Check contact and sliding surfaces for wear or scratches. Check diameter of valve lifter. Outer diameter: 15.947 - 15.957 mm (0.6278 - 0.6282 in)

3.

Check valve lifter guide inner diameter. Inner diameter: 16.000 - 16.013 mm (0.6299 - 0.6304 in) Standard clearance between valve lifter and lifter guide: 0.043 - 0.066 mm (0.0017 - 0.0026 in)

SEM243E

SEM760A

Assembly 1. 쐌 쐌 쐌

SEM638B

쐌

NGEM0018

Install valve component parts. Always use new valve oil seal. Refer to “VALVE OIL SEAL”, EM-90. Before installing valve oil seal, install inner valve spring seat (if equipped). Install outer or single (if equipped) valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side. After installing valve component parts, use plastic hammer to lightly tap valve stem tip to assure a proper fit.

EM-102

CYLINDER HEAD

VG33E AND VG33ER Assembly (Cont’d)

2. 쐌

Install camshafts, locate plates and cylinder head rear covers. Set knock pin of camshaft at the top.

GI MA

LC

SEM834B

3. 쐌 쐌

Install valve lifters into valve lifter guide. Assemble valve lifters to their original position and hold all valve lifters with wire to prevent lifters from falling off. After installing, remove the wire.

EC FE CL MT

SEM280A

4. 쐌 쐌 a. b. 5.

Install rocker shafts with rocker arms. Tighten bolts gradually in two or three stages. Before tightening, be sure to set camshaft the lobe at the position where lobe is not lifted. Set No. 1 piston at TDC on its compression stroke and tighten rocker shaft bolts for No. 2, No. 4 and No. 6 cylinders. Set No. 4 piston at TDC on its compression stroke and tighten rocker shaft bolts for No. 1, No. 3 and No. 5 cylinders. Install exhaust manifold to cylinder head in reverse order of removal.

AT TF PD AX

SEM835BA

Installation 1. a. b.

NGEM0019

Set No. 1 piston at TDC on its compression stroke as follows: Align crankshaft sprocket aligning mark with mark on oil pump body. Confirm that knock pin on camshaft is set at the top.

SU BR ST RS

SEM836B

BT HA SC EL

EM-103

IDX

CYLINDER HEAD

VG33E AND VG33ER

Installation (Cont’d)

2. 쐌

Install both drain plugs. Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”.

3.

Install exhaust manifolds to cylinder head.

4. 쐌

Install cylinder head with new gasket. Be sure to install washers between bolts and cylinder head. Do not rotate crankshaft and camshaft separately, or valves will hit piston heads.

SEM861CA

SEM862CA

WEM118

쐌

SEM877A

EM-104

CYLINDER HEAD

VG33E AND VG33ER Installation (Cont’d)

5.

AEM407

Tighten cylinder head bolts in numerical order using angle wrench [ST10120000 (J24239-01)]. Apply engine oil to threads and seating surfaces of cylinder head bolts before installing them. 쐌 Cylinder head bolts for 4, 7, 9 and 12 are longer (L1) than the others. L1: 127 mm (5.00 in) for 4, 7, 9 and 12 L2: 106 mm (4.17 in) for others 쐌 Install intake manifold and cylinder head at the same time using the following procedure: 1) Tighten cylinder head bolts to 29 N·m (3.0 kg-m, 22 ft-lb). 2) Tighten cylinder head bolts to 59 N·m (6.0 kg-m, 43 ft-lb). 3) Loosen cylinder head bolts completely. 4) Tighten cylinder head bolts to 10 N·m (1.0 kg-m, 7 ft-lb). 5) Tighten intake manifold bolts and nuts to 4 N·m (0.4 kg-m, 2.9 ft-lb). 6) Tighten intake manifold bolts and nuts to 18 N·m (1.8 kg-m, 13 ft-lb). 7) Tighten intake manifold bolts and nuts to 16 to 20 N·m (1.6 to 2.0 kg-m, 12 to 14 ft-lb). 8) Loosen intake manifold bolts and nuts completely. 9) Tighten cylinder head bolts to 29 N·m (3.0 kg-m, 22 ft-lb). 10) Turn cylinder head bolts to 60 to 65 degrees clockwise. If an angle wrench is not available, tighten cylinder head bolts to 54 to 64 N·m (5.5 to 6.5 kg-m, 40 to 47 ft-lb). 11) Tighten cylinder head sub-bolts to 9.0 to 11.8 N·m (0.92 to 1.20 kg-m, 6.7 to 8.7 ft-lb). 12) Tighten intake manifold bolts and nuts to 4 N·m (0.4 kg-m, 2.9 ft-lb). 13) Tighten intake manifold bolts and nuts to 9 N·m (0.9 kg-m, 6.5 ft-lb). 14) Tighten intake manifold bolts and nuts to 8 to 10 N·m (0.8 to 1.0 kg-m, 5.8 to 7 ft-lb).

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST RS

AEM496

쐌

If only intake manifold is removed and to be used again, install it using the following procedure: 1) Tighten all bolts and nuts to 4 N·m (0.4 kg-m, 2.9 ft-lb). 2) Tighten all bolts and nuts to 9 N·m (0.9 kg-m, 6.5 ft-lb). 3) Tighten all bolts and nuts to 8 to 10 N·m (0.8 to 1.0 kg-m, 5.8 to 7 ft-lb). CAUTION: If replacing intake manifold with a new one, cylinder head gasket must also be replaced with a new one. Refer to step 4.

BT HA SC EL

SEM825C

EM-105

IDX

CYLINDER HEAD

VG33E AND VG33ER

Installation (Cont’d)

6.

Install both rocker covers.

SEM403C

7.

Install compressor, generator and power steering pump brackets. 8. Install power steering pump. 9. Install compressor and generator. 10. Install exhaust front tube to exhaust manifold.

AEM416

11. Install rear belt cover and camshaft sprocket. 쐌 RH camshaft sprocket and LH camshaft sprocket are different parts. Be sure to install them in the correct location.

SEM303A

Identification mark

θ

RH camshaft sprocket

R3

0°53′

LH camshaft sprocket

L3

−3°27′

12. Install timing belt and adjust belt tension. Refer to “AFTER ENGINE OVERHAUL OR ENGINE REASSEMBLY (WITH ROCKER COVERS REMOVED)”, EM-87. 13. Install distributor. 1) Align mark on shaft with protruding mark on housing.

SEM837BA

2)

After installing, confirm that distributor rotor head is set as shown in figure.

SEM337F

EM-106

CYLINDER HEAD

VG33E AND VG33ER Installation (Cont’d)

14. Install injector fuel tube assembly. 15. Connect all injector harness connectors. 16. Install fuel feed and fuel return hoses to injector fuel tube assembly. 17. Install intake manifold collector. Install all parts which were removed in Step 6, under “Removal”, EM-93. 18. Install ASCD and accelerator control wire.

MA

LC

AEM452

SEM531A

GI

19. Check hydraulic valve lifter. a. Push plunger forcefully with your finger. 쐌 Be sure to check it with rocker arm in its free position (not on the lobe). b. If valve lifter moves more than 1 mm (0.04 in), air may be inside it. c. Bleed air off by running engine at 1,000 rpm under no load for about 10 minutes. d. If hydraulic valve lifters are still noisy, replace them and bleed air off again in the same manner as in Step 19 (c). 20. Install the remaining components in the reverse order of removal.

EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EM-107

IDX

SUPERCHARGER

VG33E AND VG33ER

Components

Components

NGEM0096

WEM141

EM-108

SUPERCHARGER

VG33E AND VG33ER Removal

Removal

NGEM0097

CAUTION: Do not disassemble or adjust the supercharger. 1. Disconnect the negative battery cable.

GI MA

LC 2. 3.

Disconnect the accelerator cable from the throttle body and the air inlet tube bracket. Disconnect the ASCD cable from the throttle body and the air inlet tube bracket, if equipped.

EC FE CL MT

LEM105

4. 쐌 쐌 5.

Remove the air inlet duct Disconnect the PCV hoses. Disconnect the resonator hose. Partially drain the cooling system. Refer to MA-17, “Changing Engine Coolant”.

AT TF PD AX

LEM110

6.

Remove the supercharger pulley cover and the supercharger/ air conditioning drive belt. Refer to MA-26, “Checking Drive Belts”.

SU BR ST RS

LEM106

7.

Remove the air inlet tube upper and lower supports.

BT HA SC EL

LEM107

EM-109

IDX

SUPERCHARGER

VG33E AND VG33ER

Removal (Cont’d)

8. 쐌 쐌 쐌 쐌

Remove the air inlet tube bolts, nuts, and studs. Position the air inlet tube aside. Disconnect the evaporative emission vacuum hose. Disconnect the brake booster vacuum hose. Disconnect the TPS sensor electrical connector. Disconnect the TPS switch electrical connector.

LEM108

9. 쐌 쐌

Remove the supercharger bolts and the supercharger assembly. Disconnect the boost control valve vacuum hose. Disconnect the PCV hose.

LEM109

Inspection SUPERCHARGER FLANGE 1.

Clean the mating surface of the supercharger flange.

2.

Check the flange surface for any deformation and flatness. Use a reliable straightedge and feeler gauge, or attach the supercharger flange to the intake collector mating flange, and check that the flatness is within specification. Flange flatness limit: 0.12 mm (0.005 in)

ROTOR SYSTEM 1.

LEM117

NGEM0098 NGEM0098S01

2.

NGEM0098S02

Check that the supercharger pulley rotates smoothly when turning it by hand in a clockwise direction. Rotating torque must not exceed specification. Rotating torque: 0.5 N.m (0.05 kg-m, 4 in-lb) Check that both the left and right rotors are free from any cracks or contamination.

EM-110

SUPERCHARGER

VG33E AND VG33ER Inspection (Cont’d)

SUPERCHARGER BYPASS VALVE ACTUATOR 1.

2.

LEM116

NGEM0098S03

Apply air pressure of less than 12 kPa (90 mmHg, 3.54 inHg) to the supercharger bypass valve actuator’s lower side hose port and check for any leakage. Check the supercharger bypass valve actuator rod for smooth movement while maintaining the pressure at the specified levels below: Rod starts to extend at approximately: 12 Kpa (90 mmHg, 3.54 inHg) Rod is fully extended at approximately: 33.3 kPa (250 mmHg, 9.84 inHg) Rod full extended length: 20.83 — 22.71 mm (0.82 — 0.89 in)

GI MA

LC EC FE CL MT

Installation

NGEM0099

To install the supercharger, follow the removal steps in reverse order. 쐌 Replace all gaskets; make sure that all gasket surfaces are clean and undamaged. 쐌 Follow all torque sequences for tightening. 쐌 Refill the cooling system. Refer to MA-17, “Changing Engine Coolant”.

AT TF PD AX SU BR ST RS BT HA SC EL

EM-111

IDX

ENGINE ASSEMBLY

VG33E AND VG33ER

Removal and Installation

Removal and Installation

NGEM0020

WARNING: 쐌 Situate vehicle on a flat and solid surface. 쐌 Place chocks at front and back of rear wheels. 쐌 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. 쐌 For safety during subsequent steps, the tension of wires should be slackened against the engine. 쐌 Before disconnecting fuel hose, release fuel pressure from fuel line. RefertoEC-1197(VG33E),EC-1197(VG33ER),“FuelPressure Release”. 쐌 Before removing front axle from transmission, place safety stands under designated front supporting points. Refer to GI-45, “Lifting Points and Tow Truck Towing”. 쐌 Be sure to hoist engine and transmission in a safe manner. 쐌 For engines not equipped with engine slingers, attach proper slingers and bolts described in the PARTS CATALOG. CAUTION: 쐌 When lifting engine, be careful not to strike adjacent parts, especially accelerator wire casing, brake lines, and brake master cylinder. 쐌 In hoisting the engine, always use engine slingers in a safe manner. 쐌 Before separating engine and transmission, remove crankshaft position sensor (OBD) from the assembly. 쐌 Always take extra care not to damage edge of crankshaft position sensor (OBD), or ring gear teeth.

쐌 쐌 쐌

Do not loosen front engine mounting insulator cover securing bolts. When cover is removed, damper oil flows out and mounting insulator will not function. Tighten to specifications. Refer to AT-271, “Removal” (automatic); MT-41, “REMOVAL AND INSTALLATION” (manual), and PD-8, “Removal and Installation” (drive shaft).

SEM322F

EM-112

ENGINE ASSEMBLY

VG33E AND VG33ER Removal and Installation (Cont’d)

REMOVAL Engine Mounting

NGEM0020S01 NGEM0020S0101

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA AEM471

SC EL

EM-113

IDX

ENGINE ASSEMBLY

VG33E AND VG33ER

Removal and Installation (Cont’d)

WEM064

1. 2.

Remove engine undercover and hood. Drain coolant from cylinder block and radiator. Refer to MA-28, “Changing Engine Coolant”. 3. Remove vacuum hoses, fuel tubes, wires, harnesses and connectors. 4. Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to EC-1197 (VG33E), EC-1197 (VG33ER), “Fuel Pressure Release”. 5. Remove radiator with shroud and cooling fan. 6. Remove drive belts. 7. Discharge refrigerant, refer to HA-64, “R-134a Service Procedure”. 8. Remove A/C compressor manifold. 9. Remove power steering oil pump from engine. 10. Remove front exhaust tubes. 11. Remove transmission from vehicle. Refer to AT-271, “Removal” (automatic); or MT-41, “REMOVAL AND INSTALLATION” (manual).

12. Install engine slingers. Slinger bolts: : 20 − 26 N·m (2.1 − 2.7 kg−m, 15 − 20 ft−lb) 13. Hoist engine with engine slingers and remove engine mounting nuts from both sides. 14. Lift and remove engine from vehicle.

SEM323F

EM-114

CYLINDER BLOCK

VG33E AND VG33ER Components

Components

NGEM0021

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEM154

EM-115

EL IDX

CYLINDER BLOCK

VG33E AND VG33ER

Components (Cont’d)

Canada Models — Block Heater

LEM112

Removal and Installation

NGEM0022

CAUTION: 쐌 When installing sliding parts such as bearings and pistons, be sure to apply engine oil on the sliding surfaces. 쐌 Place removed parts such as bearings and bearing caps in their proper order and direction. 쐌 When installing connecting rod bolts and main bearing cap bolts, apply new engine oil to threads and seating surfaces. 쐌 Do not allow any magnetic materials to contact the ring gear teeth on drive plate and rear plate.

Disassembly PISTON AND CRANKSHAFT 1. 2. 3. 4. 5. 6.

Place engine on a work stand. Drain coolant and oil. Remove timing belt. Remove oil pan and oil pump. Remove water pump. Remove cylinder head.

SEM326FA

EM-116

NGEM0023 NGEM0023S01

CYLINDER BLOCK

VG33E AND VG33ER Disassembly (Cont’d)

7. 쐌

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. CAUTION: 쐌 When piston rings are not replaced, make sure that piston rings are mounted in their original positions. 쐌 When replacing piston rings, if there is no punchmark, install with either side up.

GI MA

LC

SEM877B

8. 쐌 쐌

Remove bearing cap and crankshaft. Before removing bearing cap, measure crankshaft end play. Bolts should be loosened in two or three steps.

EC FE CL MT

SEM551E

Inspection PISTON AND PISTON PIN CLEARANCE 1.

NGEM0024

AT

NGEM0024S01

Measure inner diameter of piston pin hole “dp”. Standard diameter “dp”: 20.969 - 20.981 mm (0.8255 - 0.8260 in)

TF PD AX

SEM684E

2.

Measure outer diameter of piston pin “Dp”. Standard diameter “Dp”: 20.971 - 20.983 mm (0.8256 - 0.8261 in) 3. Calculate piston pin clearance. dp − Dp = 0 to −0.004 mm (0 to −0.0002 in) If it exceeds the above value, replace piston assembly with pin.

SU BR ST RS

AEM024

PISTON RING SIDE CLEARANCE

SEM024AA

NGEM0024S02

Side clearance: Top ring: 0.040 - 0.080 mm (0.0016 - 0.0031 in) 2nd ring: 0.030 - 0.070 mm (0.0012 - 0.0028 in) Oil ring: 0.015 - 0.185 mm (0.0006 - 0.0073 in) Max. limit of side clearance: Top ring: 0.11 mm (0.0043 in) 2nd ring: 0.1 mm (0.004 in) Oil ring: — If out of specification, replace piston and/or piston ring assembly.

EM-117

BT HA SC EL IDX

CYLINDER BLOCK

VG33E AND VG33ER

Inspection (Cont’d)

PISTON RING END GAP

SEM822B

NGEM0024S03

End gap: Top ring: 0.21 - 0.31 mm (0.0083 - 0.0122 in) 2nd ring: 0.50 - 0.60 mm (0.0197 - 0.0236 in) Oil ring: 0.20 - 0.60 mm (0.0079 - 0.0236 in) Max. limit of ring gap: Top ring: 0.43 mm (0.0169 in) 2nd ring: 0.69 mm (0.0272 in) Oil ring: 0.84 mm (0.0331 in) If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, rebore cylinder and use oversized piston and piston rings. Refer to “Piston, Piston Ring and Piston Pin”, EM-134. 쐌 When replacing the piston, check the cylinder block surface for scratches or seizure. If scratches or seizure are found, hone or replace the cylinder block.

CONNECTING ROD BEND AND TORSION

NGEM0024S04

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. SEM038F

SEM003F

CYLINDER BLOCK DISTORTION AND WEAR 1.

NGEM0024S05

Clean upper face of cylinder block and measure the distortion. Limit: 0.10 mm (0.0039 in)

SEM394E

EM-118

CYLINDER BLOCK

VG33E AND VG33ER Inspection (Cont’d)

2.

If out of specification, resurface it. The resurfacing limit is determined by cylinder head resurfacing in 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) Nominal cylinder block height from crankshaft center: 227.60 - 227.70 mm (8.9606 - 8.9645 in) 3. If necessary, replace cylinder block.

PISTON-TO-BORE CLEARANCE

MA

LC

NGEM0024S06

1.

SEM320A

GI

Using a bore gauge, measure cylinder bore for wear, out-ofround and taper. Standard inner diameter: 91.500 - 91.530 mm (3.6024 - 3.6035 in) Refer to “Cylinder Block”, EM-133. 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: 0.015 mm (0.0006 in) Taper (A − B or A − C) standard: 0.015 mm (0.0006 in) 2. Check for scratches and seizure. If seizure is found, hone it.

EC FE CL MT AT TF PD AX

SEM321AA

쐌

If both cylinder block and piston are replaced with new ones, select piston of the same grade number according to the following table. These numbers are punched on cylinder block and piston in either Arabic or Roman numerals. Combination of grade number for cylinder bore and piston For No. 1, 2 and 6 cylinders

For No. 3, 4 and 5 cylinders

SU BR ST

Cylinder bore grade No.

1

2

3

4

5

6

1

2

3

RS

Piston grade No.

2-1

3-2

3-3

4-4

4-5

5-6

1

2

3

BT

SEM557AA

HA SC EL WEM098

EM-119

IDX

CYLINDER BLOCK

VG33E AND VG33ER

Inspection (Cont’d)

3.

SEM258C

Measure piston skirt diameter. Piston diameter “A”: Refer to “AVAILABLE PISTON”, EM-134. Measuring point “a” (Distance from the top): 49.0 mm (1.929 in) 4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance “B”: 0.025 - 0.045 mm (0.0010 - 0.0018 in) for No. 1, 2, and 6 cylinders (and No. 5 cyclinder for VG33ER only) 0.015 - 0.025 mm (0.0006 - 0.0010 in) for No. 3 and 4 cylinders 0.030 - 0.040 mm (0.0012 - 0.0016 in) for No. 5 cylinder (VG33E only) 5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to “Piston, Piston Ring and Piston Pin”, EM-134. 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 to prevent distortion of cylinder bores in final assembly. 8. Cut cylinder bores. 쐌 When any cylinder needs boring, all other cylinders must also be bored. 쐌 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. 쐌 Measurement should be done after cylinder bore cools down.

CRANKSHAFT 1. 2.

NGEM0024S07

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 0.005 mm (0.0002 in) Taper (A − B): Less than 0.005 mm (0.0002 in)

SEM316A

EM-120

CYLINDER BLOCK

VG33E AND VG33ER Inspection (Cont’d)

3.

Measure crankshaft runout. Runout (Total indicator reading): Less than 0.10 mm (0.0039 in)

GI MA

LC

SEM434

BEARING CLEARANCE 쐌

NGEM0024S08

Either of the following two methods may be used, however, method A gives more reliable results and is preferable. Method A (Using bore gauge & micrometer)

Main Bearing 1.

EC FE

NGEM0024S0801

Set main bearings in their proper positions on cylinder block and main bearing cap.

CL MT

SEM208E

2. Install main bearing cap to cylinder block. Tighten all bolts in correct order in two or three stages. 3. Measure inner diameter “A” of each main bearing.

AT TF PD AX

SEM505A

4. 5.

AEM033

6. 7.

Measure outer diameter “Dm” of each crankshaft main journal. Calculate main bearing clearance. No. 1 Main bearing clearance (A − Dm): Standard 0.030 - 0.048 mm (0.0012 - 0.0019 in) Limit 0.060 mm (0.0024 in) No. 2, 3, 4 Main bearing clearance (A − Dm): Standard 0.038 - 0.065 mm (0.0015 - 0.0026 in) Limit 0.080 mm (0.0031 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.

SU BR ST RS BT HA SC EL

EM-121

IDX

CYLINDER BLOCK

VG33E AND VG33ER

Inspection (Cont’d)

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) Grind the crankshaft to specification, and use available service parts. Refer to “Crankshaft”, EM-135.

SEM184A

8.

a.

If crankshaft is reused, measure main bearing clearances and select thickness of main bearings. If crankshaft is replaced with a new one, it is necessary to 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.

AEM501

b.

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 example or table.

SEM167B

No. 1 main bearing grade number (Identification color): Crankshaft journal

Main journal grade number

grade number

3

4

5

6

3

0 (Black)

1 (Brown)

2 (Green)

3 (Yellow)

4

1 (Brown)

2 (Green)

3 (Yellow)

4 (Blue)

5

2 (Green)

3 (Yellow)

4 (Blue)

5 (Pink)

6

3 (Yellow)

4 (Blue)

5 (Pink)

6 ( Purple)

Except No. 1 main bearing grade number (Identification color): Crankshaft journal grade number

Main journal grade number 0

1

2

0

0 (Black)

1 (Brown)

2 (Green)

1

1 (Brown)

2 (Green)

3 (Yellow)

2

2 (Green)

3 (Yellow)

4 (Blue)

EM-122

CYLINDER BLOCK

VG33E AND VG33ER Inspection (Cont’d)

Connecting Rod Bearing (Big end)

NGEM0024S0802

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.

GI MA

LC

AEM027

4. 5.

6. 7. AEM034

Measure outer diameter “Dp” of each crankshaft pin journal. Calculate connecting rod bearing clearance. Connecting rod bearing clearance (C − Dp): Standard 0.024 - 0.064 mm (0.0009 - 0.0025 in) Limit 0.090 mm (0.0035 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 “Available Main Bearing”, EM-136.

EC FE CL MT AT TF PD AX

Method B (Using plastigage) CAUTION: 쐌 Do not turn crankshaft or connecting rod while plastigage is being inserted. 쐌 When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. Then if excessive bearing clearance exists, use a thicker main bearing or undersized bearing so that the specified bearing clearance is obtained.

SU BR ST RS

EM142

CONNECTING ROD BUSHING CLEARANCE (SMALL BT END) NGEM0024S09 1. 2. 3.

SEM673E

Measure inner diameter “C” of bushing. 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.

EM-123

HA SC EL IDX

CYLINDER BLOCK

VG33E AND VG33ER

Inspection (Cont’d)

REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) NGEM0024S10 1.

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 so that 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)

FLYWHEEL/DRIVE PLATE RUNOUT

AEM100

NGEM0024S11

Runout (Total indicator reading): Flywheel (M/T model) Less than 0.15 mm (0.0059 in) Drive plate (A/T model) Less than 0.15 mm (0.0059 in) CAUTION: 쐌 Be careful not to damage the ring gear teeth. 쐌 Check the drive plate for deformation or cracks. 쐌 Do not allow any magnetic materials to contact the ring gear teeth. 쐌 Do not surface flywheel or drive plate. Replace as necessary.

Assembly PISTON 1. 2. 쐌 쐌 쐌 SEM400F

3.

NGEM0025 NGEM0025S01

Install new snap ring on one side of piston pin hole. 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. Set piston rings as shown.

SEM160B

EM-124

CYLINDER BLOCK

VG33E AND VG33ER Assembly (Cont’d)

CRANKSHAFT

NGEM0025S02

1.

Set main bearings in their proper positions on cylinder block and main bearing cap. 쐌 Confirm that correct main bearings are used. 쐌 Apply new engine oil to bearing surfaces. Refer to “BEARING CLEARANCE”, EM-121.

GI MA

LC

SEM208E

2. 쐌 쐌 쐌 쐌 SEM550EA

Install crankshaft and main bearing caps and tighten bolts to the specified torque. Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction. Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward sequentially. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand. Lubricate threads and seat surfaces of the bolts with new engine oil.

Measure crankshaft end play. Crankshaft end play: Standard 0.050 - 0.170 mm (0.0020 - 0.0067 in) Limit 0.30 mm (0.0118 in) If beyond the limit, replace bearing with a new one.

EC FE CL MT

3.

AT TF PD AX

SEM158B

4.

Install connecting rod bearings in connecting rods and connecting rod caps. 쐌 Confirm that correct bearings are used. Refer to “Connecting Rod Bearing (Big End)”, EM-123. 쐌 Install bearings so that oil hole in connecting rod aligns with oil hole of bearing.

SU BR ST RS

SEM159B

5. a. 쐌 쐌

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.

BT HA SC EL

SEM620

EM-125

IDX

CYLINDER BLOCK

VG33E AND VG33ER

Assembly (Cont’d)

b. 쐌

Install connecting rod bearing caps. Lubricate threads and seat surfaces with new engine oil. Tighten connecting rod bearing cap nuts to the specified torque. : Connecting rod bearing nut (1) Tighten to 14 to 16 N·m (1.4 to 1.6 kg-m, 10 to 12 ft-lb). (2) Tighten nuts 60 to 65 degrees clockwise. If an 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).

EM329

6.

Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit 0.40 mm (0.0157 in) If beyond the limit, replace connecting rod and/or crankshaft.

SEM512A

7.

Install rear oil seal retainer.

SEM338F

REPLACING PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T) 1.

Remove pilot bushing (M/T) or pilot converter (A/T).

2.

Install pilot bushing (M/T) or pilot converter (A/T).

SEM916AA

AEM495

EM-126

NGEM0025S03

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER General Specifications

General Specifications Cylinder arrangement

=NGEM0026

GI

V-6 3,275 cm3 (199.84 cu in)

Displacement Bore and stroke

MA

91.5 x 83 mm (3.602 x 3.27 in)

Valve arrangement

OHC

Firing order

1-2-3-4-5-6 Compression

2

Oil

1

Number of piston rings Number of main bearings

LC

4 VG33E

8.9:1

VG33ER

8.3:1

EC

Compression ratio

FE Cylinder number

CL MT AT SEM713A

Unit: kPa (kg/cm2, psi)/300 rpm

Compression pressure

Standard

1,196 (12.2, 173)

Minimum

883 (9.0, 128)

Differential limit between cylinders

TF PD AX

98 (1.0, 14)

Unit: degree

SU

Valve timing

BR ST RS BT EM120

a

b

c

d

e

f

240

244

4

60

9

51

HA SC EL

EM-127

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Cylinder Head

Cylinder Head

NGEM0027

Unit: mm (in)

Head surface distortion

Standard

Limit

Less than 0.03 (0.0012)

0.1 (0.004)

SEM082B

Valve

NGEM0028

VALVE

NGEM0028S01

Unit: mm (in)

SEM188

Intake

42.0 - 42.2 (1.654 - 1.661)

Valve head diameter “D” Exhaust

34.95 - 35.25 (1.376 - 1.388)

Intake

125.3 - 125.9 (4.933 - 4.957)

Exhaust

124.2 - 124.8 (4.890 - 4.913)

Valve length “L” Intake

6.965 - 6.980 (0.2742 - 0.2748)

Exhaust

7.962 - 7.970 (0.3135 - 0.3138)

Valve stem diameter “d” Intake Valve seat angle “α”

45°15′ - 45°45′ Exhaust Intake

1.15 - 1.45 (0.0453 - 0.0571)

Exhaust

1.35 - 1.65 (0.0531 - 0.0650)

Valve margin “T” Valve margin “T” limit

More than 0.5 (0.020)

Valve stem end surface grinding limit

Less than 0.2 (0.008) Intake

0 (0)

Exhaust

0 (0)

Valve clearance

EM-128

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Valve (Cont’d)

VALVE SPRING

Free height

Pressure

Out-of-square

NGEM0028S02

Outer

51.2 mm (2.016 in)

Inner

44.1 mm (1.736 in)

Single

50.47 mm (1.987 in)

Outer

523.7 N (53.4 kg, 117.7 lb) at 30.0 mm (1.181 in)

Inner

255.0 N (26.0 kg, 57.3 lb) at 25.0 mm (0.984 in)

Single

770 - 837 N (78.5 - 85.4 kg, 173.1 - 188.2 lb) at 30.0 mm (1.181 in)

Outer

2.2 mm (0.087 in)

Inner

1.9 mm (0.075 in)

Single

2.0 mm (0.079 in)

GI MA

LC EC

HYDRAULIC VALVE LIFTER

NGEM0028S03

Unit: mm (in) Lifter outside diameter

15.947 - 15.957 (0.6278 - 0.6282)

Lifter guide inside diameter

16.000 - 16.013 (0.6299 - 0.6304)

Clearance between lifter and lifter guide

FE CL

0.043 - 0.066 (0.0017 - 0.0026)

MT

VALVE GUIDE

NGEM0028S04

Unit: mm (in)

AT

Standard

Service

Intake

11.023 - 11.034 (0.4340 - 0.4344)

11.223 - 11.234 (0.4418 - 0.4423)

Exhaust

12.023 - 12.034 (0.4733 - 0.4738)

12.223 - 12.234 (0.4812 - 0.4817)

Outer diameter

TF

Valve guide Inner diameter (Finished size)

Intake

7.000 - 7.018 (0.2756 - 0.2763)

Exhaust

8.000 - 8.011 (0.3150 - 0.3154)

PD

Intake

10.975 - 10.996 (0.4321 - 0.4329)

11.175 - 11.196 (0.4400 - 0.4408)

Exhaust

11.975 - 11.996 (0.4715 - 0.4723)

12.175 - 12.196 (0.4793 - 0.4802)

Cylinder head valve guide hole diameter

AX

Intake Interference fit of valve guide

0.027 - 0.059 (0.0011 - 0.0023)

SU

Exhaust Standard Intake

Max. tolerance

BR

0.020 - 0.053 (0.0008 - 0.0021)

Stem to guide clearance

0.10 (0.0039) Exhaust

0.030 - 0.049 (0.0012 - 0.0019)

Valve deflection limit

—

ST

0.20 (0.0079)

ROCKER SHAFT AND ROCKER ARM

NGEM0028S05

Unit: mm (in) Rocker shaft

Outer diameter

17.979 - 18.000 (0.7078 - 0.7087)

Rocker arm

Inner diameter

18.007 - 18.028 (0.7089 - 0.7098)

Clearance between rocker arm and rocker shaft

RS BT

0.007 - 0.049 (0.0003 - 0.0019)

HA SC EL

EM-129

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Valve Seat

Valve Seat INTAKE VALVE SEAT

NGEM0029 NGEM0029S01

SEM639F

EM-130

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Valve Seat (Cont’d)

EXHAUST VALVE SEAT

NGEM0029S02

GI MA

LC EC FE CL MT AT AEM455

TF PD AX SU BR ST RS BT HA SC EL

EM-131

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Camshaft and Camshaft Bearing

Camshaft and Camshaft Bearing

NGEM0030

Unit: mm (in)

SEM893BA

Camshaft journal to bearing clearance

Inner diameter of camshaft bearing

Outer diameter of camshaft journal

Camshaft runout [TIR*] Camshaft end play

Standard

Max. tolerance

0.060 - 0.105 (0.0024 - 0.0041)

0.15 (0.0059)

A: 47.000 - 47.025 (1.8504 - 1.8514)

—

B: 42.500 - 42.525 (1.6732 - 1.6742)

—

C: 48.000 - 48.025 (1.8898 - 1.8907)

—

A: 46.920 - 46.940 (1.8472 - 1.8480)

—

B: 42.420 - 42.440 (1.6701 - 1.6709)

—

C: 47.920 - 47.940 (1.8866 - 1.8874)

—

Less than 0.04 (0.0016)

0.1 (0.004)

0.03 - 0.06 (0.0012 - 0.0024)

—

EM671

Intake

38.943 - 39.133 (1.5332 - 1.5407)

Exhaust

38.943 - 39.133 (1.5332 - 1.5407)

Cam height “A” Wear limit of cam height

0.15 (0.0059)

*Total indicator reading

EM-132

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Cylinder Block

Cylinder Block

NGEM0031

Unit: mm (in)

GI MA

LC SEM321A

Standard

Less than 0.03 (0.0012)

Surface flatness Limit

0.10 (0.0039) Grade No. 1

91.500 - 91.505 (3.6024 - 3.6026)

Grade No. 2

91.505 - 91.510 (3.6026 - 3.6027)

Grade No. 3

91.510 - 91.515 (3.6027 - 3.6029)

Grade No. 4

91.515 - 91.520 (3.6029 - 3.6031)

Grade No. 5

91.520 - 91.525 (3.6031 - 3.6033)

Grade No. 6

91.525 - 91.530 (3.6033 - 3.6035)

Grade No. 1

91.500 - 91.510 (3.6024 - 3.6027)

Grade No. 2

91.510 - 91.520 (3.6027 - 3.6031)

Grade No. 3

91.520 - 91.530 (3.6031 - 3.6035)

Grade No. 1

91.515 - 91.520 (3.6029 - 3.6031)

Grade No. 2

91.520 - 91.525 (3.6031 - 3.6033)

Grade No. 3

91.525 - 91.530 (3.6033 - 3.6035)

Grade No. 4

91.530 - 91.535 (3.6035 - 3.6037)

Grade No. 5

91.535 - 91.540 (3.6037 - 3.6039)

Grade No. 6

91.540 - 91.545 (3.6039 - 3.6041)

Standard (for No. 3 and 4 cylinders)

Cylinder bore

Inner diameter

EC

Standard (for No. 1, 2 and 6 cylinders)

FE CL MT AT TF PD AX

Standard (for No. 5 cylinder)

Wear limit

0.20 (0.0079)

Out-of-round (X − Y)

Less than 0.015 (0.0006)

Taper (A − B or A − C)

Less than 0.015 (0.0006)

No. 1 main journal Main journal inner diameter

Except No. 1 main journal

Difference in inner diameter between cylinders

Grade No.3

66.645 - 66.651 (2.6238 - 2.6240)

Grade No. 4

66.651 - 66.657 (2.6240 - 2.6243)

Grade No. 5

66.657 - 62.663 (2.6243 - 2.6245)

Grade No. 6

66.663 - 66.669 (2.6245 - 2.6248)

Grade No. 0

66.645 - 66.654 (2.6238 - 2.6242)

Grade No. 1

66.654 - 66.663 (2.6242 - 2.6245)

Grade No. 2

66.663 - 66.672 (2.6245 - 2.6249)

SU BR ST RS BT HA SC

Standard

Less than 0.05 (0.0020)

EL

EM-133

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Piston, Piston Ring and Piston Pin

Piston, Piston Ring and Piston Pin AVAILABLE PISTON

NGEM0032 NGEM0032S01

Unit: mm (in)

SEM882E

Standard (for No. 3, 4 and 5 cylinders)

Piston skirt diameter “A” Standard (for No. 1, 2 and 6 cylinders)

Grade No. 2-1

91.480 - 91.485 (3.6016 - 3.6018)

Grade No. 3-2

91.485 - 91.490 (3.6018 - 3.6020)

Grade No. 3-3

91.490 - 91.495 (3.6020 - 3.6022)

Grade No. 4-4

91.495 - 91.500 (3.6022 - 3.6024)

Grade No. 4-5

91.500 - 91.505 (3.6024 - 3.6026)

Grade No. 5-6

91.505 - 91.510 (3.6026 - 3.6027)

Grade No. 1

91.465 - 91.475 (3.6010 - 3.6014)

Grade No. 2

91.475 - 91.485 (3.6014 - 3.6018)

Grade No. 3

91.485 - 91.495 (3.6018 - 3.6022)

0.25 (0.0098) oversize (Service)

91.715 - 91.745 (3.6108 - 3.6120)

0.50 (0.0197) oversize (Service)

91.965 - 91.995 (3.6207 - 3.6218)

“a” dimension

49.0 (1.929) Grade No. 0

20.969 - 20.975 (0.8255 - 0.8258)

Grade No. 1

20.975 - 20.981 (0.8258 - 0.8260)

Piston pin hole diameter

Piston clearance to cylinder block

Standard

For No. 3 and 4 cylinders

0.015 - 0.025 (0.0006 - 0.0010)

For No. 1, 2 and 6 cylinders (No. 5 cylinder VG33ER only)

0.025 - 0.045 (0.0010 - 0.0018)

For No. 5 cylinder (VG33E only)

0.030 - 0.040 (0.0012 - 0.0016)

PISTON RING

NGEM0032S02

Unit: mm (in)

Side clearance

Ring gap

Standard

Limit

Top

0.040 - 0.080 (0.0016 - 0.0031)

0.11 (0.0043)

2nd

0.030 - 0.070 (0.0012 - 0.0028)

0.10 (0.004)

Oil

0.015 - 0.185 (0.0006 - 0.0073)

—

Top

0.21 - 0.31 (0.0083 - 0.0122)

0.43 (0.0169)

2nd

0.50 - 0.60 (0.0197 - 0.0236)

0.69 (0.0272)

Oil (rail ring)

0.20 - 0.60 (0.0079 - 0.0236)

0.84 (0.0331)

EM-134

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Piston, Piston Ring and Piston Pin (Cont’d)

PISTON PIN

NGEM0032S03

Unit: mm (in) Piston pin outer diameter

GI

20.971 - 20.983 (0.8256 - 0.8261)

Interference fit of piston pin to piston

0 to −0.004 (0 to −0.0002)

Piston pin to connecting rod bushing clearance

MA

0.005 - 0.017 (0.0002 - 0.0007)

Values measured at ambient temperature of 20°C (68°F)

Connecting Rod

NGEM0033

Unit: mm (in) Center distance

LC

154.1 - 154.2 (6.067 - 6.071)

Bend, torsion [per 100 (3.94)]

Bend: 0.15 (0.0059) Torsion: 0.30 (0.0118)

Limit

Piston pin bushing inner diameter*

20.982 - 20.994 (0.8261 - 0.8265)

Connecting rod big end inner diameter

53.000 - 53.013 (2.0866 - 2.0871) Standard

EC FE

0.20 - 0.35 (0.0079 - 0.0138)

Side clearance Limit

CL

0.40 (0.0157)

*After installing in connecting rod

MT

Crankshaft

NGEM0034

Unit: mm (in) Grade No. 3

62.696 - 62.975 (2.4683 - 2.4793

Grade No. 4

62.963 - 62.969 (2.4789 - 2.4791)

Grade No. 5

62.957 - 62.963 (2.4786 - 2.4789)

Grade No. 6

62.951 - 62.957 (2.4784 - 2.4786)

Grade No. 0

62.967 - 62.975 (2.4790 - 2.4793)

Grade No. 1

62.959 - 62.967 (2.4787 - 2.4790)

Grade No. 2

62.951 - 62.959 (2.4784 - 2.4787)

AT

No. 1 main journal Main journal dia. “Dm”

Except No. 1 main journal

Pin journal dia. “Dp”

TF PD AX

49.955 - 49.974 (1.9667 - 1.9675)

Center distance “r”

SU

41.5 (1.634)

Out-of-round (X − Y)

Standard

Less than 0.005 (0.0002)

Taper (A − B)

Standard

Less than 0.005 (0.0002)

Standard

Less than 0.025 (0.0010)

Limit

Less than 0.10 (0.0039)

BR

Runout [TIR] Standard

ST

0.050 - 0.170 (0.0020 - 0.0067)

Free end play Limit

RS

0.30 (0.0118)

BT HA SC SEM645

EM-135

EM715

EL IDX

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Available Main Bearing

Available Main Bearing

NGEM0084

SEM327A

NO. 1 MAIN BEARING Width “W” mm (in)

NGEM0084S01

Grade number

Thickness “T” mm (in)

Identification color(mark)

0

1.822 - 1.825 (0.0717 - 0.0719)

Black (A)

1

1.825 - 1.828 (0.0719 - 0.0720)

Brown (B)

2

1.828 - 1.831 (0.0720 - 0.0721)

Green (C)

3

1.831 - 1.834 (0.0721 - 0.0722)

4

1.834 - 1.837 (0.0722 - 0.0723)

Blue (E)

5

1.837 - 1.840 (0.0723 - 0.0724)

Pink (F)

6

1.840 - 1.843 (0.0724 - 0.0726)

Purple (G)

22.4 - 22.6 (0.882 - 0.890)

Yellow (D)

NO. 2 AND 3 MAIN BEARING Width “W” mm (in)

NGEM0084S02

Grade number

Thickness “T” mm (in)

Identification color

0

1.817 - 1.821 (0.0715 - 0.0717)

Black

1

1.821 - 1.825 (0.0717 - 0.0719)

Brown

2

1.825 - 1.829 (0.0719 - 0.0720)

3

1.829 - 1.833 (0.0720 - 0.0722)

Yellow

4

1.833 - 1.837 (0.0722 - 0.0723)

Blue

18.9 - 19.1 (0.744 - 0.752)

Green

NO. 4 MAIN BEARING

NGEM0084S03

Grade number

Thickness “T” mm (in)

Identification color

0

1.817 - 1.821 (0.0715 - 0.0717)

Black

1

1.821 - 1.825 (0.0717 - 0.0719)

Brown

2

1.825 - 1.829 (0.0719 - 0.0720)

Green

3

1.829 - 1.833 (0.0720 - 0.0722)

Yellow

4

1.833 - 1.837 (0.0722 - 0.0723)

Blue

UNDER SIZE

NGEM0084S04

Unit: mm (in) Thickness “T” mm (in) No.1 main bearing

1.956 - 1.962 (0.0770 - 0.0772)

No.2,3 and No.4 main bearing

1.948 - 1956 (0.0767 - 0.0770)

0.25 (0.0098)

EM-136

Main journal diameter “Dm” Grind so that bearing clearance is the specified value.

SERVICE DATA AND SPECIFICATIONS (SDS) VG33E AND VG33ER Available Connecting Rod Bearing

Available Connecting Rod Bearing CONNECTING ROD BEARING UNDERSIZE

NGEM0036 NGEM0036S01

Unit: mm (in)

Standard

Undersize

Thickness

Crank pin journal diameter “Dp”

1.502 - 1.506 (0.0591 - 0.0593)

49.955 - 49.974 (1.9667 - 1.9675)

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)

GI MA

Grind so that bearing clearance is the specified value.

LC

Miscellaneous Components

NGEM0037

Unit: mm (in) Drive plate runout [TIR]

EC

Less than 0.15 (0.0059)

BEARING CLEARANCE

NGEM0037S01

FE

Unit: mm (in) Standard

0.030 - 0.048 (0.0012 - 0.0019)

No. 1 Main bearing clearance Limit

CL

0.060 (0.0024)

Standard

0.038 - 0.065 (0.0015 - 0.0026)

No. 2, 3, 4 Main bearing clearance Limit

MT

0.080 (0.0031)

Standard

0.024 - 0.064 (0.0009 - 0.0025)

Connecting rod bearing clearance Limit

AT

0.090 (0.0035)

TF PD AX SU BR ST RS BT HA SC EL

EM-137

IDX

NOTES

ENGINE LUBRICATION & COOLING SYSTEMS SECTION

LC

GI MA EM

EC

CONTENTS KA24DE ENGINE LUBRICATION SYSTEM..................................3 Precautions ..................................................................3 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″.........3 LIQUID GASKET APPLICATION PROCEDURE ............3

Preparation ..................................................................4 SPECIAL SERVICE TOOLS ........................................4 Lubrication Circuit ........................................................5 Oil Pressure Check......................................................6 Oil Pump ......................................................................6 REMOVAL AND INSTALLATION .................................6 REGULATOR VALVE INSPECTION ............................7 OIL FILTER ...............................................................7 OIL PUMP INSPECTION ............................................7 Service Data and Specifications (SDS).......................8 OIL PRESSURE CHECK ............................................8 REGULATOR VALVE .................................................8 OIL PUMP .................................................................8 ENGINE COOLING SYSTEM..........................................9 Precautions ..................................................................9 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″.........9 LIQUID GASKET APPLICATION PROCEDURE ............9

Preparation ................................................................10 SPECIAL SERVICE TOOLS ......................................10 Cooling Circuit ...........................................................10 System Check............................................................11 CHECKING COOLING SYSTEM HOSES ...................11 CHECKING RADIATOR ............................................11 CHECKING COOLING SYSTEM FOR LEAKS ............11 CHECKING RADIATOR CAP ....................................12 Water Pump ...............................................................12 REMOVAL ...............................................................12 INSPECTION ...........................................................12 INSTALLATION........................................................13 Thermostat.................................................................13 REMOVAL ...............................................................13 INSPECTION ...........................................................13 INSTALLATION........................................................13

FE

Radiator .....................................................................14 REMOVAL AND INSTALLATION ...............................14 COMPONENTS .......................................................15 INSPECTION ...........................................................15 Cooling Fan (Crankshaft driven) ...............................16 REMOVAL AND INSTALLATION ...............................16 INSPECTION ...........................................................16 Refilling Engine Coolant ............................................16 Overheating Cause Analysis .....................................17 Service Data and Specifications (SDS).....................18 THERMOSTAT ........................................................18 RADIATOR ..............................................................18 VG33E AND VG33ER ENGINE LUBRICATION SYSTEM................................19 Precautions ................................................................19 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″.......19 LIQUID GASKET APPLICATION PROCEDURE ..........19

Preparation ................................................................20 SPECIAL SERVICE TOOLS ......................................20 Lubrication Circuit ......................................................20 Oil Pressure Check....................................................21 Oil Pump ....................................................................21 REMOVAL AND INSTALLATION ...............................21 DISASSEMBLY AND ASSEMBLY..............................22 INSPECTION ...........................................................23 REGULATOR VALVE INSPECTION ..........................23 OIL FILTER .............................................................23 OIL FILTER BRACKET .............................................24 Service Data and Specifications (SDS).....................25 OIL PRESSURE CHECK ..........................................25 REGULATOR VALVE ...............................................25 OIL PUMP ...............................................................25 ENGINE COOLING SYSTEM........................................26 Precautions ................................................................26 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″.......26 LIQUID GASKET APPLICATION PROCEDURE ..........26

Preparation ................................................................27

CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS SPECIAL SERVICE TOOLS ......................................27 Cooling Circuit ...........................................................27 System Check............................................................27 CHECKING COOLING SYSTEM HOSES ...................27 CHECKING RADIATOR CAP ....................................28 CHECKING RADIATOR ............................................28 CHECKING COOLING SYSTEM FOR LEAKS ............29 Water Pump ...............................................................29 REMOVAL ...............................................................29 INSPECTION ...........................................................30 INSTALLATION........................................................30 Thermostat.................................................................31 REMOVAL ...............................................................31 INSPECTION ...........................................................31 INSTALLATION........................................................32

LC-2

(Cont’d)

Radiator .....................................................................32 REMOVAL AND INSTALLATION ...............................32 COMPONENTS .......................................................33 INSPECTION ...........................................................33 Cooling Fan (Crankshaft driven) ...............................34 REMOVAL AND INSTALLATION ...............................34 INSPECTION ...........................................................34 Refilling Engine Coolant ............................................35 Overheating Cause Analysis .....................................35 Service Data and Specifications (SDS).....................36 THERMOSTAT ........................................................36 RADIATOR ..............................................................36

ENGINE LUBRICATION SYSTEM

KA24DE Precautions

Precautions SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER”

GI NGLC0066

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 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), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

MA EM

EC FE CL MT

LIQUID GASKET APPLICATION PROCEDURE 1.

2. 쐌 쐌 SEM164F

3. 4. 5.

NGLC0067

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 Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”.) For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm (0.138 to 0.177 in). For areas except oil pan, be sure liquid gasket diameter is 2.0 to 3.0 mm (0.079 to 0.118 in). 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.

AT TF PD AX SU BR ST RS

AEM080

BT HA SC EL

LC-3

IDX

ENGINE LUBRICATION SYSTEM

KA24DE

Preparation

Preparation SPECIAL SERVICE TOOLS

=NGLC0068

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description

(J34301-C) Oil pressure gauge set 1: (J34301-1) Oil pressure gauge 2: (J34301-2) Hoses 3: (J34298) Adapter 4: (J34282-1) Adapter 5: (790-301-1230-A) 60° adapter 6: (J34301-15) Square socket AAT896

Measuring oil pressure Maximum measuring range: 1,379 kPa (14 kg/cm2, 200 psi)

WS39930000 ( — Tube presser

Pressing the tube of liquid gasket )

NT052

Removing and installing oil filter

KV10115801 (J38956) Oil filter wrench

NT362

LC-4

ENGINE LUBRICATION SYSTEM

KA24DE Lubrication Circuit

Lubrication Circuit

NGLC0069

GI MA EM

EC FE CL MT AT TF PD AX SU BR ST RS BT HA WLC030

1. 2. 3. 4. 5.

Connecting rod Connecting rod bearing Main bearing Oil filter Oil strainer

6. 7. 8. 9.

Oil pump Oil pan Piston oil jet Timing chain tensioner

LC-5

10. 11. 12. 13.

Idler sprocket Upper timing chain tensioner Exhaust camshaft Intake camshaft

SC EL IDX

ENGINE LUBRICATION SYSTEM

KA24DE

Oil Pressure Check

Oil Pressure Check

NGLC0070

WARNING: 쐌 Be careful not to burn yourself, as the engine and oil may be hot. 쐌 Put the shift lever in the Neutral “N” position. 1. Check oil level. 2. Remove oil pressure switch. 3. Install pressure gauge. 4. Start engine and warm it up to normal operating temperature. 5. Check oil pressure with engine running under no-load. Unit: kPa (kg/cm2, psi)

쐌 6.

Engine speed

Approximate discharge pressure

Idle speed

More than 78 (0.8, 11)

3,000 rpm

412 - 481 (4.2 - 4.9, 60 - 70)

If difference is extreme, check oil passage and oil pump for oil leaks. Install oil pressure switch with sealant. : 12.25 – 17.15 N·m (1.3 – 1.7 kg-m, 9 – 12 ft-lb)

ALC059

Oil Pump REMOVAL AND INSTALLATION

NGLC0071

SLC945-A

LC-6

ENGINE LUBRICATION SYSTEM

KA24DE Oil Pump (Cont’d)

쐌 쐌 쐌

Always replace with new oil seal and gasket. When removing oil pump, turn crankshaft so that No. 1 piston is at TDC on its compression stroke. When installing oil pump, apply engine oil to gears, then align punch mark on drive spindle and oil hole on oil pump.

GI MA EM

ALC054

REGULATOR VALVE INSPECTION 1. 2. 3. 쐌

NGLC0072

Visually inspect components for wear and damage. Check oil pressure regulator valve sliding surface and valve spring. Coat regulator valve with engine oil. Check that it falls smoothly into the valve hole by its own weight. Replace regulator valve set or oil pump assembly, if damaged.

EC FE CL MT

ALC058

OIL FILTER

NGLC0073

The oil filter is a small, full-flow cartridge type and is provided with a relief valve. 쐌 Use Tool KV10115801 (J38956) for removing oil filter.

AT TF PD AX

ALC124

OIL PUMP INSPECTION

NGLC0074

SU

Unit: mm (in)

BR

Using a feeler gauge, check the following clearances. Standard clearance: Rotor tip clearance 1

SLC026

Less than 0.12 (0.0047)

Outer rotor to body clearance 2

0.15 - 0.21 (0.0059 - 0.0083)

Side clearance (with gasket) 3

0.04 - 0.100 (0.0016 - 0.0039)

쐌 쐌

If the tip clearance (1) exceeds the limit, replace rotor set. If body to rotor clearances (2, 3) exceed the limit, replace oil pump assembly.

ST RS BT HA SC EL

SLC732

LC-7

IDX

ENGINE LUBRICATION SYSTEM

KA24DE

Service Data and Specifications (SDS)

Service Data and Specifications (SDS) OIL PRESSURE CHECK

NGLC0075

Unit: kPa (kg/cm2, psi) Engine speed

Approximate discharge pressure

Idle speed

More than 78 (0.8 , 11)

3,000 rpm

412 - 481 (4.2 - 4.9, 60 - 70)

REGULATOR VALVE

NGLC0131

Unit: mm (in) Regulator valve to oil pump cover clearance

0.040 - 0.097 (0.0016 - 0.0038)

OIL PUMP

NGLC0076

Unit: mm (in) Rotor tip clearance

Less than 0.12 (0.0047)

Outer rotor to body clearance

0.15 - 0.21 (0.0059 - 0.0083)

Side clearance (with gasket)

0.04 - 0.100 (0.0016 - 0.0039)

LC-8

ENGINE COOLING SYSTEM

KA24DE Precautions

Precautions SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER”

GI NGLC0133

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 Supplemental Restraint System consists of driver air bag modules (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

MA EM

EC FE CL MT

LIQUID GASKET APPLICATION PROCEDURE 1.

2. 쐌 쐌 SEM164F

3. 4. 5.

NGLC0109

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 Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”.) For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm (0.138 to 0.177 in). For areas except oil pan, be sure liquid gasket diameter is 2.0 to 3.0 mm (0.079 to 0.118 in). 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.

AT TF PD AX SU BR ST RS

AEM080

BT HA SC EL

LC-9

IDX

ENGINE COOLING SYSTEM

KA24DE

Preparation

Preparation SPECIAL SERVICE TOOLS

=NGLC0110

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description

EG17650301 (J33984-A) Radiator cap tester adapter

Adapting radiator cap tester to radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in)

NT564

WS39930000 ( — Tube presser

Pressing the tube of liquid gasket )

NT052

Cooling Circuit

NGLC0111

ALC117

LC-10

ENGINE COOLING SYSTEM

KA24DE System Check

System Check

NGLC0112

WARNING: 쐌 Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. 쐌 Wrap a thick cloth around the radiator cap. Slowly turn it a quarter turn to allow built-up pressure to escape. Carefully remove the radiator cap by turning it all the way.

CHECKING COOLING SYSTEM HOSES

MA EM

NGLC0112S01

Check hoses for the following: 쐌 Improper attachment 쐌 Leaks 쐌 Cracks 쐌 Damage 쐌 Chafing 쐌 Deterioration

CHECKING RADIATOR

GI

EC FE NGLC0112S02

Check radiator for mud or clogging. If necessary, clean radiator as follows. CAUTION: 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. 쐌 Tape the harness 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 when water coming out of the radiator flows clear. 4. Blow air into the back side of radiator core vertically downward. 쐌 Use compressed air lower than 490 kPa (5 kg/cm2, 71 psi) and keep the air hose end more than 30 cm (11.8 in) away. 5. Blow air again into all the radiator core surfaces once per minute until no water blows out and the core is dry.

CL MT AT TF PD AX SU BR ST RS

CHECKING COOLING SYSTEM FOR LEAKS

NGLC0112S03

To check for leakage, apply pressure to the cooling system with a radiator cap tester. Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi) CAUTION: Higher pressure than specified may cause radiator damage.

BT HA SC EL

SLC756A

LC-11

IDX

ENGINE COOLING SYSTEM

KA24DE

System Check (Cont’d)

CHECKING RADIATOR CAP

NGLC0112S04

To check radiator cap, apply pressure to radiator cap with a radiator cap tester. Radiator cap relief pressure: Standard 78 - 98 kPa (0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 kPa (0.6 kg/cm2, 9 psi) SLC755A

Pull the negative pressure valve to open it. Check that it closes completely when released.

SMA967B

Water Pump REMOVAL

ALC077

NGLC0113

CAUTION: 쐌 When removing water pump assembly, be careful not to get coolant on drive belts. 쐌 Water pump cannot be disassembled and should be replaced as a unit. 쐌 After installing water pump, connect hose and clamp securely. Check for leaks using radiator cap tester. 1. Drain coolant from engine. Refer to MA-17, “Changing Engine Coolant”. 2. Remove fan coupling with fan. 3. Remove power steering pump drive belt, generator drive belt and A/C compressor drive belt. 4. Remove water pump.

INSPECTION 쐌 쐌

Check body assembly for rust or corrosion. Check for rough operation due to excessive end play.

SLC738

LC-12

NGLC0114

ENGINE COOLING SYSTEM

KA24DE Water Pump (Cont’d)

INSTALLATION 1. 쐌

NGLC0115

Use a scraper to remove liquid gasket from water pump. Also remove traces of liquid gasket from mating surface of cylinder block.

GI MA EM

SLC188A

2.

Apply a continuous bead of liquid gasket to mating surface of water pump. 쐌 Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”. When filling the radiator with coolant, refer to MA-17, “Changing Engine Coolant”. When installing the drive belts, refer to MA-16, “Checking Drive Belts”.

EC FE CL MT

ALC078

Thermostat

AT

REMOVAL 쐌 1. 2. 3. 4.

NGLC0116

Be careful not to spill coolant over engine compartment. Use a rag to absorb coolant. Drain coolant from engine. Refer to MA-17, “Changing Engine Coolant”. Remove air cleaner and air duct assembly. Remove water hose from water inlet housing. Remove water inlet housing, then take out thermostat.

TF PD AX

ALC087

INSPECTION 1. 2.

Valve opening temperature Valve lift

3.

NGLC0117

Check valve seating condition at normal room temperature. It should seat tightly. Check valve opening temperature and valve lift.

SU BR

76.5°C (170°F) More than 8 mm/90°C (0.31 in/194°F)

Check if valve closes at 5°C (9°F) below valve opening temperature.

ST RS

SLC343

INSTALLATION 1. 쐌 2. 쐌

NGLC0118

Use a scraper to remove old liquid gasket from water inlet. Also remove traces of liquid gasket from mating surface of front cover. Apply a continuous bead of liquid gasket to mating surface of water inlet. Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”.

BT HA SC EL

ALC088

LC-13

IDX

ENGINE COOLING SYSTEM

KA24DE

Thermostat (Cont’d)

3. 4. 5. 6. 7. 쐌

Install thermostat with jiggle valve or air bleeder at upper side. Install water inlet housing. Install water hose to water inlet housing. Install air cleaner and air duct assembly. Refill engine coolant. Refer to MA-17, “Changing Engine Coolant”. After installation, run engine for a few minutes and check for leaks.

SLC097

Radiator REMOVAL AND INSTALLATION 1. 2.

NGLC0119

Remove under cover. Drain coolant from radiator. Refer to MA-17, “Changing Engine Coolant”. 3. Disconnect upper and lower radiator hoses. 4. Remove air cleaner and air duct assembly. 5. Remove lower radiator shroud. 6. Remove radiator shroud. 7. Disconnect coolant reservoir hose. 8. Remove radiator. 9. After replacing radiator, install all parts in reverse order of removal. 10. Refill engine coolant. Refer to MA-17, “Changing Engine Coolant”. 쐌 After installation, run engine for a few minutes, and check for leaks.

LC-14

ENGINE COOLING SYSTEM

KA24DE Radiator (Cont’d)

COMPONENTS

NGLC0120

GI MA EM

EC FE CL MT AT TF PD WLC032

AX INSPECTION 1.

Apply pressure with Tool. Specified pressure value: 157 kPa (1.6 kg/cm2, 23 psi)

NGLC0130

SU BR ST RS

SLC933-A

2.

Check for leakage.

BT HA SC EL

SLC934

LC-15

IDX

ENGINE COOLING SYSTEM

KA24DE

Cooling Fan (Crankshaft driven)

Cooling Fan (Crankshaft driven) REMOVAL AND INSTALLATION 쐌 쐌 쐌 ALC089

쐌

NGLC0121

Do not release the drive belt tension by removing the fan/water pump pulley. Fan coupling cannot be disassembled and should be replaced as a unit. If front mark F is present, install fan so that side marked F faces the front. Install the drive belt only after the fan and fan coupling to water pump flange bolts/nuts have been properly torqued. Proper alignment of these components is essential. Improper alignment will cause them to wobble and may eventually cause the fan to separate from the water pump, causing extensive damage.

INSPECTION

NGLC0122

Check fan coupling for rough operation, wobbling, oil leakage, or bent bimetal fins.

SLC072

After assembly, verify the fan does not wobble or flap while the engine is running. WARNING: 쐌 When the engine is running, keep hands and clothing away from moving parts such as drive belts and fan.

SLC151B

Refilling Engine Coolant

NGLC0123

For details on refilling the engine cooling system, refer to MA-17, “REFILLING ENGINE COOLANT”.

LC-16

ENGINE COOLING SYSTEM

KA24DE Overheating Cause Analysis

Overheating Cause Analysis Symptom

GI

Check items

Water pump malfunction

Worn or loose drive belt

Thermostat stuck closed Poor heat transfer

=NGLC0125

MA

— Dust contamination or paper clogging

Damaged fins

—

EM

Mechanical damage Clogged radiator cooling tube

Excess foreign material (rust, dirt, sand, etc.)

Fan coupling does not operate Reduced air flow

EC

High resistance to fan rota- Fan and coupling tion

—

FE

Damaged fan blades

Cooling system parts malfunction

Damaged radiator shroud

—

Improper coolant mixture ratio

—

Poor coolant quality

—

Fan shroud

—

CL

— Coolant quality, viscosity

MT — Loose clamp

Cooling hose

AT

Cracked hose Water pump

Poor sealing

TF

Loose Radiator cap Poor sealing

Coolant leaks

O-ring for damage, deterioration or improper fitting

Insufficient coolant Radiator

Overflowing reservoir tank

SU

Cracked reservoir tank Cylinder head deterioration

Exhaust gas leaks into cooling system

AX

Cracked radiator tank Cracked radiator core

Reservoir tank

PD

Cylinder head gasket deterioration

BR ST RS BT HA SC EL

LC-17

IDX

ENGINE COOLING SYSTEM

KA24DE

Overheating Cause Analysis (Cont’d) Symptom

Check items Excessive payload Driving in low gear for extended time

Abusive driving

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 or restricted air flow

Blocked radiator grille

Mud contamination or paper clogging

Blocked radiator

Dirty radiator

Blocked condenser

Dirty condenser

Blockage in front of radiator

Installed large fog lamp

—

Service Data and Specifications (SDS) THERMOSTAT

NGLC0126

Valve opening temperature

76.5°C (170°F)

Valve lift

More than 8 mm/90°C (0.31 in/194°F)

RADIATOR

NGLC0127

Unit: kPa (kg/cm2, psi) Standard

78 - 98 (0.8 - 1.0, 11 - 14)

Cap relief pressure Limit

59 (0.6, 9)

Leakage test pressure

157 (1.6, 23)

LC-18

ENGINE LUBRICATION SYSTEM

VG33E AND VG33ER Precautions

Precautions SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER”

GI NGLC0134

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 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), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

MA EM

EC FE CL MT

LIQUID GASKET APPLICATION PROCEDURE 1.

2. 쐌 쐌 SEM371C

3. 4. 5.

NGLC0001

Use a scraper to remove all traces of old liquid gasket from mating surface and grooves. Also, completely clean any oil from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”.) Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) diameter (for oil pan). Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) diameter (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.

AT TF PD AX SU BR ST RS

AEM080

BT HA SC EL

LC-19

IDX

ENGINE LUBRICATION SYSTEM

VG33E AND VG33ER

Preparation

Preparation SPECIAL SERVICE TOOLS

=NGLC0002

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description

ST25051001 (J25695-1) Oil pressure gauge

Measuring oil pressure Maximum measuring range: 2,452 kPa (25 kg/cm2, 356 psi)

NT558

Adapting oil pressure gauge to cylinder block

ST25052000 (J25695-2) Hose

NT559

Removing and installing oil filter

KV10115801 (J38956) Oil filter wrench

NT362

WS39930000 ( — Tube presser

Pressing the tube of liquid gasket )

NT052

Lubrication Circuit

NGLC0003

SLC082B

LC-20

ENGINE LUBRICATION SYSTEM

VG33E AND VG33ER Oil Pressure Check

Oil Pressure Check

NGLC0004

WARNING: 쐌 Be careful not to burn yourself, as the engine and oil may be hot. 쐌 Put the shift lever in the Neutral “N” position. 1. Check oil level. 2. Remove oil pressure switch.

GI MA EM

ALC120

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.

EC

Unit: kPa (kg/cm2, psi)

SLC926

Engine speed

Approximate discharge pressure

Idle speed

More than 59 (0.6, 9)

2,000 rpm

412 - 451 (4.2 - 4.6, 60 - 65)

FE CL

If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant. : 12.25 – 17.15 N·m (1.3 – 1.7 kg-m, 9 – 12 ft-lb)

MT AT TF PD AX

Oil Pump REMOVAL AND INSTALLATION 1. 2. 3. 4. 5.

SU NGLC0005

Drain engine oil. Drain engine coolant from drain plug on radiator. Remove air duct from mass air flow sensor to throttle body. Remove cooling fan. Remove radiator hoses (upper and lower) and fan shroud. Refer to “Radiator”, LC-32. 6. Remove drive belts. Refer to MA-26, “Checking Drive Belts”. 7. Remove crankshaft pulley and front upper and lower belt covers. Refer to EM-82, “TIMING BELT”. 8. Remove oil pan. Refer to EM-79, “ OIL PAN”. 9. Remove oil strainer. 10. Remove oil pump assembly.

BR ST RS BT HA SC EL

LC-21

IDX

ENGINE LUBRICATION SYSTEM

VG33E AND VG33ER

Oil Pump (Cont’d)

DISASSEMBLY AND ASSEMBLY

NGLC0006

WLC022

쐌 쐌 쐌

Always replace with new oil seal and gasket. When installing oil pump, apply engine oil to inner and outer gears. Be sure that O-ring is properly installed.

LC-22

ENGINE LUBRICATION SYSTEM

VG33E AND VG33ER Oil Pump (Cont’d)

INSPECTION

NGLC0007

Using a feeler gauge, straightedge and micrometers, check the following clearances:

GI

Unit: mm (in) Body to outer rotor radial clearance 1

0.114 - 0.200 (0.0045 - 0.0079)

Inner rotor to outer rotor tip clearance 2

Below 0.18 (0.0071)

Body to inner rotor axial clearance 3

0.05 - 0.09 (0.0020 - 0.0035)

Body to outer rotor axial clearance 4

0.050 - 0.110 (0.0020 - 0.0043)

Inner rotor to brazed portion of housing clearance 5

0.045 - 0.091 (0.0018 - 0.0036)

MA EM

SLC072B

쐌 쐌

If the tip clearance (2) exceeds the limit, replace rotor set. If body to rotor clearances (1, 3, 4, 5) exceed the limit, replace oil pump body assembly.

EC FE CL MT

SLC073B

AT TF PD AX WLC020

REGULATOR VALVE INSPECTION

NGLC0008

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 oil pump assembly.

SU BR ST RS

SLC074B

OIL FILTER

NGLC0009

The oil filter is a small, full-flow cartridge type and is provided with a relief valve. 쐌 Use Tool KV10115801 (J38956) for removing oil filter.

BT HA SC EL

SLC035B

LC-23

IDX

ENGINE LUBRICATION SYSTEM

VG33E AND VG33ER

Oil Pump (Cont’d)

OIL FILTER BRACKET 1. 2. 3.

Remove oil filter. Disconnect oil pressure switch and connector. Remove oil filter bracket.

ALC121

LC-24

NGLC0010

ENGINE LUBRICATION SYSTEM

VG33E AND VG33ER

Service Data and Specifications (SDS)

Service Data and Specifications (SDS) OIL PRESSURE CHECK

=NGLC0011

Unit: kPa (kg/cm2, psi) Engine speed

Approximate discharge pressure

Idle speed

More than 59 (0.6, 9)

2,000 rpm

412 - 451 (4.2 - 4.6, 60 - 65)

GI MA EM

REGULATOR VALVE

NGLC0012

Unit: mm (in) Regulator valve to oil pump cover clearance

0.040 - 0.097 (0.0016 - 0.0038)

OIL PUMP

NGLC0013

EC

Unit: mm (in) Body to outer rotor radial clearance

0.114 - 0.200 (0.0045 - 0.0079)

Inner rotor to outer rotor tip clearance

FE

Below 0.18 (0.0071)

Body to inner rotor axial clearance

0.05 - 0.09 (0.0020 - 0.0035)

Body to outer rotor axial clearance

0.050 - 0.110 (0.0020 - 0.0043)

Inner rotor to brazed portion of housing clearance

0.045 - 0.091 (0.0018 - 0.0036)

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

LC-25

IDX

ENGINE COOLING SYSTEM

VG33E AND VG33ER

Precautions

Precautions SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER”

NGLC0135

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 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), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

LIQUID GASKET APPLICATION PROCEDURE 1.

2. 쐌 쐌 SEM371C

3. 4. 5.

NGLC0014

Use a scraper to remove all traces of old liquid gasket from mating surface and grooves. Also, completely clean any oil from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”.) Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) dia. (for oil pan). Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) dia. (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.

AEM080

LC-26

ENGINE COOLING SYSTEM

VG33E AND VG33ER Preparation

Preparation SPECIAL SERVICE TOOLS

=NGLC0015

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

MA

Description

EG17650301 (J33984-A) Radiator cap tester adapter

Adapting radiator cap tester to radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in)

EM

EC

NT564

WS39930000 ( — Tube presser

GI

Pressing the tube of liquid gasket )

FE CL

NT052

MT

Cooling Circuit

NGLC0016

AT TF PD AX SU BR ST

ALC122

System Check

NGLC0017

WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter turn to allow built-up pressure to escape. Carefully remove the cap by turning it all the way.

CHECKING COOLING SYSTEM HOSES

NGLC0017S01

Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

LC-27

RS BT HA SC EL IDX

ENGINE COOLING SYSTEM

VG33E AND VG33ER

System Check (Cont’d)

CHECKING RADIATOR CAP

NGLC0017S02

To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure: Standard 78 - 98 kPa (0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 kPa (0.6 kg/cm2, 9 psi)

SLC755A

Pull the negative pressure valve to open it. Check that it closes completely when released.

CHECKING RADIATOR

SMA967B

NGLC0017S04

Check radiator for mud or clogging. If necessary, clean radiator as follows. CAUTION: 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. 쐌 Tape the harness 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 when stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically downward 쐌 Use compressed air lower than 490 kPa (5 kg/cm2, 71 psi) and keep the air hose end more than 30 cm (11.8 in) away from the core. 5. Blow air again into all the radiator core surfaces once per minute until no water blows out and the core is dry.

LC-28

ENGINE COOLING SYSTEM

VG33E AND VG33ER System Check (Cont’d)

CHECKING COOLING SYSTEM FOR LEAKS

NGLC0017S03

To check for leakage, apply pressure to the cooling system with a tester. Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi) CAUTION: Higher pressure than specified may cause radiator damage.

GI MA EM

SLC756A

Water Pump REMOVAL

NGLC0018

EC FE CL MT AT TF PD

SLC076B

CAUTION: 쐌 When removing water pump assembly, be careful not to get coolant on timing 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. 쐌 To avoid deforming timing cover, make sure there is adequate clearance between it and the hose clamp.

AX SU BR ST RS BT HA SC EL

LC-29

IDX

ENGINE COOLING SYSTEM

VG33E AND VG33ER

Water Pump (Cont’d)

1.

Drain coolant from drain plugs on both sides of cylinder block and radiator. Refer to MA-28, “Changing Engine Coolant”.

2.

Remove radiator hoses (upper and lower) and fan shroud. Refer to “Radiator”. Remove drive belts. Refer to MA-26, “Checking Drive Belts”. Remove water pump pulley. Remove crankshaft pulley and front (upper and lower) belt cover. Refer to EM-82, “TIMING BELT”. Remove water pump.

SMA207CA

SMA208CA

3. 4. 5. 6.

INSPECTION 1. 2.

NGLC0019

Check for badly rusted or corroded body assembly and vanes. Check for rough operation due to excessive end play.

ALC123

INSTALLATION 1. 쐌

NGLC0132

Use a scraper to remove liquid gasket from water pump. Also remove traces of liquid gasket from mating surface of cylinder block.

SLC188A

LC-30

ENGINE COOLING SYSTEM

VG33E AND VG33ER Water Pump (Cont’d)

2.

Apply a continuous bead of liquid gasket to mating surface of the water pump. 쐌 Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”. When filling the radiator with coolant, refer to MA-28, “Changing Engine Coolant”. When installing the drive belts, refer to MA-26, “Checking Drive Belts”.

GI MA EM

ALC078

Thermostat REMOVAL 1. 2. 3. 4. 5.

NGLC0020

Drain engine coolant from drain plugs on radiator. Remove radiator hoses (upper and lower) and fan shroud. Remove drive belts. Remove pulley bracket. Remove water inlet and thermostat assembly.

EC FE CL MT

INSPECTION 1.

NGLC0021

Check valve seating condition at ordinary temperatures. It should seat tightly.

AT TF PD AX SU BR ST RS

SLC081B

2.

Check valve opening temperature and valve lift.

Description Valve opening temperature Valve lift

3.

VG33E

VG33ER

82°C (180°F)

76.5°C (170°F)

More than 10 mm/95°C (0.39 in/203°F)

More than 10 mm/90°C (0.39 in/194°F)

Then check if valve is closed at 5°C (9°F) below valve opening temperature.

BT HA SC EL

SLC343

LC-31

IDX

ENGINE COOLING SYSTEM

VG33E AND VG33ER

Thermostat (Cont’d)

INSTALLATION

NGLC0022

1.

Install thermostat with jiggle valve or air bleeder at upper side.

2. 쐌

When installing water inlet apply liquid gasket as shown. Use Genuine Silicone RTV or equivalent. Refer to GI-50, “Recommended Chemical Products and Sealants”. 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.

SLC077B

쐌 쐌

SLC078B

Radiator REMOVAL AND INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9.

NGLC0023

Remove under cover. Drain coolant from radiator drain plug. Remove air duct. (From mass air flow sensor to throttle body) Disconnect radiator upper and lower hoses. Remove A/T oil cooler hoses. (A/T model only) Remove radiator lower shroud. Disconnect reservoir tank hose. Remove radiator. After repairing or replacing radiator, install any part removed in reverse order of removal. 10. Refill the engine cooling system. Refer to MA-28, “Changing Engine Coolant”. 쐌 After installation, run the engine until it reaches normal operating temperature and check for leaks.

LC-32

ENGINE COOLING SYSTEM

VG33E AND VG33ER Radiator (Cont’d)

COMPONENTS

NGLC0024

GI MA EM

EC FE CL MT AT TF PD WLC031

AX INSPECTION 1.

Apply pressure with Tool. Specified pressure value: 157 kPa (1.6 kg/cm2, 23 psi)

NGLC0028

SU BR ST RS

SLC933-A

2.

Check for leakage.

BT HA SC EL

SLC934

LC-33

IDX

ENGINE COOLING SYSTEM

VG33E AND VG33ER

Cooling Fan (Crankshaft driven)

Cooling Fan (Crankshaft driven) REMOVAL AND INSTALLATION 쐌 쐌 쐌 SLC066B

쐌

NGLC0029

Do not release the drive belt tension by removing the fan/water pump pulley. Fan coupling cannot be disassembled and should be replaced as a unit. If front mark F is present, install fan so that side marked F faces the front. Install the drive belt only after the fan and fan coupling to water pump flange bolts/nuts have been properly torqued. Proper alignment of these components is essential. Improper alignment will cause them to wobble and may eventually cause the fan to separate from the water pump causing extensive damage.

INSPECTION

NGLC0030

Check fan coupling for rough operation, wobbling, oil leakage or bent bimetal fins.

SLC067B

After assembly, verify the fan does not wobble or flap while the engine is running. WARNING: 쐌 When the engine is running, keep hands and clothing away from moving parts such as drive belts and fan.

SLC151B

LC-34

ENGINE COOLING SYSTEM

VG33E AND VG33ER Refilling Engine Coolant

Refilling Engine Coolant

=NGLC0031

For details on refilling the engine cooling system, refer to MA-29, “REFILLING ENGINE COOLANT”.

GI MA EM

Overheating Cause Analysis Symptom

Poor heat transfer

NGLC0032

EC

Check items

Water pump malfunction

—

Thermostat stuck closed

—

FE

Dust contamination or paper clogging

Damaged fins

—

CL

Mechanical damage Clogged radiator cooling tube

MT

Excess foreign material (rust, dirt, sand, etc.)

Cooling fan does not operate Reduced air flow

AT

High resistance to fan rota- Fan and coupling tion

—

TF

Damaged fan blades

Cooling system parts malfunction

Damaged radiator shroud

—

Improper coolant mixture ratio

—

Poor coolant quality

—

PD

Fan shroud — Coolant quality, viscosity

AX

— Loose clamp Cooling hose

SU

Cracked hose Water pump

Poor sealing

BR

Loose Radiator cap Coolant leaks Insufficient coolant Radiator

Poor sealing

ST

O-ring for damage, deterioration or improper fitting

RS

Cracked radiator tank Cracked radiator core

Reservoir tank

Cracked reservoir tank Cylinder head deterioration

Overflowing reservoir tank

Exhaust gas leaks into cooling system

BT

Cylinder head gasket deterioration

HA SC EL

LC-35

IDX

ENGINE COOLING SYSTEM

VG33E AND VG33ER

Overheating Cause Analysis (Cont’d) Symptom

Check items Excessive payload Driving in low gear for extended time

Abusive driving

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 or restricted air flow

Blocked radiator grille

Mud contamination or paper clogging

Blocked radiator

Dirty radiator

Blocked condenser

Dirty condenser

Blockage in front of radiator

Installed large fog lamp

—

Service Data and Specifications (SDS) THERMOSTAT

NGLC0033

Description

VG33E

VG33ER

82°C (180°F)

76.5°C (170°F)

More than 10 mm/95°C (0.39 in/203°F)

More than 10 mm/90°C (0.39 in/194°F)

Valve opening temperature Valve lift

RADIATOR

NGLC0034

Unit: kPa (kg/cm2, psi) Standard

78 - 98 (0.8 - 1.0, 11 - 14)

Cap relief pressure Limit

59 (0.6, 9)

Leakage test pressure

157 (1.6, 23)

LC-36

ENGINE CONTROL SYSTEM SECTION

EC

GI MA EM LC

CONTENTS KA24DE TROUBLE DIAGNOSIS - INDEX ..................................18 Alphabetical & P No. Index for DTC .........................18 PRECAUTIONS .............................................................23 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″.............23 Precautions for On Board Diagnostic (OBD) System of Engine ......................................................23 Engine Fuel & Emission Control System ..................24 Precautions ................................................................25 Wiring Diagrams and Trouble Diagnosis...................26 PREPARATION .............................................................27 Special Service Tools ................................................27 Commercial Service Tools .........................................27 ENGINE AND EMISSION CONTROL OVERALL SYSTEM.........................................................................29 Engine Control Component Parts Location...............29 Circuit Diagram ..........................................................31 System Diagram ........................................................32 Vacuum Hose Drawing ..............................................33 System Chart .............................................................34 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ...............................................35 Multiport Fuel Injection (MFI) System .......................35 Distributor Ignition (DI) System .................................37 Air Conditioning Cut Control......................................39 Fuel Cut Control (at no load & high engine speed) ........................................................................39 Evaporative Emission System ...................................40 On Board Refueling Vapor Recovery (ORVR) ..........45 Positive Crankcase Ventilation ..................................55 BASIC SERVICE PROCEDURE ...................................57 Fuel Pressure Release ..............................................57 Fuel Pressure Check .................................................57 Fuel Pressure Regulator Check ................................58 Injector .......................................................................58 Fast Idle Cam (FIC)...................................................59

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment .................................................................59 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................73 Introduction ................................................................73 Two Trip Detection Logic ...........................................73 Emission-related Diagnostic Information ...................74 Malfunction Indicator Lamp (MIL)..............................88 OBD System Operation Chart ...................................88 CONSULT-II ...............................................................94 Generic Scan Tool (GST) ........................................106 TROUBLE DIAGNOSIS - INTRODUCTION................108 Introduction ..............................................................108 Work Flow................................................................110 TROUBLE DIAGNOSIS - BASIC INSPECTION .........112 Basic Inspection.......................................................112 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION .............................................................126 DTC Inspection Priority Chart..................................126 Fail-safe Chart .........................................................127 Symptom Matrix Chart.............................................128 CONSULT-II Reference Value in Data Monitor Mode ........................................................................132 Major Sensor Reference Graph in Data Monitor Mode ........................................................................134 ECM Terminals and Reference Value .....................137 TROUBLE DIAGNOSIS - SPECIFICATION VALUE..........................................................................146 Description ...............................................................146 Testing Condition .....................................................146 Inspection Procedure...............................................146 Diagnostic Procedure ..............................................147 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.....................................................................150 Description ...............................................................150 Diagnostic Procedure ..............................................150 TROUBLE DIAGNOSIS FOR POWER SUPPLY........151 Main Power Supply and Ground Circuit..................151 DTC P0031, P0032 HO2S1 HEATER .........................158

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS Description ...............................................................158 CONSULT-II Reference Value in Data Monitor Mode ........................................................................158 ECM Terminals and Reference Value .....................158 On Board Diagnosis Logic.......................................158 DTC Confirmation Procedure ..................................159 Wiring Diagram ........................................................160 Diagnostic Procedure ..............................................161 DTC P0037, P0038 HO2S2 HEATER .........................163 Description ...............................................................163 CONSULT-II Reference Value in Data Monitor Mode ........................................................................163 ECM Terminals and Reference Value .....................163 On Board Diagnosis Logic.......................................163 DTC Confirmation Procedure ..................................164 Wiring Diagram ........................................................165 Diagnostic Procedure ..............................................166 DTC P0101, P0102, P0103 MAF SENSOR ................168 Component Description ...........................................168 CONSULT-II Reference Value in Data Monitor Mode ........................................................................168 ECM Terminals and Reference Value .....................168 On Board Diagnosis Logic.......................................168 DTC Confirmation Procedure ..................................169 Overall Function Check ...........................................171 Wiring Diagram ........................................................172 Diagnostic Procedure ..............................................173 DTC P0107, P0108 ABSOLUTE PRESSURE SENSOR ......................................................................178 Component Description ...........................................178 On Board Diagnosis Logic.......................................178 DTC Confirmation Procedure ..................................178 Diagnostic Procedure ..............................................179 DTC P0112, P0113, P0127 IAT SENSOR...................180 Component Description ...........................................180 On Board Diagnosis Logic.......................................180 DTC Confirmation Procedure ..................................181 Wiring Diagram ........................................................182 Diagnostic Procedure ..............................................183 DTC P0117, P0118 ECT SENSOR..............................185 Component Description ...........................................185 CONSULT-II Reference Value in Data Monitor Mode ........................................................................185 On Board Diagnosis Logic.......................................185 DTC Confirmation Procedure ..................................186 Wiring Diagram ........................................................187 Diagnostic Procedure ..............................................188 DTC P0121, P0122, P0123 TP SENSOR ...................190 Component Description ...........................................190 CONSULT-II Reference Value in Data Monitor Mode ........................................................................190 ECM Terminals and Reference Value .....................191

(Cont’d)

On Board Diagnosis Logic.......................................191 DTC Confirmation Procedure ..................................192 Wiring Diagram ........................................................195 Diagnostic Procedure ..............................................196 DTC P0125 ECT SENSOR..........................................204 Component Description ...........................................204 On Board Diagnosis Logic.......................................204 DTC Confirmation Procedure ..................................204 Wiring Diagram ........................................................206 Diagnostic Procedure ..............................................207 DTC P0128 THERMOSTAT FUNCTION.....................209 On Board Diagnosis Logic.......................................209 Possible Cause........................................................209 DTC Confirmation Procedure ..................................209 Diagnostic Procedure ..............................................210 DTC P0132 HO2S1......................................................211 Component Description ...........................................211 CONSULT-II Reference Value in Data Monitor Mode ........................................................................211 ECM Terminals and Reference Value .....................211 On Board Diagnosis Logic.......................................212 DTC Confirmation Procedure ..................................212 Wiring Diagram ........................................................213 Diagnostic Procedure ..............................................214 DTC P0133 HO2S1......................................................218 Component Description ...........................................218 CONSULT-II Reference Value in Data Monitor Mode ........................................................................218 ECM Terminals and Reference Value .....................218 On Board Diagnosis Logic.......................................219 DTC Confirmation Procedure ..................................219 Overall Function Check ...........................................220 Wiring Diagram ........................................................221 Diagnostic Procedure ..............................................222 DTC P0134 HO2S1......................................................229 Component Description ...........................................229 CONSULT-II Reference Value in Data Monitor Mode ........................................................................229 ECM Terminals and Reference Value .....................229 On Board Diagnosis Logic.......................................230 DTC Confirmation Procedure ..................................231 Overall Function Check ...........................................232 Wiring Diagram ........................................................233 Diagnostic Procedure ..............................................234 DTC P0138 HO2S2......................................................237 Component Description ...........................................237 CONSULT-II Reference Value in Data Monitor Mode ........................................................................237 ECM Terminals and Reference Value .....................237 On Board Diagnosis Logic.......................................237 DTC Confirmation Procedure ..................................238 Overall Function Check ...........................................238

EC-2

CONTENTS Wiring Diagram ........................................................239 Diagnostic Procedure ..............................................240 DTC P0139 HO2S2......................................................245 Component Description ...........................................245 CONSULT-II Reference Value in Data Monitor Mode ........................................................................245 ECM Terminals and Reference Value .....................245 On Board Diagnosis Logic.......................................245 DTC Confirmation Procedure ..................................246 Overall Function Check ...........................................247 Wiring Diagram ........................................................248 Diagnostic Procedure ..............................................249 DTC P0171 FUEL INJECTION SYSTEM FUNCTION ...................................................................255 On Board Diagnosis Logic.......................................255 DTC Confirmation Procedure ..................................255 Wiring Diagram ........................................................257 Diagnostic Procedure ..............................................258 DTC P0172 FUEL INJECTION SYSTEM FUNCTION ...................................................................262 On Board Diagnosis Logic.......................................262 DTC Confirmation Procedure ..................................262 Wiring Diagram ........................................................264 Diagnostic Procedure ..............................................265 DTC P0181, P0182, P0183 FTT SENSOR .................269 Component Description ...........................................269 On Board Diagnosis Logic.......................................269 DTC Confirmation Procedure ..................................270 Wiring Diagram ........................................................271 Diagnostic Procedure ..............................................272 DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION.....................................275 On Board Diagnosis Logic.......................................275 Overall Function Check ...........................................275 Diagnostic Procedure ..............................................277 Main 11 Causes of Overheating..............................280 DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE ...............281 On Board Diagnosis Logic.......................................281 DTC Confirmation Procedure ..................................281 Diagnostic Procedure ..............................................282 DTC P0327, P0328 KS................................................290 Component Description ...........................................290 ECM Terminals and Reference Value .....................290 On Board Diagnosis Logic.......................................290 DTC Confirmation Procedure ..................................290 Wiring Diagram ........................................................291 Diagnostic Procedure ..............................................292 DTC P0335 CKP SENSOR (OBD)..............................294 Component Description ...........................................294 ECM Terminals and Reference Value .....................294 On Board Diagnosis Logic.......................................294

(Cont’d)

DTC Confirmation Procedure ..................................295 Wiring Diagram ........................................................296 Diagnostic Procedure ..............................................297 DTC P0340 CMP SENSOR .........................................300 Component Description ...........................................300 ECM Terminals and Reference Value .....................300 On Board Diagnosis Logic.......................................301 DTC Confirmation Procedure ..................................302 Wiring Diagram ........................................................303 Diagnostic Procedure ..............................................304 DTC P0400 EGR FUNCTION......................................308 Description ...............................................................308 On Board Diagnosis Logic.......................................309 DTC Confirmation Procedure ..................................310 Overall Function Check ...........................................311 Wiring Diagram ........................................................312 Diagnostic Procedure ..............................................313 DTC P0402 EGRC-BPT VALVE FUNCTION..............320 Description ...............................................................320 On Board Diagnosis Logic.......................................320 DTC Confirmation Procedure ..................................321 Overall Function Check ...........................................322 Diagnostic Procedure ..............................................323 DTC P0405, P0406 EGRT SENSOR ..........................328 Component Description ...........................................328 On Board Diagnosis Logic.......................................328 DTC Confirmation Procedure ..................................329 Overall Function Check ...........................................330 Wiring Diagram ........................................................331 Diagnostic Procedure ..............................................332 DTC P0420 THREE WAY CATALYST FUNCTION ...334 On Board Diagnosis Logic.......................................334 DTC Confirmation Procedure ..................................334 Overall Function Check ...........................................335 Diagnostic Procedure ..............................................336 DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING ..................................................339 System Description..................................................339 On Board Diagnosis Logic.......................................339 DTC Confirmation Procedure ..................................340 Overall Function Check ...........................................340 Diagnostic Procedure ..............................................341 DTC P0442 EVAP CONTROL SYSTEM.....................350 On Board Diagnosis Logic.......................................350 DTC Confirmation Procedure ..................................351 Diagnostic Procedure ..............................................353 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE ..................366 Description ...............................................................366 CONSULT-II Reference Value in Data Monitor Mode ........................................................................366 ECM Terminals and Reference Value .....................367

EC-3

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS On Board Diagnosis Logic.......................................367 DTC Confirmation Procedure ..................................368 Wiring Diagram ........................................................369 Diagnostic Procedure ..............................................370 DTC P0447 EVAP CANISTER VENT CONTROL VALVE..........................................................................373 Component Description ...........................................373 CONSULT-II Reference Value in Data Monitor Mode ........................................................................373 ECM Terminals and Reference Value .....................373 On Board Diagnosis Logic.......................................373 DTC Confirmation Procedure ..................................374 Wiring Diagram ........................................................375 Diagnostic Procedure ..............................................376 DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR .................................................380 Component Description ...........................................380 CONSULT-II Reference Value in Data Monitor Mode ........................................................................380 ECM Terminals and Reference Value .....................380 On Board Diagnosis Logic.......................................381 DTC Confirmation Procedure ..................................382 Wiring Diagram ........................................................383 Diagnostic Procedure ..............................................384 DTC P0455 EVAP CONTROL SYSTEM.....................393 On Board Diagnosis Logic.......................................393 DTC Confirmation Procedure ..................................394 Diagnostic Procedure ..............................................395 DTC P0456, P1456 EVAP CONTROL SYSTEM ........405 On Board Diagnosis Logic.......................................405 Possible Cause........................................................405 DTC Confirmation Procedure ..................................406 Diagnostic Procedure ..............................................408 DTC P0460 FUEL LEVEL SENSOR...........................420 Component Description ...........................................420 On Board Diagnostic Logic......................................420 Possible Cause........................................................420 DTC Confirmation Procedure ..................................420 Wiring Diagram ........................................................421 Diagnostic Procedure ..............................................422 DTC P0461 FUEL LEVEL SENSOR...........................424 Component Description ...........................................424 On Board Diagnostic Logic......................................424 Possible Cause........................................................424 Overall Function Check ...........................................424 DTC P0462, P0463 FUEL LEVEL SENSOR ..............426 Component Description ...........................................426 On Board Diagnostic Logic......................................426 Possible Cause........................................................426 DTC Confirmation Procedure ..................................426 Wiring Diagram ........................................................427 Diagnostic Procedure ..............................................428

(Cont’d)

DTC P0500 VSS ..........................................................430 Component Description ...........................................430 ECM Terminals and Reference Value .....................430 On Board Diagnosis Logic.......................................430 DTC Confirmation Procedure ..................................430 Overall Function Check ...........................................431 Wiring Diagram ........................................................432 Diagnostic Procedure ..............................................433 DTC P0505 ISC SYSTEM ...........................................434 Description ...............................................................434 CONSULT-II Reference Value in Data Monitor Mode ........................................................................435 ECM Terminals and Reference Value .....................435 On Board Diagnosis Logic.......................................435 DTC Confirmation Procedure ..................................436 Wiring Diagram ........................................................437 Diagnostic Procedure ..............................................438 DTC P0510 CTP SWITCH...........................................440 Component Description ...........................................440 ECM Terminals and Reference Value .....................440 On Board Diagnosis Logic.......................................440 DTC Confirmation Procedure ..................................441 Overall Function Check ...........................................441 Wiring Diagram ........................................................442 Diagnostic Procedure ..............................................443 DTC P0605 ECM .........................................................447 Component Description ...........................................447 On Board Diagnosis Logic.......................................447 DTC Confirmation Procedure ..................................447 Diagnostic Procedure ..............................................448 DTC P1143 HO2S1......................................................449 Component Description ...........................................449 CONSULT-II Reference Value in Data Monitor Mode ........................................................................449 ECM Terminals and Reference Value .....................449 On Board Diagnosis Logic.......................................450 DTC Confirmation Procedure ..................................450 Overall Function Check ...........................................451 Diagnostic Procedure ..............................................451 DTC P1144 HO2S1......................................................456 Component Description ...........................................456 CONSULT-II Reference Value in Data Monitor Mode ........................................................................456 ECM Terminals and Reference Value .....................456 On Board Diagnosis Logic.......................................457 DTC Confirmation Procedure ..................................457 Overall Function Check ...........................................458 Diagnostic Procedure ..............................................458 DTC P1146 HO2S2......................................................463 Component Description ...........................................463 CONSULT-II Reference Value in Data Monitor Mode ........................................................................463

EC-4

CONTENTS ECM Terminals and Reference Value .....................463 On Board Diagnosis Logic.......................................463 DTC Confirmation Procedure ..................................464 Overall Function Check ...........................................465 Wiring Diagram ........................................................466 Diagnostic Procedure ..............................................467 DTC P1147 HO2S2......................................................473 Component Description ...........................................473 CONSULT-II Reference Value in Data Monitor Mode ........................................................................473 ECM Terminals and Reference Value .....................473 On Board Diagnosis Logic.......................................473 DTC Confirmation Procedure ..................................474 Overall Function Check ...........................................475 Wiring Diagram ........................................................476 Diagnostic Procedure ..............................................477 DTC P1148 CLOSED LOOP CONTROL ....................483 On Board Diagnosis Logic.......................................483 DTC Confirmation Procedure ..................................483 Overall Function Check ...........................................484 Diagnostic Procedure ..............................................484 DTC P1217 ENGINE OVER TEMPERATURE............485 On Board Diagnosis Logic.......................................485 Overall Function Check ...........................................485 Diagnostic Procedure ..............................................486 Main 11 Causes of Overheating..............................489 DTC P1336 CKP SENSOR (OBD)..............................490 Component Description ...........................................490 ECM Terminals and Reference Value .....................490 On Board Diagnosis Logic.......................................491 DTC Confirmation Procedure ..................................491 Wiring Diagram ........................................................492 Diagnostic Procedure ..............................................493 DTC P1400 EGRC-SOLENOID VALVE ......................496 Component Description ...........................................496 CONSULT-II Reference Value in Data Monitor Mode ........................................................................496 ECM Terminals and Reference Value .....................496 On Board Diagnosis Logic.......................................496 DTC Confirmation Procedure ..................................497 Overall Function Check ...........................................497 Wiring Diagram ........................................................498 Diagnostic Procedure ..............................................499 DTC P1402 EGR FUNCTION......................................503 Description ...............................................................503 On Board Diagnosis Logic.......................................504 DTC Confirmation Procedure ..................................504 Wiring Diagram ........................................................506 Diagnostic Procedure ..............................................507 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE...................................512 Description ...............................................................512

(Cont’d)

CONSULT-II Reference Value in Data Monitor Mode ........................................................................512 ECM Terminals and Reference Value .....................513 On Board Diagnosis Logic.......................................513 DTC Confirmation Procedure ..................................514 Wiring Diagram ........................................................515 Diagnostic Procedure ..............................................516 DTC P1446 EVAP CANISTER VENT CONTROL VALVE..........................................................................523 Component Description ...........................................523 CONSULT-II Reference Value in Data Monitor Mode ........................................................................523 ECM Terminals and Reference Value .....................523 On Board Diagnosis Logic.......................................523 DTC Confirmation Procedure ..................................524 Diagnostic Procedure ..............................................525 DTC P1448 EVAP CANISTER VENT CONTROL VALVE..........................................................................529 Component Description ...........................................529 CONSULT-II Reference Value in Data Monitor Mode ........................................................................529 ECM Terminals and Reference Value .....................529 On Board Diagnosis Logic.......................................529 DTC Confirmation Procedure ..................................530 Overall Function Check ...........................................531 Diagnostic Procedure ..............................................531 DTC P1464 FUEL LEVEL SENSOR...........................536 Component Description ...........................................536 On Board Diagnostic Logic......................................536 Possible Cause........................................................536 DTC Confirmation Procedure ..................................536 Wiring Diagram ........................................................537 Diagnostic Procedure ..............................................538 DTC P1490 VACUUM CUT VALVE BYPASS VALVE..........................................................................539 Description ...............................................................539 CONSULT-II Reference Value in Data Monitor Mode ........................................................................539 ECM Terminals and Reference Value .....................539 On Board Diagnosis Logic.......................................540 DTC Confirmation Procedure ..................................540 Wiring Diagram ........................................................541 Diagnostic Procedure ..............................................542 DTC P1491 VACUUM CUT VALVE BYPASS VALVE..........................................................................546 Description ...............................................................546 CONSULT-II Reference Value in Data Monitor Mode ........................................................................546 ECM Terminals and Reference Value .....................546 On Board Diagnosis Logic.......................................547 DTC Confirmation Procedure ..................................547 Overall Function Check ...........................................548

EC-5

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CONTENTS Wiring Diagram ........................................................549 Diagnostic Procedure ..............................................550 DTC P1706 PNP SWITCH...........................................556 Component Description ...........................................556 CONSULT-II Reference Value in Data Monitor Mode ........................................................................556 ECM Terminals and Reference Value .....................556 On Board Diagnosis Logic.......................................556 DTC Confirmation Procedure ..................................557 Overall Function Check ...........................................558 Wiring Diagram ........................................................559 Diagnostic Procedure For M/T Models....................560 IGNITION SIGNAL.......................................................562 Component Description ...........................................562 CONSULT-II Reference Value in Data Monitor Mode ........................................................................562 ECM Terminals and Reference Value .....................563 Wiring Diagram ........................................................564 Diagnostic Procedure ..............................................565 INJECTOR ...................................................................571 Component Description ...........................................571 ECM Terminals and Reference Value .....................571 Wiring Diagram ........................................................572 Diagnostic Procedure ..............................................573 START SIGNAL...........................................................576 CONSULT-II Reference Value in Data Monitor Mode ........................................................................576 ECM Terminals and Reference Value .....................576 Wiring Diagram ........................................................577 Diagnostic Procedure ..............................................578 FUEL PUMP.................................................................580 System Description..................................................580 Component Description ...........................................580 CONSULT-II Reference Value in Data Monitor Mode ........................................................................580 ECM Terminals and Reference Value .....................581 Wiring Diagram ........................................................582 Diagnostic Procedure ..............................................583 POWER STEERING OIL PRESSURE SWITCH.........588 Component Description ...........................................588 CONSULT-II Reference Value in Data Monitor Mode ........................................................................588 ECM Terminals and Reference Value .....................588 Wiring Diagram ........................................................589 Diagnostic Procedure ..............................................590 IACV-FICD SOLENOID VALVE...................................592 Component Description ...........................................592 ECM Terminals and Reference Value .....................592 Wiring Diagram ........................................................593 Diagnostic Procedure ..............................................594 MIL & DATA LINK CONNECTORS ............................598 Wiring Diagram ........................................................598

(Cont’d)

SERVICE DATA AND SPECIFICATIONS (SDS) .......599 Fuel Pressure Regulator..........................................599 Idle Speed and Ignition Timing................................599 Ignition Coil ..............................................................599 Mass Air Flow Sensor..............................................599 Engine Coolant Temperature Sensor ......................599 EGR Temperature Sensor .......................................599 Fuel Pump ...............................................................599 IACV-AAC Valve ......................................................599 Injector .....................................................................600 Resistor....................................................................600 Throttle Position Sensor ..........................................600 Heated Oxygen Sensor 1 Heater ............................600 Calculated Load Value.............................................600 Intake Air Temperature Sensor................................600 Heated Oxygen Sensor 2 Heater ............................600 Crankshaft Position Sensor (OBD)..........................600 Fuel Tank Temperature Sensor ...............................600 VG33E TROUBLE DIAGNOSIS - INDEX ................................601 Alphabetical & P No. Index for DTC .......................601 PRECAUTIONS ...........................................................609 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...........609 Precautions for On Board Diagnostic (OBD) System of Engine and A/T.......................................609 Engine Fuel & Emission Control System ................610 Precautions ..............................................................611 Wiring Diagrams and Trouble Diagnosis.................612 PREPARATION ...........................................................613 Special Service Tools ..............................................613 Commercial Service Tools .......................................613 ENGINE AND EMISSION CONTROL OVERALL SYSTEM.......................................................................616 Engine Control Component Parts Location.............616 Circuit Diagram ........................................................618 System Diagram ......................................................619 Vacuum Hose Drawing ............................................620 System Chart ...........................................................621 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION .............................................622 Multiport Fuel Injection (MFI) System .....................622 Distributor Ignition (DI) System ...............................624 Air Conditioning Cut Control....................................625 Fuel Cut Control (at no load & high engine speed) ......................................................................626 Evaporative Emission System .................................626 On Board Refueling Vapor Recovery (ORVR) ........632 Positive Crankcase Ventilation ................................642 BASIC SERVICE PROCEDURE .................................644 Fuel Pressure Release ............................................644

EC-6

CONTENTS Fuel Pressure Check ...............................................644 Fuel Pressure Regulator Check ..............................645 Injector .....................................................................645 Fast Idle Cam (FIC).................................................646 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment ...............................................................648 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION .............................................................660 Introduction ..............................................................660 Two Trip Detection Logic .........................................660 Emission-related Diagnostic Information .................661 Malfunction Indicator Lamp (MIL)............................675 OBD System Operation Chart .................................676 CONSULT-II .............................................................682 Generic Scan Tool (GST) ........................................695 TROUBLE DIAGNOSIS - INTRODUCTION................697 Introduction ..............................................................697 Work Flow................................................................699 TROUBLE DIAGNOSIS - BASIC INSPECTION .........701 Basic Inspection.......................................................701 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION .............................................................715 DTC Inspection Priority Chart..................................715 Fail-safe Chart .........................................................716 Symptom Matrix Chart.............................................717 CONSULT-II Reference Value in Data Monitor Mode ........................................................................721 Major Sensor Reference Graph in Data Monitor Mode ........................................................................723 ECM Terminals and Reference Value .....................726 TROUBLE DIAGNOSIS - SPECIFICATION VALUE..........................................................................735 Description ...............................................................735 Testing Condition .....................................................735 Inspection Procedure...............................................735 Diagnostic Procedure ..............................................736 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.....................................................................739 Description ...............................................................739 Diagnostic Procedure ..............................................739 TROUBLE DIAGNOSIS FOR POWER SUPPLY........740 Main Power Supply and Ground Circuit..................740 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER.......................................................................746 Description ...............................................................746 CONSULT-II Reference Value in Data Monitor Mode ........................................................................746 ECM Terminals and Reference Value .....................746 On Board Diagnosis Logic.......................................746 DTC Confirmation Procedure ..................................747 Wiring Diagram ........................................................748 Diagnostic Procedure ..............................................750

(Cont’d)

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER.......................................................................753 Description ...............................................................753 CONSULT-II Reference Value in Data Monitor Mode ........................................................................753 ECM Terminals and Reference Value .....................753 On Board Diagnosis Logic.......................................754 DTC Confirmation Procedure ..................................754 Wiring Diagram ........................................................755 Diagnostic Procedure ..............................................757 DTC P0101, P0102, P0103 MAF SENSOR ................761 Component Description ...........................................761 CONSULT-II Reference Value in Data Monitor Mode ........................................................................761 ECM Terminals and Reference Value .....................761 On Board Diagnosis Logic.......................................761 DTC Confirmation Procedure ..................................762 Overall Function Check ...........................................764 Wiring Diagram ........................................................765 Diagnostic Procedure ..............................................766 DTC P0112, P0113, P0127 IAT SENSOR...................770 Component Description ...........................................770 On Board Diagnosis Logic.......................................770 DTC Confirmation Procedure ..................................770 Wiring Diagram ........................................................772 Diagnostic Procedure ..............................................773 DTC P0117, P0118 ECT SENSOR..............................775 Component Description ...........................................775 On Board Diagnosis Logic.......................................775 DTC Confirmation Procedure ..................................776 Wiring Diagram ........................................................777 Diagnostic Procedure ..............................................778 DTC P0121, P0122, P0123 TP SENSOR ...................780 Description ...............................................................780 CONSULT-II Reference Value in Data Monitor Mode ........................................................................780 ECM Terminals and Reference Value .....................781 On Board Diagnosis Logic.......................................781 DTC Confirmation Procedure ..................................782 Wiring Diagram ........................................................785 Diagnostic Procedure ..............................................786 DTC P0125 ECT SENSOR..........................................793 Description ...............................................................793 On Board Diagnosis Logic.......................................793 DTC Confirmation Procedure ..................................794 Wiring Diagram ........................................................795 Diagnostic Procedure ..............................................796 DTC P0128 THERMOSTAT FUNCTION.....................798 On Board Diagnosis Logic.......................................798 DTC Confirmation Procedure ..................................798 Diagnostic Procedure ..............................................799 DTC P0132, P0152 HO2S1 .........................................800

EC-7

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CONTENTS Component Description ...........................................800 CONSULT-II Reference Value in Data Monitor Mode ........................................................................800 ECM Terminals and Reference Value .....................800 On Board Diagnosis Logic.......................................801 DTC Confirmation Procedure ..................................801 Wiring Diagram ........................................................802 Diagnostic Procedure ..............................................804 DTC P0133, P0153 HO2S1 .........................................808 Component Description ...........................................808 CONSULT-II Reference Value in Data Monitor Mode ........................................................................808 ECM Terminals and Reference Value .....................808 On Board Diagnosis Logic.......................................809 DTC Confirmation Procedure ..................................809 Overall Function Check ...........................................810 Wiring Diagram ........................................................811 Diagnostic Procedure ..............................................813 DTC P0134, P0154 HO2S1 .........................................822 Component Description ...........................................822 CONSULT-II Reference Value in Data Monitor Mode ........................................................................822 ECM Terminals and Reference Value .....................822 On Board Diagnosis Logic.......................................823 DTC Confirmation Procedure ..................................824 Overall Function Check ...........................................825 Wiring Diagram ........................................................826 Diagnostic Procedure ..............................................828 DTC P0138, P0158 HO2S2 .........................................833 Component Description ...........................................833 CONSULT-II Reference Value in Data Monitor Mode ........................................................................833 ECM Terminals and Reference Value .....................833 On Board Diagnosis Logic.......................................833 DTC Confirmation Procedure ..................................834 Overall Function Check ...........................................834 Wiring Diagram ........................................................836 Diagnostic Procedure ..............................................838 DTC P0139, P0159 HO2S2 .........................................843 Component Description ...........................................843 CONSULT-II Reference Value in Data Monitor Mode ........................................................................843 ECM Terminals and Reference Value .....................843 On Board Diagnosis Logic.......................................843 DTC Confirmation Procedure ..................................844 Overall Function Check ...........................................845 Wiring Diagram ........................................................846 Diagnostic Procedure ..............................................848 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION ...................................................................853 On Board Diagnosis Logic.......................................853 DTC Confirmation Procedure ..................................854

(Cont’d)

Wiring Diagram ........................................................855 Diagnostic Procedure ..............................................857 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION ...................................................................862 On Board Diagnosis Logic.......................................862 DTC Confirmation Procedure ..................................863 Wiring Diagram ........................................................864 Diagnostic Procedure ..............................................866 DTC P0181, P0182, P0183 FTT SENSOR .................870 Component Description ...........................................870 On Board Diagnosis Logic.......................................870 DTC Confirmation Procedure ..................................871 Wiring Diagram ........................................................872 Diagnostic Procedure ..............................................873 DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION.....................................875 On Board Diagnosis Logic.......................................875 Possible Cause........................................................875 Overall Function Check ...........................................876 Diagnostic Procedure ..............................................878 Main 12 Causes of Overheating..............................881 DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE ...............882 On Board Diagnosis Logic.......................................882 DTC Confirmation Procedure ..................................883 Diagnostic Procedure ..............................................883 DTC P0327, P0328 KS................................................891 Component Description ...........................................891 ECM Terminals and Reference Value .....................891 On Board Diagnosis Logic.......................................891 DTC Confirmation Procedure ..................................891 Wiring Diagram ........................................................892 Diagnostic Procedure ..............................................893 DTC P0335 CKP SENSOR (OBD)..............................895 Component Description ...........................................895 ECM Terminals and Reference Value .....................895 On Board Diagnosis Logic.......................................896 DTC Confirmation Procedure ..................................896 Wiring Diagram ........................................................897 Diagnostic Procedure ..............................................898 DTC P0340 CMP SENSOR .........................................901 Component Description ...........................................901 ECM Terminals and Reference Value .....................901 On Board Diagnosis Logic.......................................902 DTC Confirmation Procedure ..................................903 Wiring Diagram ........................................................904 Diagnostic Procedure ..............................................905 DTC P0420, P0430 THREE WAY CATALYST FUNCTION ...................................................................908 On Board Diagnosis Logic.......................................908 DTC Confirmation Procedure ..................................908 Overall Function Check ...........................................909

EC-8

CONTENTS Diagnostic Procedure ..............................................910 DTC P0441 EVAP CONTROL SYSTEM.....................913 System Description..................................................913 On Board Diagnosis Logic.......................................913 DTC Confirmation Procedure ..................................914 Overall Function Check ...........................................915 Diagnostic Procedure ..............................................916 DTC P0442 EVAP CONTROL SYSTEM.....................925 On Board Diagnosis Logic.......................................925 DTC Confirmation Procedure ..................................927 Diagnostic Procedure ..............................................928 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE ..................939 Description ...............................................................939 CONSULT-II Reference Value in Data Monitor Mode ........................................................................939 ECM Terminals and Reference Value .....................940 On Board Diagnosis Logic.......................................941 DTC Confirmation Procedure ..................................941 Wiring Diagram ........................................................942 Diagnostic Procedure ..............................................943 DTC P0447 EVAP CANISTER VENT CONTROL VALVE..........................................................................946 Component Description ...........................................946 CONSULT-II Reference Value in Data Monitor Mode ........................................................................946 ECM Terminals and Reference Value .....................946 On Board Diagnosis Logic.......................................947 DTC Confirmation Procedure ..................................947 Wiring Diagram ........................................................948 Diagnostic Procedure ..............................................949 DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR .................................................952 Component Description ...........................................952 CONSULT-II Reference Value in Data Monitor Mode ........................................................................952 ECM Terminals and Reference Value .....................952 On Board Diagnosis Logic.......................................953 DTC Confirmation Procedure ..................................953 Wiring Diagram ........................................................954 Diagnostic Procedure ..............................................955 Component Inspection.............................................961 DTC P0455 EVAP CONTROL SYSTEM.....................963 On Board Diagnosis Logic.......................................963 DTC Confirmation Procedure ..................................964 Diagnostic Procedure ..............................................966 DTC P0456, P1456 EVAP CONTROL SYSTEM ........976 On Board Diagnosis Logic.......................................976 DTC Confirmation Procedure ..................................977 Overall Function Check ...........................................978 Diagnostic Procedure ..............................................979 DTC P0460 FUEL LEVEL SENSOR...........................990

(Cont’d)

Component Description ...........................................990 ECM Terminals and Reference Value .....................990 On Board Diagnosis Logic.......................................990 DTC Confirmation Procedure ..................................991 Wiring Diagram ........................................................992 Diagnostic Procedure ..............................................993 DTC P0461 FUEL LEVEL SENSOR...........................995 Component Description ...........................................995 On Board Diagnosis Logic.......................................995 Overall Function Check ...........................................995 DTC P0462, P0463 FUEL LEVEL SENSOR ..............997 Component Description ...........................................997 ECM Terminals and Reference Value .....................997 On Board Diagnosis Logic.......................................997 DTC Confirmation Procedure ..................................998 Wiring Diagram ........................................................999 Diagnostic Procedure ............................................1000 DTC P0500 VSS ........................................................1002 Component Description .........................................1002 ECM Terminals and Reference Value ...................1002 On Board Diagnosis Logic.....................................1002 DTC Confirmation Procedure ................................1002 Overall Function Check .........................................1003 Wiring Diagram ......................................................1004 Diagnostic Procedure ............................................1005 DTC P0505 ISC SYSTEM .........................................1006 Description .............................................................1006 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1007 ECM Terminals and Reference Value ...................1007 On Board Diagnosis Logic.....................................1007 DTC Confirmation Procedure ................................1008 Wiring Diagram ......................................................1009 Diagnostic Procedure ............................................1010 DTC P0510 CTP SWITCH.........................................1012 Component Description .........................................1012 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1012 ECM Terminals and Reference Value ...................1012 On Board Diagnosis Logic.....................................1012 DTC Confirmation Procedure ................................1013 Overall Function Check .........................................1013 Wiring Diagram ......................................................1014 Diagnostic Procedure ............................................1015 DTC P0600 A/T CONTROL.......................................1019 System Description................................................1019 ECM Terminals and Reference Value ...................1019 On Board Diagnosis Logic.....................................1019 DTC Confirmation Procedure ................................1020 Overall Function Check .........................................1020 Wiring Diagram ......................................................1021 Diagnostic Procedure ............................................1022

EC-9

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CONTENTS DTC P0605 ECM .......................................................1024 Component Description .........................................1024 On Board Diagnosis Logic.....................................1024 DTC Confirmation Procedure ................................1024 Diagnostic Procedure ............................................1025 DTC P1143, P1163 HO2S1 .......................................1026 Component Description .........................................1026 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1026 ECM Terminals and Reference Value ...................1026 On Board Diagnosis Logic.....................................1027 DTC Confirmation Procedure ................................1028 Overall Function Check .........................................1029 Diagnostic Procedure ............................................1029 DTC P1144, P1164 HO2S1 .......................................1035 Component Description .........................................1035 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1035 ECM Terminals and Reference Value ...................1035 On Board Diagnosis Logic.....................................1036 DTC Confirmation Procedure ................................1037 Overall Function Check .........................................1038 Diagnostic Procedure ............................................1038 DTC P1146, P1166 HO2S2 .......................................1044 Component Description .........................................1044 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1044 ECM Terminals and Reference Value ...................1044 On Board Diagnosis Logic.....................................1044 DTC Confirmation Procedure ................................1045 Overall Function Check .........................................1046 Wiring Diagram ......................................................1047 Diagnostic Procedure ............................................1049 DTC P1147, P1167 HO2S2 .......................................1054 Component Description .........................................1054 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1054 ECM Terminals and Reference Value ...................1054 On Board Diagnosis Logic.....................................1054 DTC Confirmation Procedure ................................1055 Overall Function Check .........................................1056 Wiring Diagram ......................................................1057 Diagnostic Procedure ............................................1059 DTC P1148, P1168 CLOSED LOOP CONTROL......1064 On Board Diagnosis Logic.....................................1064 DTC Confirmation Procedure ................................1064 Overall Function Check .........................................1065 Diagnostic Procedure ............................................1065 DTC P1217 ENGINE OVER TEMPERATURE..........1066 On Board Diagnosis Logic.....................................1066 Overall Function Check .........................................1066 Diagnostic Procedure ............................................1067

(Cont’d)

Main 12 Causes of Overheating............................1070 DTC P1336 CKP SENSOR (OBD)............................1071 Component Description .........................................1071 ECM Terminals and Reference Value ...................1071 On Board Diagnosis Logic.....................................1072 DTC Confirmation Procedure ................................1072 Wiring Diagram ......................................................1073 Diagnostic Procedure ............................................1074 DTC P1442 EVAP CONTROL SYSTEM...................1078 On Board Diagnosis Logic.....................................1078 DTC Confirmation Procedure ................................1079 Diagnostic Procedure ............................................1079 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE.................................1080 Description .............................................................1080 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1080 ECM Terminals and Reference Value ...................1081 On Board Diagnosis Logic.....................................1081 DTC Confirmation Procedure ................................1082 Wiring Diagram ......................................................1083 Diagnostic Procedure ............................................1084 DTC P1446 EVAP CANISTER VENT CONTROL VALVE........................................................................1092 Component Description .........................................1092 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1092 ECM Terminals and Reference Value ...................1092 On Board Diagnosis Logic.....................................1093 DTC Confirmation Procedure ................................1093 Wiring Diagram ......................................................1094 Diagnostic Procedure ............................................1095 DTC P1448 EVAP CANISTER VENT CONTROL VALVE........................................................................1099 Component Description .........................................1099 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1099 ECM Terminals and Reference Value ...................1099 On Board Diagnosis Logic.....................................1099 DTC Confirmation Procedure ................................1100 Overall Function Check .........................................1101 Wiring Diagram ......................................................1102 Diagnostic Procedure ............................................1103 DTC P1464 FUEL LEVEL SENSOR.........................1107 Component Description .........................................1107 ECM Terminals and Reference Value ...................1107 On Board Diagnosis Logic.....................................1107 DTC Confirmation Procedure ................................1107 Wiring Diagram ......................................................1109 Diagnostic Procedure ............................................ 1110 DTC P1490 VACUUM CUT VALVE BYPASS VALVE........................................................................ 1111

EC-10

CONTENTS Description ............................................................. 1111 CONSULT-II Reference Value in Data Monitor Mode ...................................................................... 1111 ECM Terminals and Reference Value ................... 1111 On Board Diagnosis Logic..................................... 1112 DTC Confirmation Procedure ................................ 1112 Wiring Diagram ...................................................... 1113 Diagnostic Procedure ............................................ 1114 DTC P1491 VACUUM CUT VALVE BYPASS VALVE........................................................................ 1117 Description ............................................................. 1117 CONSULT-II Reference Value in Data Monitor Mode ...................................................................... 1117 ECM Terminals and Reference Value ................... 1117 On Board Diagnosis Logic..................................... 1118 DTC Confirmation Procedure ................................ 1118 Overall Function Check ......................................... 1119 Wiring Diagram ......................................................1120 Diagnostic Procedure ............................................1121 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE ...........................................................................1126 Component Description .........................................1126 ECM Terminals and Reference Value ...................1126 On Board Diagnosis Logic.....................................1126 DTC Confirmation Procedure ................................1126 Wiring Diagram ......................................................1127 Diagnostic Procedure ............................................1128 DTC P1706 PNP SWITCH.........................................1129 Component Description .........................................1129 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1129 ECM Terminals and Reference Value ...................1129 On Board Diagnosis Logic.....................................1129 DTC Confirmation Procedure ................................1130 Overall Function Check .........................................1131 Wiring Diagram ......................................................1132 Diagnostic Procedure ............................................1133 IGNITION SIGNAL.....................................................1138 Component Description .........................................1138 ECM Terminals and Reference Value ...................1138 Wiring Diagram ......................................................1139 Diagnostic Procedure ............................................1140 INJECTOR .................................................................1144 Component Description .........................................1144 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1144 ECM Terminals and Reference Value ...................1144 Wiring Diagram ......................................................1145 Diagnostic Procedure ............................................1146 START SIGNAL.........................................................1149 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1149

(Cont’d)

ECM Terminals and Reference Value ...................1149 Wiring Diagram ......................................................1150 Diagnostic Procedure ............................................1151 FUEL PUMP...............................................................1153 System Description................................................1153 Component Description .........................................1153 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1153 ECM Terminals and Reference Value ...................1154 Wiring Diagram ......................................................1155 Diagnostic Procedure ............................................1156 POWER STEERING OIL PRESSURE SWITCH.......1160 Component Description .........................................1160 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1160 ECM Terminals and Reference Value ...................1160 Wiring Diagram ......................................................1161 Diagnostic Procedure ............................................1162 IACV-FICD SOLENOID VALVE.................................1165 Component Description .........................................1165 ECM Terminals and Reference Value ...................1165 Wiring Diagram ......................................................1166 Diagnostic Procedure ............................................1167 MIL & DATA LINK CONNECTORS ..........................1171 Wiring Diagram ......................................................1171 SERVICE DATA AND SPECIFICATIONS (SDS) .....1172 Fuel Pressure Regulator........................................1172 Idle Speed and Ignition Timing..............................1172 Ignition Coil ............................................................1172 Mass Air Flow Sensor............................................1172 Engine Coolant Temperature Sensor ....................1172 Heated Oxygen Sensor 1 Heater ..........................1172 Fuel Pump .............................................................1172 IACV-AAC Valve ....................................................1172 Injector ...................................................................1173 Throttle Position Sensor ........................................1173 Calculated Load Value...........................................1173 Intake Air Temperature Sensor..............................1173 Heated Oxygen Sensor 2 Heater ..........................1173 Crankshaft Position Sensor (OBD)........................1173 Fuel Tank Temperature Sensor .............................1173

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS

VG33ER TROUBLE DIAGNOSIS - INDEX ..............................1174 Alphabetical & P No. Index for DTC .....................1174 PRECAUTIONS .........................................................1182 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″.........1182 Precautions for On Board Diagnostic (OBD) System of Engine and A/T.....................................1182 Engine Fuel & Emission Control System ..............1183 Precautions ............................................................1184

EC-11

BT HA SC EL IDX

CONTENTS Wiring Diagrams and Trouble Diagnosis...............1185 PREPARATION .........................................................1186 Special Service Tools ............................................1186 Commercial Service Tools .....................................1186 ENGINE AND EMISSION CONTROL OVERALL SYSTEM.....................................................................1189 Engine Control Component Parts Location...........1189 Circuit Diagram ......................................................1191 System Diagram ....................................................1192 Vacuum Hose Drawing ..........................................1193 System Chart .........................................................1194 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ...........................................1195 Multiport Fuel Injection (MFI) System ...................1195 Distributor Ignition (DI) System .............................1197 Air Conditioning Cut Control..................................1198 Fuel Cut Control (at no load & high engine speed) ....................................................................1199 Evaporative Emission System ...............................1199 On Board Refueling Vapor Recovery (ORVR) ......1205 Positive Crankcase Ventilation ..............................1215 BASIC SERVICE PROCEDURE ...............................1217 Fuel Pressure Release ..........................................1217 Fuel Pressure Check .............................................1217 Fuel Pressure Regulator Check ............................1218 Injector ...................................................................1218 Fast Idle Cam (FIC)...............................................1219 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment .............................................................1220 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...........................................................1232 Introduction ............................................................1232 Two Trip Detection Logic .......................................1232 Emission-related Diagnostic Information ...............1233 Malfunction Indicator Lamp (MIL)..........................1247 OBD System Operation Chart ...............................1248 CONSULT-II ...........................................................1254 Generic Scan Tool (GST) ......................................1267 TROUBLE DIAGNOSIS - INTRODUCTION..............1269 Introduction ............................................................1269 Work Flow..............................................................1271 TROUBLE DIAGNOSIS - BASIC INSPECTION .......1273 Basic Inspection.....................................................1273 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...........................................................1288 DTC Inspection Priority Chart................................1288 Fail-safe Chart .......................................................1289 Symptom Matrix Chart...........................................1290 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1294 Major Sensor Reference Graph in Data Monitor Mode ......................................................................1296

(Cont’d)

ECM Terminals and Reference Value ...................1299 TROUBLE DIAGNOSIS - SPECIFICATION VALUE........................................................................1308 Description .............................................................1308 Testing Condition ...................................................1308 Inspection Procedure.............................................1308 Diagnostic Procedure ............................................1309 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT...................................................................1312 Description .............................................................1312 Diagnostic Procedure ............................................1312 TROUBLE DIAGNOSIS FOR POWER SUPPLY......1313 Main Power Supply and Ground Circuit................1313 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER.....................................................................1319 Description .............................................................1319 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1319 ECM Terminals and Reference Value ...................1319 On Board Diagnosis Logic.....................................1319 DTC Confirmation Procedure ................................1320 Wiring Diagram ......................................................1321 Diagnostic Procedure ............................................1323 DTC P0037, P0038, P0057, P0058 HO2S2 HEATER.....................................................................1326 Description .............................................................1326 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1326 ECM Terminals and Reference Value ...................1326 On Board Diagnosis Logic.....................................1327 DTC Confirmation Procedure ................................1327 Wiring Diagram ......................................................1328 Diagnostic Procedure ............................................1330 DTC P0101, P0102, P0103 MAF SENSOR ..............1334 Component Description .........................................1334 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1334 ECM Terminals and Reference Value ...................1334 On Board Diagnosis Logic.....................................1334 DTC Confirmation Procedure ................................1335 Overall Function Check .........................................1337 Wiring Diagram ......................................................1338 Diagnostic Procedure ............................................1339 DTC P0112, P0113, P0127 IAT SENSOR.................1343 Component Description .........................................1343 On Board Diagnosis Logic.....................................1343 DTC Confirmation Procedure ................................1343 Wiring Diagram ......................................................1345 Diagnostic Procedure ............................................1346 DTC P0117, P0118 ECT SENSOR............................1348 Component Description .........................................1348 On Board Diagnosis Logic.....................................1348

EC-12

CONTENTS DTC Confirmation Procedure ................................1349 Wiring Diagram ......................................................1350 Diagnostic Procedure ............................................1351 DTC P0121, P0122, P0123 TP SENSOR .................1353 Description .............................................................1353 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1353 ECM Terminals and Reference Value ...................1354 On Board Diagnosis Logic.....................................1354 DTC Confirmation Procedure ................................1355 Wiring Diagram ......................................................1358 Diagnostic Procedure ............................................1359 DTC P0125 ECT SENSOR........................................1366 Description .............................................................1366 On Board Diagnosis Logic.....................................1366 DTC Confirmation Procedure ................................1367 Wiring Diagram ......................................................1368 Diagnostic Procedure ............................................1369 DTC P0128 THERMOSTAT FUNCTION...................1372 On Board Diagnosis Logic.....................................1372 DTC Confirmation Procedure ................................1372 Diagnostic Procedure ............................................1373 DTC P0132, P0152 HO2S1 .......................................1374 Component Description .........................................1374 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1374 ECM Terminals and Reference Value ...................1374 On Board Diagnosis Logic.....................................1375 DTC Confirmation Procedure ................................1375 Wiring Diagram ......................................................1376 Diagnostic Procedure ............................................1378 DTC P0133, P0153 HO2S1 .......................................1382 Component Description .........................................1382 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1382 ECM Terminals and Reference Value ...................1382 On Board Diagnosis Logic.....................................1383 DTC Confirmation Procedure ................................1383 Overall Function Check .........................................1384 Wiring Diagram ......................................................1385 Diagnostic Procedure ............................................1387 DTC P0134, P0154 HO2S1 .......................................1396 Component Description .........................................1396 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1396 ECM Terminals and Reference Value ...................1396 On Board Diagnosis Logic.....................................1397 DTC Confirmation Procedure ................................1398 Overall Function Check .........................................1399 Wiring Diagram ......................................................1400 Diagnostic Procedure ............................................1402 DTC P0138, P0158 HO2S2 .......................................1407

(Cont’d)

Component Description .........................................1407 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1407 ECM Terminals and Reference Value ...................1407 On Board Diagnosis Logic.....................................1407 DTC Confirmation Procedure ................................1408 Overall Function Check .........................................1408 Wiring Diagram ......................................................1410 Diagnostic Procedure ............................................1412 DTC P0139, P0159 HO2S2 .......................................1417 Component Description .........................................1417 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1417 ECM Terminals and Reference Value ...................1417 On Board Diagnosis Logic.....................................1417 DTC Confirmation Procedure ................................1418 Overall Function Check .........................................1419 Wiring Diagram ......................................................1420 Diagnostic Procedure ............................................1422 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION .................................................................1427 On Board Diagnosis Logic.....................................1427 DTC Confirmation Procedure ................................1428 Wiring Diagram ......................................................1429 Diagnostic Procedure ............................................1431 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION .................................................................1436 On Board Diagnosis Logic.....................................1436 DTC Confirmation Procedure ................................1437 Wiring Diagram ......................................................1438 Diagnostic Procedure ............................................1440 DTC P0181, P0182, P0183 FTT SENSOR ...............1444 Component Description .........................................1444 On Board Diagnosis Logic.....................................1444 DTC Confirmation Procedure ................................1445 Wiring Diagram ......................................................1446 Diagnostic Procedure ............................................1447 DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION...................................1449 On Board Diagnosis Logic.....................................1449 Possible Cause......................................................1449 Overall Function Check .........................................1450 Diagnostic Procedure ............................................1452 Main 12 Causes of Overheating............................1455 DTC P0245 SCB VALVE CONTROL SOLENOID VALVE........................................................................1456 Description .............................................................1456 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1457 ECM Terminals and Reference Value ...................1457 On Board Diagnosis Logic.....................................1457 DTC Confirmation Procedure ................................1458

EC-13

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FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS Wiring Diagram ......................................................1459 Diagnostic Procedure ............................................1460 DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE .............1462 On Board Diagnosis Logic.....................................1462 DTC Confirmation Procedure ................................1463 Diagnostic Procedure ............................................1463 DTC P0327, P0328 KS..............................................1471 Component Description .........................................1471 ECM Terminals and Reference Value ...................1471 On Board Diagnosis Logic.....................................1471 DTC Confirmation Procedure ................................1471 Wiring Diagram ......................................................1472 Diagnostic Procedure ............................................1473 DTC P0335 CKP SENSOR (OBD)............................1475 Component Description .........................................1475 ECM Terminals and Reference Value ...................1475 On Board Diagnosis Logic.....................................1476 DTC Confirmation Procedure ................................1476 Wiring Diagram ......................................................1477 Diagnostic Procedure ............................................1478 DTC P0340 CMP SENSOR .......................................1481 Component Description .........................................1481 ECM Terminals and Reference Value ...................1481 On Board Diagnosis Logic.....................................1482 DTC Confirmation Procedure ................................1483 Wiring Diagram ......................................................1484 Diagnostic Procedure ............................................1485 DTC P0420, P0430 THREE WAY CATALYST FUNCTION .................................................................1488 On Board Diagnosis Logic.....................................1488 DTC Confirmation Procedure ................................1488 Overall Function Check .........................................1489 Diagnostic Procedure ............................................1490 DTC P0441 EVAP CONTROL SYSTEM...................1493 System Description................................................1493 On Board Diagnosis Logic.....................................1493 DTC Confirmation Procedure ................................1494 Overall Function Check .........................................1495 Diagnostic Procedure ............................................1496 DTC P0442 EVAP CONTROL SYSTEM...................1505 On Board Diagnosis Logic.....................................1505 DTC Confirmation Procedure ................................1507 Diagnostic Procedure ............................................1508 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE ................1519 Description .............................................................1519 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1519 ECM Terminals and Reference Value ...................1520 On Board Diagnosis Logic.....................................1521 DTC Confirmation Procedure ................................1521

(Cont’d)

Wiring Diagram ......................................................1522 Diagnostic Procedure ............................................1523 DTC P0447 EVAP CANISTER VENT CONTROL VALVE........................................................................1526 Component Description .........................................1526 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1526 ECM Terminals and Reference Value ...................1526 On Board Diagnosis Logic.....................................1527 DTC Confirmation Procedure ................................1527 Wiring Diagram ......................................................1528 Diagnostic Procedure ............................................1529 DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR ...............................................1532 Component Description .........................................1532 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1532 ECM Terminals and Reference Value ...................1532 On Board Diagnosis Logic.....................................1533 DTC Confirmation Procedure ................................1533 Wiring Diagram ......................................................1534 Diagnostic Procedure ............................................1535 Component Inspection...........................................1541 DTC P0455 EVAP CONTROL SYSTEM...................1543 On Board Diagnosis Logic.....................................1543 DTC Confirmation Procedure ................................1544 Diagnostic Procedure ............................................1546 DTC P0456, P1456 EVAP CONTROL SYSTEM ......1556 On Board Diagnosis Logic.....................................1556 DTC Confirmation Procedure ................................1557 Overall Function Check .........................................1558 Diagnostic Procedure ............................................1559 DTC P0460 FUEL LEVEL SENSOR.........................1570 Component Description .........................................1570 ECM Terminals and Reference Value ...................1570 On Board Diagnosis Logic.....................................1570 DTC Confirmation Procedure ................................1571 Wiring Diagram ......................................................1572 Diagnostic Procedure ............................................1573 DTC P0461 FUEL LEVEL SENSOR.........................1575 Component Description .........................................1575 On Board Diagnosis Logic.....................................1575 Overall Function Check .........................................1575 DTC P0462, P0463 FUEL LEVEL SENSOR ............1577 Component Description .........................................1577 ECM Terminals and Reference Value ...................1577 On Board Diagnosis Logic.....................................1577 DTC Confirmation Procedure ................................1578 Wiring Diagram ......................................................1579 Diagnostic Procedure ............................................1580 DTC P0500 VSS ........................................................1582 Component Description .........................................1582

EC-14

CONTENTS ECM Terminals and Reference Value ...................1582 On Board Diagnosis Logic.....................................1582 DTC Confirmation Procedure ................................1582 Overall Function Check .........................................1583 Wiring Diagram ......................................................1584 Diagnostic Procedure ............................................1585 DTC P0505 ISC SYSTEM .........................................1586 Description .............................................................1586 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1587 ECM Terminals and Reference Value ...................1587 On Board Diagnosis Logic.....................................1587 DTC Confirmation Procedure ................................1588 Wiring Diagram ......................................................1589 Diagnostic Procedure ............................................1590 DTC P0510 CTP SWITCH.........................................1592 Component Description .........................................1592 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1592 ECM Terminals and Reference Value ...................1592 On Board Diagnosis Logic.....................................1592 DTC Confirmation Procedure ................................1593 Overall Function Check .........................................1593 Wiring Diagram ......................................................1594 Diagnostic Procedure ............................................1595 DTC P0600 A/T CONTROL.......................................1599 System Description................................................1599 ECM Terminals and Reference Value ...................1599 On Board Diagnosis Logic.....................................1599 DTC Confirmation Procedure ................................1600 Wiring Diagram ......................................................1601 Diagnostic Procedure ............................................1602 DTC P0605 ECM .......................................................1604 Component Description .........................................1604 On Board Diagnosis Logic.....................................1604 DTC Confirmation Procedure ................................1604 Diagnostic Procedure ............................................1605 DTC P1143, P1163 HO2S1 .......................................1606 Component Description .........................................1606 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1606 ECM Terminals and Reference Value ...................1606 On Board Diagnosis Logic.....................................1607 DTC Confirmation Procedure ................................1608 Overall Function Check .........................................1609 Diagnostic Procedure ............................................1609 DTC P1144, P1164 HO2S1 .......................................1615 Component Description .........................................1615 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1615 ECM Terminals and Reference Value ...................1615 On Board Diagnosis Logic.....................................1616

(Cont’d)

DTC Confirmation Procedure ................................1617 Overall Function Check .........................................1618 Diagnostic Procedure ............................................1618 DTC P1146, P1166 HO2S2 .......................................1624 Component Description .........................................1624 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1624 ECM Terminals and Reference Value ...................1624 On Board Diagnosis Logic.....................................1624 DTC Confirmation Procedure ................................1625 Overall Function Check .........................................1626 Wiring Diagram ......................................................1627 Diagnostic Procedure ............................................1629 DTC P1147, P1167 HO2S2 .......................................1634 Component Description .........................................1634 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1634 ECM Terminals and Reference Value ...................1634 On Board Diagnosis Logic.....................................1634 DTC Confirmation Procedure ................................1635 Overall Function Check .........................................1636 Wiring Diagram ......................................................1637 Diagnostic Procedure ............................................1639 DTC P1148, P1168 CLOSED LOOP CONTROL......1644 On Board Diagnosis Logic.....................................1644 DTC Confirmation Procedure ................................1644 Overall Function Check .........................................1645 Diagnostic Procedure ............................................1645 DTC P1217 ENGINE OVER TEMPERATURE..........1646 On Board Diagnosis Logic.....................................1646 Overall Function Check .........................................1646 Diagnostic Procedure ............................................1647 Main 12 Causes of Overheating............................1650 DTC P1336 CKP SENSOR (OBD)............................1651 Component Description .........................................1651 ECM Terminals and Reference Value ...................1651 On Board Diagnosis Logic.....................................1652 DTC Confirmation Procedure ................................1652 Wiring Diagram ......................................................1653 Diagnostic Procedure ............................................1654 DTC P1442 EVAP CONTROL SYSTEM...................1658 On Board Diagnosis Logic.....................................1658 DTC Confirmation Procedure ................................1659 Diagnostic Procedure ............................................1659 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE.................................1660 Description .............................................................1660 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1660 ECM Terminals and Reference Value ...................1661 On Board Diagnosis Logic.....................................1661 DTC Confirmation Procedure ................................1662

EC-15

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FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS Wiring Diagram ......................................................1663 Diagnostic Procedure ............................................1664 DTC P1446 EVAP CANISTER VENT CONTROL VALVE........................................................................1672 Component Description .........................................1672 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1672 ECM Terminals and Reference Value ...................1672 On Board Diagnosis Logic.....................................1673 DTC Confirmation Procedure ................................1673 Wiring Diagram ......................................................1674 Diagnostic Procedure ............................................1675 DTC P1448 EVAP CANISTER VENT CONTROL VALVE........................................................................1679 Component Description .........................................1679 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1679 ECM Terminals and Reference Value ...................1679 On Board Diagnosis Logic.....................................1679 DTC Confirmation Procedure ................................1680 Overall Function Check .........................................1681 Wiring Diagram ......................................................1682 Diagnostic Procedure ............................................1683 DTC P1464 FUEL LEVEL SENSOR.........................1687 Component Description .........................................1687 ECM Terminals and Reference Value ...................1687 On Board Diagnosis Logic.....................................1687 DTC Confirmation Procedure ................................1687 Wiring Diagram ......................................................1689 Diagnostic Procedure ............................................1690 DTC P1490 VACUUM CUT VALVE BYPASS VALVE........................................................................1691 Description .............................................................1691 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1691 ECM Terminals and Reference Value ...................1691 On Board Diagnosis Logic.....................................1692 DTC Confirmation Procedure ................................1692 Wiring Diagram ......................................................1693 Diagnostic Procedure ............................................1694 DTC P1491 VACUUM CUT VALVE BYPASS VALVE........................................................................1697 Description .............................................................1697 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1697 ECM Terminals and Reference Value ...................1697 On Board Diagnosis Logic.....................................1698 DTC Confirmation Procedure ................................1698 Overall Function Check .........................................1699 Wiring Diagram ......................................................1700 Diagnostic Procedure ............................................1701

(Cont’d)

DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE ...........................................................................1706 Component Description .........................................1706 ECM Terminals and Reference Value ...................1706 On Board Diagnosis Logic.....................................1706 DTC Confirmation Procedure ................................1706 Wiring Diagram ......................................................1707 Diagnostic Procedure ............................................1708 DTC P1706 PNP SWITCH.........................................1709 Component Description .........................................1709 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1709 ECM Terminals and Reference Value ...................1709 On Board Diagnosis Logic.....................................1709 DTC Confirmation Procedure ................................1710 Overall Function Check .........................................1711 Wiring Diagram ......................................................1712 Diagnostic Procedure ............................................1713 IGNITION SIGNAL.....................................................1718 Component Description .........................................1718 ECM Terminals and Reference Value ...................1718 Wiring Diagram ......................................................1719 Diagnostic Procedure ............................................1720 INJECTOR .................................................................1724 Component Description .........................................1724 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1724 ECM Terminals and Reference Value ...................1724 Wiring Diagram ......................................................1725 Diagnostic Procedure ............................................1726 START SIGNAL.........................................................1729 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1729 ECM Terminals and Reference Value ...................1729 Wiring Diagram ......................................................1730 Diagnostic Procedure ............................................1731 FUEL PUMP...............................................................1733 System Description................................................1733 Component Description .........................................1733 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1733 ECM Terminals and Reference Value ...................1734 Wiring Diagram ......................................................1735 Diagnostic Procedure ............................................1736 POWER STEERING OIL PRESSURE SWITCH.......1740 Component Description .........................................1740 CONSULT-II Reference Value in Data Monitor Mode ......................................................................1740 ECM Terminals and Reference Value ...................1740 Wiring Diagram ......................................................1741 Diagnostic Procedure ............................................1742 IACV-FICD SOLENOID VALVE.................................1745

EC-16

CONTENTS Component Description .........................................1745 ECM Terminals and Reference Value ...................1745 Wiring Diagram ......................................................1746 Diagnostic Procedure ............................................1747 MIL & DATA LINK CONNECTORS ..........................1751 Wiring Diagram ......................................................1751 SERVICE DATA AND SPECIFICATIONS (SDS) .....1752 Fuel Pressure Regulator........................................1752 Idle Speed and Ignition Timing..............................1752 Ignition Coil ............................................................1752 Mass Air Flow Sensor............................................1752

(Cont’d)

Engine Coolant Temperature Sensor ....................1752 Heated Oxygen Sensor 1 Heater ..........................1752 Fuel Pump .............................................................1752 IACV-AAC Valve ....................................................1752 Injector ...................................................................1753 Throttle Position Sensor ........................................1753 Calculated Load Value...........................................1753 Intake Air Temperature Sensor..............................1753 Heated Oxygen Sensor 2 Heater ..........................1753 Crankshaft Position Sensor (OBD)........................1753 Fuel Tank Temperature Sensor .............................1753

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-17

IDX

TROUBLE DIAGNOSIS — INDEX

KA24DE

Alphabetical & P No. Index for DTC

Alphabetical & P No. Index for DTC ALPHABETICAL INDEX FOR DTC

NGEC0001 NGEC0001S01

DTC*1*2 Items (CONSULT-II screen terms)

CONSULT-II GST

Reference page

Unable to access ECM

—

EC-127

ABSL PRES SEN/CIRC

P0107

EC-178

ABSL PRES SEN/CIRC

P0108

EC-178

CKP SEN/CIRCUIT

P0335

EC-294

CKP SENSOR (COG)

P1336

EC-490

CLOSED LOOP-B1

P1148

EC-483

CLOSED TP SW/CIRC

P0510

EC-440

CMP SEN/CIRCUIT

P0340

EC-300

CYL1 MISFIRE

P0301

EC-281

CYL2 MISFIRE

P0302

EC-281

CYL3 MISFIRE

P0303

EC-281

CYL4 MISFIRE

P0304

EC-281

ECM

P0605

EC-447

ECT SEN/CIRCUIT

P0117*3

EC-185

ECT SEN/CIRCUIT

P0118*3

EC-185

ECT SENSOR

P0125

EC-204

EGR SYSTEM

P0400

EC-308

EGR SYSTEM

P1402

EC-503

EGR TEMP SEN/CIRC

P0405

EC-328

EGR TEMP SEN/CIRC

P0406

EC-328

EGRC-BPT VALVE

P0402

EC-320

EGRC SOLENOID/V

P1400

EC-496

ENG OVER TEMP

P0217

EC-275

ENG OVER TEMP

P1217

EC-485

EVAP GROSS LEAK

P0455

EC-393

EVAP PURG FLOW/MON

P0441

EC-339

EVAP SMALL LEAK

P0442

EC-350

EVAP SYS PRES SEN

P0452

EC-380

EVAP SYS PRES SEN

P0453

EC-380

EVAP VERY SML LEAK

P0456

EC-405

EVAP VERY SML LEAK

P1456

EC-405

FTT SEN/CIRCUIT

P0182

EC-269

FTT SEN/CIRCUIT

P0183

EC-269

FTT SENSOR

P0181

EC-269

EC-18

TROUBLE DIAGNOSIS — INDEX

KA24DE

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2 Items (CONSULT-II screen terms)

CONSULT-II GST

Reference page

FUEL LEV SEN SLOSH

P0460

EC-420

FUEL LEVEL SEN/CIRC

P1464

EC-536

FUEL LEVEL SENSOR

P0461

EC-424

FUEL LEVL SEN/CIRC

P0462

EC-426

FUEL LEVL SEN/CIRC

P0463

EC-426

FUEL SYS-LEAN-B1

P0171

EC-255

FUEL SYS-RICH-B1

P0172

EC-262

HO2S1 (B1)

P0132

EC-211

HO2S1 (B1)

P0133

EC-218

HO2S1 (B1)

P0134

EC-229

HO2S1 (B1)

P1143

EC-449

HO2S1 (B1)

P1144

EC-456

HO2S1 HTR (B1)

P0031

EC-158

HO2S1 HTR (B1)

P0032

EC-158

HO2S2 HTR (B1)

P0037

EC-163

HO2S2 HTR (B1)

P0038

EC-163

HO2S2 (B1)

P0138

EC-237

HO2S2 (B1)

P0139

EC-245

HO2S2 (B1)

P1146

EC-463

HO2S2 (B1)

P1147

EC-473

IAT SEN/CIRCUIT

P0112*3

EC-180

IAT SEN/CIRCUIT

P0113*3

EC-180

IAT SENSOR

P0127

EC-180

ISC SYSTEM/CIRC

P0505

EC-434

KNOCK SEN/CIRC-B1

P0327

EC-290

KNOCK SEN/CIRC-B1

P0328

EC-290

MAF SEN/CIRCUIT

P0101

EC-168

MAF SEN/CIRCUIT

P0102*3

EC-168

MAF SEN/CIRCUIT

P0103*3

EC-168

MULTI CYL MISFIRE

P0300

EC-281

BT

NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED.

P0000

—

HA

P-N POS SW/CIRCUIT

P1706

EC-556

PURG VOLUME CONT/V

P0444

EC-366

PURG VOLUME CONT/V

P0445

EC-366

PURG VOLUME CONT/V

P1444

EC-512

EC-19

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS

SC EL IDX

TROUBLE DIAGNOSIS — INDEX

KA24DE

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2 Items (CONSULT-II screen terms)

CONSULT-II GST

Reference page

THERMSTAT FNCTN

P0128

EC-209

TP SEN/CIRCUIT

P0121

EC-190

TP SEN/CIRCUIT

P0122*3

EC-190

TP SEN/CIRCUIT

P0123*3

EC-190

TW CATALYST SYS-B1

P0420

EC-334

VC CUT/V BYPASS/V

P1491

EC-546

VC/V BYPASS/V

P1490

EC-539

VEH SPEED SEN/CIRC

P0500

EC-430

VENT CONTROL VALVE

P0447

EC-373

VENT CONTROL VALVE

P1446

EC-523

VENT CONTROL VALVE

P1448

EC-529

*1: 1st trip DTC No. is the same as DTC No. *2: These numbers are prescribed by SAE J2012. *3: When the fail-safe operation occurs, the MIL illuminates.

P NO. INDEX FOR DTC

NGEC0001S02

DTC*1*2 CONSULT-II GST —

Items (CONSULT-II screen terms) Unable to access ECM

Reference page

EC-127

P0000

NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED.

P0031

HO2S1 HTR (B1)

EC-158

P0032

HO2S1 HTR (B1)

EC-158

P0037

HO2S2 HTR (B1)

EC-163

P0038

HO2S2 HTR (B1)

EC-163

P0101

MAF SEN/CIRCUIT

EC-168

P0102*3

MAF SEN/CIRCUIT

EC-168

P0103*3

MAF SEN/CIRCUIT

EC-168

P0107

ABSL PRES SEN/CIRC

EC-178

P0108

ABSL PRES SEN/CIRC

EC-178

P0112*3

IAT SEN/CIRCUIT

EC-180

P0113*3

IAT SEN/CIRCUIT

EC-180

P0117*3

ECT SEN/CIRCUIT

EC-185

P0118*3

ECT SEN/CIRCUIT

EC-185

P0121

TP SEN/CIRCUIT

EC-190

P0122*3

TP SEN/CIRCUIT

EC-190

P0123*3

TP SEN/CIRCUIT

EC-190

—

EC-20

TROUBLE DIAGNOSIS — INDEX

KA24DE

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2 Items (CONSULT-II screen terms)

CONSULT-II GST

Reference page

P0125

ECT SENSOR

EC-204

P0127

IAT SENSOR

EC-180

P0128

THERMSTAT FNCTN

EC-209

P0132

HO2S1 (B1)

EC-211

P0133

HO2S1 (B1)

EC-218

P0134

HO2S1 (B1)

EC-229

P0138

HO2S2 (B1)

EC-237

P0139

HO2S2 (B1)

EC-245

P0171

FUEL SYS-LEAN-B1

EC-255

P0172

FUEL SYS-RICH-B1

EC-262

P0181

FTT SENSOR

EC-269

P0182

FTT SEN/CIRCUIT

EC-269

P0183

FTT SEN/CIRCUIT

EC-269

P0217

ENG OVER TEMP

EC-275

P0300

MULTI CYL MISFIRE

EC-281

P0301

CYL1 MISFIRE

EC-281

P0302

CYL2 MISFIRE

EC-281

P0303

CYL3 MISFIRE

EC-281

P0304

CYL4 MISFIRE

EC-281

P0327

KNOCK SEN/CIRC-B1

EC-290

P0328

KNOCK SEN/CIRC-B1

EC-290

P0335

CKP SEN/CIRCUIT

EC-294

P0340

CMP SEN/CIRCUIT

EC-300

P0400

EGR SYSTEM

EC-308

P0402

EGRC-BPT VALVE

EC-320

P0405

EGR TEMP SEN/CIRC

EC-328

P0406

EGR TEMP SEN/CIRC

EC-328

P0420

TW CATALYST SYS-B1

EC-334

P0441

EVAP PURG FLOW/MON

EC-339

P0442

EVAP SMALL LEAK

EC-350

P0444

PURG VOLUME CONT/V

EC-366

P0445

PURG VOLUME CONT/V

EC-366

P0447

VENT CONTROL VALVE

EC-373

P0452

EVAP SYS PRES SEN

EC-380

P0453

EVAP SYS PRES SEN

EC-380

P0455

EVAP GROSS LEAK

EC-393

EC-21

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — INDEX

KA24DE

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2 Items (CONSULT-II screen terms)

CONSULT-II GST

Reference page

P0456

EVAP VERY SML LEAK

EC-405

P0460

FUEL LEV SEN SLOSH

EC-420

P0461

FUEL LEVEL SENSOR

EC-424

P0462

FUEL LEVL SEN/CIRC

EC-426

P0463

FUEL LEVL SEN/CIRC

EC-426

P0500

VEH SPEED SEN/CIRC

EC-430

P0505

ISC SYSTEM/CIRC

EC-434

P0510

CLOSED TP SW/CIRC

EC-440

P0605

ECM

EC-447

P1143

HO2S1 (B1)

EC-449

P1144

HO2S1 (B1)

EC-456

P1146

HO2S2 (B1)

EC-463

P1147

HO2S2 (B1)

EC-473

P1148

CLOSED LOOP-B1

EC-483

P1217

ENG OVER TEMP

EC-485

P1336

CKP SENSOR (COG)

EC-490

P1400

EGRC SOLENOID/V

EC-496

P1402

EGR SYSTEM

EC-503

P1444

PURG VOLUME CONT/V

EC-512

P1446

VENT CONTROL VALVE

EC-523

P1448

VENT CONTROL VALVE

EC-529

P1456

EVAP VERY SML LEAK

EC-405

P1464

FUEL LEVEL SEN/CIRC

EC-536

P1490

VC/V BYPASS/V

EC-539

P1491

VC CUT/V BYPASS/V

EC-546

P1706

P-N POS SW/CIRCUIT

EC-556

*1: 1st trip DTC No. is the same as DTC No. *2: These numbers are prescribed by SAE J2012. *3: When the fail-safe operation occurs, the MIL illuminates.

EC-22

PRECAUTIONS

KA24DE

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGEC0002

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: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

Precautions for On Board Diagnostic (OBD) System of Engine

NGEC0003

The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the driver of a malfunction causing emission deterioration. CAUTION: 쐌 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 MIL to light up. 쐌 Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MIL to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) 쐌 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 “Description”, “HARNESS CONNECTOR”, EL-7. 쐌 Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MIL to light up due to the short circuit. 쐌 Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MIL to light up due to the malfunction of the EGR system or fuel injection system, etc. 쐌 Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before returning the vehicle to the customer.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-23

IDX

PRECAUTIONS

KA24DE

Engine Fuel & Emission Control System

Engine Fuel & Emission Control System

NGEC0004

SEC744C

EC-24

PRECAUTIONS

KA24DE Precautions

Precautions 쐌

NGEC0005

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.

GI MA EM LC

SEF289H

쐌

When connecting ECM harness connector, tighten securing bolt until the gap between orange indicators disappears. : 3 - 5 N·m (0.3 - 0.5 kg-m, 26 - 43 in-lb)

FE CL MT

SEF308Q

쐌

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.

AT TF PD AX

SEF291H

쐌

Before replacing ECM, perform Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-137.

SU BR ST RS

MEF040D

쐌

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.

BT HA SC EL

SEF217U

EC-25

IDX

PRECAUTIONS

KA24DE

Precautions (Cont’d)

쐌

쐌

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 the ECM terminals, such as the ground.

SEF348N

Wiring Diagrams and Trouble Diagnosis

NGEC0006

When you read Wiring diagrams, refer to the following: 쐌 “HOW TO READ WIRING DIAGRAMS”, GI-10. 쐌 “POWER SUPPLY ROUTING”, EL-10. When you perform trouble diagnosis, refer to the following: 쐌 “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES” in GI-33. 쐌 “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”, GI-22.

EC-26

PREPARATION

KA24DE Special Service Tools

Special Service Tools

NGEC0007

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

GI

Description

MA Loosening or tightening heated oxygen sensor 1 with 22 mm (0.87 in) hexagon nut

KV10117100 (J36471-A) Heated oxygen sensor wrench

EM LC

NT379

Loosening or tightening heated oxygen sensor 2 a: 22 mm (0.87 in)

KV10114400 (J-38365) Heated oxygen sensor wrench

FE CL

NT636

(J-45178) TPS test connector

Used to test the throttle position sensor

MT AT TF

LEC120A

PD AX

Commercial Service Tools Tool name

NGEC0008

SU

Description

Fuel filler cap adapter

Checking fuel tank vacuum relief valve opening pressure

BR ST RS

NT653

Locating the EVAP leak

Leak detector (J41416)

BT HA SC EL

NT703

EC-27

IDX

PREPARATION

KA24DE

Commercial Service Tools (Cont’d) Tool name

Description

EVAP service port adapter (J41413-OBD)

Applying positive pressure through EVAP service port

NT704

Removing and installing engine coolant temperature sensor

Socket wrench

NT705

Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with anti-seize lubricant shown in “Commercial Service tools”. a: J-43897-18 18 mm diameter, for Zirconia Oxygen Sensor b: J-43897-12 12 mm diameter, for Titania Oxygen Sensor

Oxygen sensor thread cleaner (J-43897-18) (J-43897-12)

AEM488

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads.

Anti-seize lubricant (Permatex姟 133AR or equivalent meeting MIL specification MIL-A907)

AEM489

EC-28

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

KA24DE

Engine Control Component Parts Location

Engine Control Component Parts Location

NGEC0009

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEF711ZA

EC-29

EL IDX

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

KA24DE

Engine Control Component Parts Location (Cont’d)

WEC550

EC-30

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

KA24DE Circuit Diagram

Circuit Diagram

NGEC0010

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC961

EC-31

EL IDX

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

KA24DE

System Diagram

System Diagram

NGEC0011

SEF697ZA

EC-32

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

KA24DE

Vacuum Hose Drawing

Vacuum Hose Drawing

NGEC0012

Refer to “System Diagram” on EC-32 for vacuum control system.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC551

EC-33

IDX

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

KA24DE

System Chart

System Chart Input (Sensor) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

Camshaft position sensor Mass air flow sensor Engine coolant temperature sensor Heated oxygen sensor 1 Ignition switch Throttle position sensor PNP switch Air conditioner switch Knock sensor EGR temperature sensor*1 Crankshaft position sensor (OBD) EVAP control system pressure sensor*1 Fuel tank temperature sensor Battery voltage Power steering oil pressure switch Vehicle speed sensor Intake air temperature sensor Heated oxygen sensor 2*2 Closed throttle position switch*3

ECM Function

NGEC0013

Output (Actuator)

Fuel injection & mixture ratio control

Injectors

Distributor ignition system

Power transistor

Idle air control system

IACV-AAC valve and IACV-FICD solenoid valve

Fuel pump control

Fuel pump relay

Heated oxygen sensor 1 monitor & on board diagnostic system

Malfunction indicator lamp (On the instrument panel)

EGR control

EGRC-solenoid valve

Heated oxygen sensors 1, 2 heater control

Heated oxygen sensor heater

EVAP canister purge flow control

EVAP canister purge volume control solenoid valve

Air conditioning cut control

Air conditioner relay

ON BOARD DIAGNOSIS for EVAP system

쐌 EVAP canister vent control valve 쐌 Vacuum cut valve bypass valve

*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: This switch will operate in place of the throttle position sensor to control EVAP parts if the sensor malfunctions.

EC-34

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Multiport Fuel Injection (MFI) System

Multiport Fuel Injection (MFI) System DESCRIPTION Input/Output Signal Chart

NGEC0014

GI

NGEC0014S01

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

Density of oxygen in exhaust gas

Throttle position sensor

Throttle position Throttle valve idle position

PNP switch

Gear position

Vehicle speed sensor

Vehicle speed

Ignition switch

Start signal

Air conditioner switch

Air conditioner operation

Knock sensor

Engine knocking condition

Battery

Battery voltage

Power steering oil pressure switch

Power steering operation

Heated oxygen sensor 2*

Density of oxygen in exhaust gas

ECM function

MA

Actuator

EM LC

Fuel injection & mixture ratio control

FE

Injector

CL MT AT

* Under normal conditions, this sensor is not for engine control operation.

Basic Multiport Fuel Injection System

TF NGEC0014S02

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

NGEC0014S03

In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. 쐌 During warm-up 쐌 When starting the engine 쐌 During acceleration 쐌 Hot-engine operation 쐌 High-load, high-speed operation 쐌 During deceleration 쐌 During high engine speed operation

PD AX SU BR ST RS BT HA SC EL

EC-35

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Multiport Fuel Injection (MFI) System (Cont’d)

Mixture Ratio Feedback Control (Closed loop control)

NGEC0014S04

SEF336WB

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 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, refer to EC-229. This maintains the mixture ratio within the range of stoichiometric (ideal airfuel mixture). This stage is referred to as the closed loop control condition. Heated oxygen sensor 2 is located downstream of the three way catalyst. Even if the switching characteristics of the heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal from the heated oxygen sensor 2.

Open Loop Control

NGEC0014S05

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. 쐌 Deceleration and acceleration 쐌 High-load, high-speed operation 쐌 Malfunction of heated oxygen sensor 1 or its circuit 쐌 Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature 쐌 High engine coolant temperature 쐌 During warm-up 쐌 When starting the engine

Mixture Ratio Self-learning Control

NGEC0014S06

The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the heated oxygen sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot 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 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-36

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Multiport Fuel Injection (MFI) System (Cont’d)

Fuel Injection Timing

NGEC0014S07

GI MA EM LC SEF337W

Two types of systems are used. Sequential Multiport Fuel Injection System NGEC0014S0701 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 NGEC0014S0702 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

FE CL MT

NGEC0014S08

Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.

AT

Distributor Ignition (DI) System DESCRIPTION Input/Output Signal Chart Sensor

NGEC0015

TF

NGEC0015S01

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

Vehicle speed

Ignition switch

Start signal

Knock sensor

Engine knocking

PNP switch

Gear position

Battery

Battery voltage

ECM function

Actuator

PD AX SU

Ignition timPower transistor ing control

BR ST RS BT HA SC EL

EC-37

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Distributor Ignition (DI) System (Cont’d)

System Description

NGEC0015S02

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. 쐌 At starting 쐌 During warm-up 쐌 At idle 쐌 At low battery voltage 쐌 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.

EC-38

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Air Conditioning Cut Control

Air Conditioning Cut Control DESCRIPTION Input/Output Signal Chart Sensor

=NGEC0016

Input Signal to ECM

Air conditioner switch

Air conditioner “ON” signal

Throttle position sensor

Throttle valve opening angle

Camshaft position sensor

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Vehicle speed sensor

Vehicle speed

Power steering oil pressure switch

Power steering operation

ECM function

MA

Actuator

EM Air conditioner cut control

LC

Air conditioner relay

FE

System Description

NGEC0016S02

This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned off. 쐌 When the accelerator pedal is fully depressed. 쐌 When cranking the engine. 쐌 When the engine coolant temperature becomes excessively high. 쐌 When operating power steering and air conditioner during low engine speed or when fully releasing accelerator pedal. 쐌 When engine speed is excessively low.

CL MT AT TF

Fuel Cut Control (at no load & high engine speed)

PD

DESCRIPTION Input/Output Signal Chart Sensor

GI

NGEC0016S01

NGEC0017 NGEC0017S01

Input Signal to ECM

ECM function

Actuator

AX SU

Vehicle speed sensor

Vehicle speed

PNP switch

Neutral position

Throttle position sensor

Throttle position

Camshaft position sensor

Engine speed

Fuel cut control

Injectors

If the engine speed is above 3,000 rpm with no load, (for example, in Neutral and engine speed over 3,000 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 1,500 rpm, then fuel cut is cancelled. NOTE: This function is different from deceleration control listed under “Multiport Fuel Injection (MFI) System”, EC-35.

BR ST RS BT HA SC EL

EC-39

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Evaporative Emission System

Evaporative Emission System DESCRIPTION

=NGEC0018

SEF569XA

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.

INSPECTION EVAP Canister

NGEC0019 NGEC0019S01

Check EVAP canister as follows: 1. Pinch the fresh air hose. 2. Blow air into port A and check that air flows freely through port B.

SEF314V

Tightening Torque

NGEC0019S02

Tighten EVAP canister as shown in the figure. Make sure new O-ring is installed properly between EVAP canister and EVAP canister vent control valve.

AEC879A

EC-40

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Evaporative Emission System (Cont’d)

Fuel Tank Vacuum Relief Valve (Built into fuel fillerNGEC0019S03 cap) 1. 2.

SEF427N

Wipe clean valve housing. Check valve opening pressure and vacuum. Pressure: 16.0 - 20.0 kPa (0.163 - 0.204 kg/cm2, 2.32 - 2.90 psi) Vacuum: −6.0 to −3.5 kPa (−0.061 to −0.036 kg/cm2, −0.87 to −0.51 psi) 3. If out of specification, replace fuel filler cap as an assembly. CAUTION: Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on.

GI MA EM LC

FE CL MT

SEF943S

Vacuum Cut Valve and Vacuum Cut Valve Bypass NGEC0019S05 Valve Refer to EC-546.

EVAP Canister Purge Volume Control Solenoid Valve NGEC0019S06 Refer to EC-512.

Fuel Tank Temperature Sensor

AT TF

NGEC0019S08

Refer to EC-269.

PD AX

EVAP Service Port

NGEC0019S09

Positive pressure is delivered to the EVAP system through the EVAP service port. If fuel vapor leakage in the EVAP system occurs, use a leak detector to locate the leak.

SU BR ST RS

SEF462UC

BT HA SC EL

EC-41

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Evaporative Emission System (Cont’d)

How to Detect Fuel Vapor Leakage

PEF658U

SEF200U

SEF503V

NGEC0019S10

CAUTION: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not start engine. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in EVAP system. NOTE: Improper installation of adapter to the service port may cause a leak. With CONSULT-II 1) Attach the EVAP service port adapter securely to the EVAP service port. 2) Also attach the pressure pump and hose. 3) Turn ignition switch “ON”. 4) Select the “EVAP SYSTEM CLOSE” of “WORK SUPPORT MODE” with CONSULT-II. 5) Touch “START”. A bar graph (Pressure indicating display) will appear on the screen. 6) Apply positive pressure to the EVAP system until the pressure indicator reaches the middle of the bar graph. 7) Remove the EVAP service port adapter and hose with pressure pump. 8) Locate the leak using a leak detector. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43. Without CONSULT-II 1) Attach the EVAP service port adapter securely to the EVAP service port and pressure pump with pressure gauge to the EVAP service port. 2) Apply battery voltage to between the terminals of both EVAP canister vent control valve and vacuum cut valve bypass valve to make a closed EVAP system. 3) To locate the leak, deliver positive pressure to the EVAP system until pressure gauge points reach 1.38 to 2.76 kPa (0.014 to 0.028 kg/cm2, 0.2 to 0.4 psi). 4) Remove the EVAP service port adapter and hose with pressure pump. 5) Locate the leak using a leak detector. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43.

EC-42

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Evaporative Emission System (Cont’d)

EVAPORATIVE EMISSION LINE DRAWING

=NGEC0020

NOTE: Do not use soapy water or any type of solvent while installing vacuum hoses or purge hoses.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL SEF712Z

EC-43

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Evaporative Emission System (Cont’d)

WEC555

EC-44

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR)

On Board Refueling Vapor Recovery (ORVR)

NGEC1002

SYSTEM DESCRIPTION

NGEC1002S01

GI MA EM LC

FE CL SEF206VA

From the beginning of refueling, the fuel tank pressure goes up. When the pressure reaches the setting value of the refueling control valve (RCV) opening pressure, the RCV is opened. After RCV opens, the air and vapor inside the fuel tank go through refueling EVAP vapor cut valve, RCV and refueling vapor line to the EVAP canister. The vapor is absorbed by the EVAP canister and the air is released to the atmosphere. When the refueling has reached the full level of the fuel tank, the refueling EVAP vapor cut valve is closed and refueling is stopped because of auto shut-off. The vapor which was absorbed by the EVAP canister is purged during driving. The RCV is always closed during driving and the evaporative emission control system is operated the same as conventional system. WARNING: When conducting inspections below, be sure to observe the following: 쐌 Put a “CAUTION: INFLAMMABLE” sign in workshop. 쐌 Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. 쐌 Be sure to furnish the workshop with a CO2 fire extinguisher. CAUTION: 쐌 Before removing fuel line parts, carry out the following procedures: a) Put drained fuel in an explosion-proof container and put lid on securely. b) Release fuel pressure from fuel line. Refer to “Fuel Pressure Release”, EC-57. c) Disconnect battery ground cable. 쐌 Always replace O-ring when the fuel gauge retainer is removed. 쐌 Do not kink or twist hose and tube when they are installed. 쐌 Do not tighten hose and clamps excessively to avoid damaging hoses. 쐌 After installation, run engine and check for fuel leaks at connection. 쐌 Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire.

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-45

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

DIAGNOSTIC PROCEDURE Symptom: Fuel Odor from EVAP Canister Is Strong. 1

NGEC1002S02 NGEC1002S0201

CHECK EVAP CANISTER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 2.

NG

䊳

GO TO 3.

2

CHECK IF EVAP CANISTER SATURATED WITH WATER

Does water drain from the EVAP canister?

SEF596U

Yes or No Yes

䊳

GO TO 3.

No (With CONSULT-II)

䊳

GO TO 6.

No (Without CONSULTII)

䊳

GO TO 7.

3

REPLACE EVAP CANISTER

Replace EVAP canister with a new one. 䊳

GO TO 4.

EC-46

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

4 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

GI MA EM LC

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator.

FE CL

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace water separator.

MT AT

5

DETECT MALFUNCTIONING PART

Check the EVAP hose between EVAP canister and water separator for clogging or poor connection. 䊳

Repair or replace EVAP hose.

TF PD AX SU BR ST RS BT HA SC EL

EC-47

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

6 1. 2. a. b. c. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE With CONSULT-II Remove fuel tank. Refer to FE-4, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel feed hose located on the fuel gauge retainer. Connect a spare fuel hose, one side to fuel gauge retainer where the hose was removed and the other side to a fuel container. Drain fuel using “FUEL PUMP RELAY” in “ACTIVE TEST” mode with CONSULT-II. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable.

SEF707Z

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

EC-48

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

7 1. 2. a. b. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE Without CONSULT-II Remove fuel tank. Refer to FE-4, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel gauge retainer. Drain fuel from the tank using a hand pump into a fuel container. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable.

GI MA EM LC

FE CL MT AT TF PD AX SEF707Z

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

SU BR ST RS BT HA SC EL

EC-49

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

8

CHECK REFUELING CONTROL VALVE

1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage.

SEF706Z

OK or NG OK

䊳

INSPECTION END

NG

䊳

Replace refueling control valve with fuel tank.

Symptom: Cannot Refuel/Fuel Odor From The Fuel Filler Opening Is Strong While Refueling. 1

CHECK EVAP CANISTER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 2.

NG

䊳

GO TO 3.

EC-50

NGEC1002S0202

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

2

CHECK IF EVAP CANISTER SATURATED WITH WATER

Does water drain from the EVAP canister?

GI MA EM LC SEF596U

Yes or No Yes

䊳

GO TO 3.

No

䊳

GO TO 6.

FE CL

3

REPLACE EVAP CANISTER

Replace EVAP canister with a new one. 䊳

4 1. 2. 3. 4.

MT

GO TO 4.

AT

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

TF PD AX SU BR SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator.

ST RS

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace water separator.

5

BT HA

DETECT MALFUNCTIONING PART

Check the EVAP hose between EVAP canister and water separator for clogging or poor connection. 䊳

Repair or replace EVAP hose.

SC EL

EC-51

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

6

CHECK VENT HOSES AND VENT TUBES

Check hoses and tubes between EVAP canister and refueling control valve for clogging, kink, looseness and improper connection. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair or replace hoses and tubes.

7

CHECK FILLER NECK TUBE

Check signal line and recirculation line for clogging, dents and cracks. OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace filler neck tube.

8

CHECK REFUELING CONTROL VALVE

1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage.

SEF706Z

OK or NG OK (With CONSULT-II)

䊳

GO TO 9.

OK (Without CONSULTII)

䊳

GO TO 10.

NG

䊳

Replace refueling control valve with fuel tank.

EC-52

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

9 1. 2. a. b. c. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE With CONSULT-II Remove fuel tank. Refer to FE-4, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel feed hose located on the fuel gauge retainer. Connect a spare fuel hose, one side to fuel gauge retainer where the hose was removed and the other side to a fuel container. Drain fuel using “FUEL PUMP RELAY” in “ACTIVE TEST” mode with CONSULT-II. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable.

GI MA EM LC

FE CL MT AT TF PD AX

SEF707Z

SU

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

BR ST RS BT HA SC EL

EC-53

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

10 1. 2. a. b. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE Without CONSULT-II Remove fuel tank. Refer to FE-4, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel gauge retainer. Drain fuel from the tank using a hand pump into a fuel container. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable.

SEF707Z

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

11

CHECK FUEL FILLER TUBE

Check filler neck tube and hose connected to the fuel tank for clogging, dents and cracks. OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace fuel filler tube.

12

CHECK ONE-WAY FUEL VALVE-I

Check one-way valve for clogging. OK or NG OK

䊳

GO TO 13.

NG

䊳

Repair or replace one-way fuel valve with fuel tank.

EC-54

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

13

CHECK ONE-WAY FUEL VALVE-II

1. Make sure that fuel is drained from the tank. 2. Remove fuel filler tube and hose. 3. Check one-way fuel valve for operation as follows. When a stick is inserted, the valve should open, when removing stick it should close.

GI MA EM LC

SEF665U

FE

Do not drop any material into the tank. OK or NG OK

䊳

INSPECTION END

NG

䊳

Replace fuel filler tube or replace one-way fuel valve with fuel tank.

CL MT

Positive Crankcase Ventilation DESCRIPTION

NGEC0022

AT TF PD AX SU BR ST

AEC042B

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.

EC-55

RS BT HA SC EL IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

KA24DE

Positive Crankcase Ventilation (Cont’d)

INSPECTION PCV (Positive Crankcase Ventilation) Valve

NGEC0023 NGEC0023S01

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.

NGEC0023S02

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-56

BASIC SERVICE PROCEDURE

KA24DE Fuel Pressure Release

Fuel Pressure Release

NGEC0024

Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.

WITH CONSULT-II 1. 2. 3. SEF163X

4.

NGEC0024S01

Start engine. Perform “FUEL PRESSURE 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.

GI MA EM LC

FE CL MT

PEF823K

WITHOUT CONSULT-II 1. 2. 3. 4.

NGEC0024S02

Remove fuse for fuel pump. 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.

AT TF PD AX

SEF164X

Fuel Pressure Check 쐌 쐌 쐌 쐌 쐌

AEC064B

1. 2. 3. 4. 5.

SEF318V

NGEC0025

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 electrical systems operating (i.e. lights, rear defog., A/C ect.). Fuel pressure gauge may indicate false readings due to varying engine loads and changes in manifold vacuum. 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 (2.4 kg/cm2, 34 psi) With vacuum hose disconnected Approximately 294 kPa (3.0 kg/cm2, 43 psi)

EC-57

SU BR ST RS BT HA SC EL IDX

BASIC SERVICE PROCEDURE

KA24DE

Fuel Pressure Regulator Check

If results are unsatisfactory, perform Fuel Pressure Regulator Check, EC-58.

Fuel Pressure Regulator Check

NGEC0026

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.

SEF319V

SEF116V

NGEC0027

Release fuel pressure to zero. Remove injector tube assembly with injectors from intake manifold. 3. Remove injectors from injector tube assembly. 쐌 Push injector tail piece. 쐌 Do not pull on the connector. 4. Install injector to fuel tube assembly. a. Clean exterior of injector tail piece. b. Use new O-rings. Always replace O-rings with new ones. Lubricate O-rings with a smear of engine oil. 5. Install injectors with fuel tube assembly to intake manifold. Tighten in numerical order shown in the figure. a. First, tighten all bolts to 9.3 to 10.8 N·m (0.95 to 1.1 kg-m, 6.9 to 8.0 ft-lb). b. Then, tighten all bolts to 21 to 26 N·m (2.1 to 2.7 kg-m, 15 to 20 ft-lb). 6. Install fuel hoses to fuel tube assembly. 7. Reinstall any parts removed in reverse order of removal. CAUTION: After properly connecting injectors to fuel tube assembly, check connections for fuel leakage.

SEF117V

EC-58

BASIC SERVICE PROCEDURE

KA24DE Fast Idle Cam (FIC)

Fast Idle Cam (FIC) COMPONENT DESCRIPTION

NGEC0502

The FIC is installed on the throttle body to maintain adequate engine speed while the engine is cold. It is operated by a volumetric change in wax located inside the thermo-element. The thermoelement is operated by engine coolant temperature. For inspection refer to “TROUBLE DIAGNOSIS-BASIC INSPECTION”, “Basic Inspection”, EC-112.

GI MA EM LC

SEF500V

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment

NGEC0028

PREPARATION

NGEC0028S01

쐌 a) b) c) d) e) f) g)

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.) h) Fuel pressure i) Engine compression j) EGR valve operation k) Throttle valve l) EVAP system 쐌 On models equipped with air conditioner, checks should be carried out while the air conditioner is “OFF”. 쐌 When measuring “CO” percentage, insert probe more than 40 cm (15.7 in) into tail pipe. 쐌 Turn off headlamps, heater blower, rear window defogger. 쐌 Keep front wheels pointed straight ahead.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-59

IDX

BASIC SERVICE PROCEDURE

KA24DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

Overall Inspection Sequence

NGEC0028S0101

SEF554YA

NOTE: If a vehicle contains a part which is operating outside of design specifications with no MIL 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-60

BASIC SERVICE PROCEDURE

KA24DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

INSPECTION PROCEDURE 1

=NGEC0028S02

INSPECTION START

GI

1. Visually check the following: 쐌 Air cleaner clogging 쐌 Hoses and duct for leaks 쐌 EGR valve operation 쐌 Electrical connectors 쐌 Gasket (intake manifold, cylinder head, exhaust system) 쐌 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.

MA EM LC

FE CL SEF810K

3. Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load. 4. Make sure that no DTC is displayed with CONSULT-II or GST. OK or NG OK

䊳

쐌 GO TO 2. (With CONSULT-II) 쐌 GO TO 3. (Without CONSULT-II)

NG

䊳

1. Repair or replace components as necessary. 2. GO TO 2. (With CONSULT-II) 3. GO TO 3. (Without CONSULT-II)

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-61

IDX

BASIC SERVICE PROCEDURE

KA24DE

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.

SEF320V

MT: 20°±2° BTDC OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-62

BASIC SERVICE PROCEDURE

KA24DE

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.

GI MA EM LC SEF978U

3. Turn off engine and disconnect throttle position sensor harness connector.

FE CL MT AT SEF265S

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.

TF PD AX SU SEF320V

BR

MT: 20°±2° BTDC OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

ST RS BT HA SC EL

EC-63

IDX

BASIC SERVICE PROCEDURE

KA24DE

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.

SEF265S

Models with CONSULT-II

䊳

GO TO 2.

Models without CONSULT-II

䊳

GO TO 3.

5

CHECK BASE IDLE SPEED

With CONSULT-II 1. Read idle speed in “IGNITION TIMING ADJ” in “WORK SUPPORT” mode.

SEF713Z

MT: 750±50 rpm Without CONSULT-II 1. Check idle speed. MT: 750±50 rpm OK or NG OK (With CONSULT-II)

䊳

GO TO 7.

OK (Without CONSULTII)

䊳

GO TO 8.

NG

䊳

GO TO 6.

EC-64

BASIC SERVICE PROCEDURE

KA24DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

6

ADJUST BASE IDLE SPEED

1. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. 2. Adjust idle speed by turning idle speed adjusting screw.

GI MA EM LC

SEF240SA

MT: 750±50 rpm

FE Models with CONSULT-II

䊳

GO TO 7.

Models without CONSULT-II

䊳

GO TO 8.

7

CL MT

CHECK TARGET IDLE SPEED

With CONSULT-II 1. Touch “BACK” on CONSULT-II. 2. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed.

AT TF PD AX SU SEF602K

3. Read idle speed in “DATA MONITOR” mode with CONSULT-II.

BR ST RS BT SEF058Y

MT: 800±50 rpm

HA

OK or NG OK

䊳

GO TO 10.

NG

䊳

GO TO 9.

SC EL

EC-65

IDX

BASIC SERVICE PROCEDURE

KA24DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

8

CHECK TARGET IDLE SPEED

Without CONSULT-II 1. Turn off engine and connect throttle position sensor harness connector.

SEF265S

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. MT: 800±50 rpm OK or NG OK

䊳

GO TO 10.

NG

䊳

GO TO 9.

9

DETECT MALFUNCTIONING PART

Check the following. 1. Check IACV-AAC valve and replace if necessary. Refer to EC-434. 2. Check IACV-AAC valve harness and repair if necessary. Refer to EC-434. 3. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.) 䊳

GO TO 10.

EC-66

BASIC SERVICE PROCEDURE

KA24DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

10

CHECK HEATED OXYGEN SENSOR 1 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.

GI MA EM LC

SEF820Y

1 cycle: RICH → LEAN → RICH 2 cycles: RICH → LEAN → RICH → LEAN → RICH

CL

Without CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Set voltmeter probe between ECM terminal 50 and ground. 3. Make sure that the voltage fluctuates between 0 - 0.3V and 0.6 - 1.0V more than 5 times during 10 seconds at 2,000 rpm. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 11.

FE

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-67

IDX

BASIC SERVICE PROCEDURE

KA24DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

11 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 1 HARNESS Turn off engine and disconnect battery ground cable. Disconnect ECM harness connector. Disconnect heated oxygen sensor 1 harness connector. Then connect harness connector terminal for heated oxygen sensor 1 to ground with a jumper wire.

SEF508VB

5. Check for continuity between terminal 50 of ECM harness connector and body ground.

SEF250P

Continuity exists...OK Continuity does not exist...NG OK or NG OK

䊳

1. Connect ECM harness connector to ECM. 2. Connect battery ground cable. 3. GO TO 13.

NG

䊳

1. Repair or replace harness. 2. GO TO 12.

EC-68

BASIC SERVICE PROCEDURE

KA24DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

12

PREPARATION FOR IDLE SPEED ADJUSTING

With CONSULT-II 1. Select “IGNITION TIMING ADJ” in “WORK SUPPORT” mode. 2. Touch “START”.

GI MA EM LC

FE PEF546N

Without CONSULT-II 1. Stop engine and disconnect throttle position sensor harness connector.

CL MT AT TF PD

SEF265S

AX

2. Start engine. 䊳

GO TO 6.

SU BR ST RS BT HA SC EL

EC-69

IDX

BASIC SERVICE PROCEDURE

KA24DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

13

PREPARATION FOR “CO” % CHECK

With CONSULT-II 1. Select “ENGINE COOLANT TEMP” in “ACTIVE TEST” mode. 2. Set “COOLANT TEMP” to 5°C (41°F) by touching “Qu” and “Qd” and “UP”, “DOWN”.

SEF172Y

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.

SEF053RA

4. Connect battery ground cable. 䊳

GO TO 14.

EC-70

BASIC SERVICE PROCEDURE

KA24DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

14

CHECK “CO” %

Without CONSULT-II 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.)

GI MA EM LC

SEF810K

2. Rev engine two or three times under no-load, then run engine at idle speed.

FE CL MT AT SEF978U

3. Check “CO”%. Idle CO: 2.9 - 10.8% and engine runs smoothly. 4. With CONSULT-II After checking CO%, touch “BACK”. 5. Without CONSULT-II After checking CO%, 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.

TF PD AX

OK or NG OK

䊳

GO TO 15.

NG

䊳

GO TO 16.

SU BR ST RS BT HA SC EL

EC-71

IDX

BASIC SERVICE PROCEDURE

KA24DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

15

CHECK HEATED OXYGEN SENSOR 1 SIGNAL

With CONSULT-II 1. Replace heated oxygen sensor 1. 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 1. 2. 3. 4. 5. 6.

Without CONSULT-II Stop engine. Replace heated oxygen sensor 1. Start engine and warm it up to normal operating temperature. Run engine at approx. 2,000 rpm for approx. 2 minutes under no-load. Set voltmeter probe between ECM terminal 50 and ground. Make sure that voltage fluctuates between 0 - 0.3V and 0.6 - 1.0V more than 5 times during 10 seconds at 2,000 rpm. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V OK or NG

OK

䊳

GO TO 12.

NG

䊳

GO TO 16.

16

DETECT MALFUNCTIONING PART

1. Connect heated oxygen sensor 1 harness connector to heated oxygen sensor 1. 2. Check fuel pressure regulator. Refer to EC-58. 3. Check mass air flow sensor and its circuit. Refer to EC-168. 4. Check injector and its circuit. Refer to EC-571. Clean or replace if necessary. 5. Check engine coolant temperature sensor and its circuit. Refer to EC-185, 204. 6. Check ECM function by substituting another known-good ECM. (ECM may be the cause of a problem, but this is rarely the case.) 䊳

쐌

GO TO 12.

If a vehicle contains a part which is operating outside of design specifications with no MIL 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-72

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE Introduction

Introduction

NGEC0029

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 SAE J1979

Freeze Frame data

Mode 2 of SAE J1979

System Readiness Test (SRT) code

Mode 1 of SAE J1979

1st Trip Diagnostic Trouble Code (1st Trip DTC)

Mode 7 of SAE J1979

GI MA EM

1st Trip Freeze Frame data

LC

Test values and Test limits

Mode 6 of SAE J1979

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

CONSULT-II

X

X

X

X

X

—

GST

X

X*1

X

—

X

X

FE CL

*1: 1st trip DTC for self-diagnoses concerning SRT items cannot be shown on the GST display.

The malfunction indicator lamp (MIL) 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-127.)

Two Trip Detection Logic

NGEC0030

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 MIL 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 MIL lights up. The MIL 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 MIL, and store DTC and Freeze Frame data, even in the 1st trip, as shown below. X: Applicable MIL Items

DTC

1st trip

—: Not applicable

MT AT TF PD AX

1st trip DTC

2nd trip

1st trip 2nd trip 1st trip 2nd trip displaying displaying displaying displaying Lighting up

Blinking

Lighting up

Blinking

Misfire (Possible three way catalyst damage) — DTC: P0300 P0304 is being detected

X

—

—

—

—

—

X

—

Misfire (Possible three way catalyst damage) — DTC: P0300 P0304 is being detected

—

—

X

—

—

X

—

—

Coolant overtemperatune enrichment protection — DTC: P0217

—

X

—

—

X

—

X

—

Closed loop control — DTC: P1148

—

X

—

—

X

—

X

—

Fail-safe items (Refer to EC-127.)

—

X

—

—

X*1

—

X*1

—

Except above

—

—

—

X

—

X

X

—

SU BR ST RS

*1: Except “ECM”

BT HA SC EL

EC-73

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information

Emission-related Diagnostic Information DTC AND 1ST TRIP DTC

NGEC0031 NGEC0031S01

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 MIL 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 MIL lights up. In other words, the DTC is stored in the ECM memory and the MIL 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 MIL 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-86. For malfunctions in which 1st trip DTCs are displayed, refer to EC-84. 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 SAE J1979. 1st trip DTC detection occurs without lighting up the MIL 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-110. 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

NGEC0031S0101

DTC and 1st trip DTC can be read by the following methods. With CONSULT-II With GST CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P1148, P1706, etc. These DTCs are prescribed by SAE J2012. (CONSULT-II also displays the malfunctioning component or system.) 쐌 1st trip DTC No. is the same as DTC No. 쐌 Output of a DTC indicates a malfunction. However, 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]”.

SEC745C

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA

NGEC0031S02

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, throttle valve opening, base fuel schedule and intake air temperature at the moment a malfunction is detected. Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.

EC-74

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d)

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-97. 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/MIL on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data. Priority 1 2 3

GI MA EM

Items Freeze frame data

LC

Misfire — DTC: P0300 - P0304 Fuel Injection System Function — DTC: P0171, P0172 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-86.

FE

SYSTEM READINESS TEST (SRT) CODE

TF

CL MT AT

NGEC0031S03

System Readiness Test (SRT) code is specified in Mode 1 of SAE J1979. As part of enhanced emissions test for Inspection and Maintenance (I/M), certain states require that the status of srt be used to indicate whether the ECM has completed self-diagnosis of major emission systems and components. Completion must be verified in order for the emissions inspection to proceed. If a vehicle is rejected for a State emissions inspection due to one or more SRT items indicating “incomplete”, use the information in this service manual to set the SRT to “complete”. In most cases, the ECM will automatically complete its self-diagnosis cycle during normal usage and the SRT status will indicate “complete” for each application system. Once set as “complete”, the SRT status remains “complete” until the self-diagnosis memory is erased. Occasionally, certain portions of the self-diagnostic test may not be completed as a result of the customer’s normal driving pattern and the SRT will indicate “incomplete” for these items. NOTE: The SRT will also indicate “incomplete” if the self-diagnosis memory is erased for any reason or if the ECM memory power supply is interrupted for several hours. If, during the state emissions inspection, the SRT indicates “complete” for all test items, the inspector will continue with the emissions test. However, if the SRT indicates “incomplete” for one or more of the SRT items, the vehicle is returned to the customer untested. NOTE: If MIL is “ON” during the state emissions inspection, the vehicle is also returned to the customer untested even though the SRT indicates “complete” for all test items. Therefore, it is important to check SRT (“complete”) and DTC (No DTCs) before the inspection. This service manual contains the service procedure and support information to perform a comprehensive road test that enables the ECM to complete the SRT.

PD AX SU BR ST RS BT HA SC EL

EC-75

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d)

SRT Item

=NGEC0031S0308

The following table shows required self-diagnostic items to set the SRT to “CMPLT”. SRT item (CONSULT-II indication)

Performance Priority *

Required self-diagnostic items to set the SRT to ″CMPLT″

Corresponding DTC No.

CATALYST

3

Three way catalyst function

P0420

EVAP SYSTEM

2

EVAP control system

P0442

3

EVAP control system

P0456, P1456

3

EVAP control system purge flow monitoring

P0441

3

Heated oxygen sensor 1

P0134

Heated oxygen sensor 1

P1143

Heated oxygen sensor 1

P1144

Heated oxygen sensor 1

P0133

Heated oxygen sensor 1

P0132

Heated oxygen sensor 2

P1146

Heated oxygen sensor 2

P1147

Heated oxygen sensor 2

P0139

Heated oxygen sensor 2

P0138

Heated oxygen sensor 1 heater

P0031, P0032

Heated oxygen sensor 2 heater

P0037, P0038

EGR function

P0400

EGRC-BPT valve function

P0402

EGR function

P1402

HO2S

HO2S HTR

EGR SYSTEM

3

3

1

*: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure) one by one based on the priority for models with CONSULT-II.

EC-76

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d)

SRT Set Timing

=NGEC0031S0310

SRT is set as “complete” after self-diagnosis has been performed one or more times. Completion of SRT will occur if the result is OK or NG. The set timing is different between them and is shown in the following table. Self-diagnosis result

Example

All OK

Ignition OFF – ON – OFF

Ignition OFF – ON – OFF

Diagnosis

Ignition OFF – ON – OFF

MA Ignition OFF – ON – OFF

EM

P0400

OK (1)

– (1)

OK (2)

– (2)

P0402

OK (1)

– (1)

– (1)

OK (2)

P1402

OK (1)

OK (2)

– (2)

– (2)

“complete”

“complete”

“complete”

“complete”

P0400

OK (1)

– (1)

– (1)

– (1)

P0402

– (0)

– (0)

OK (1)

– (1)

P1402

OK (1)

OK (2)

– (2)

– (2)

“incomplete”

“incomplete”

“complete”

“complete”

P0400

OK

OK

–

–

P0402

–

–

–

–

NG

–

NG

NG (Consecutive NG)

(1st trip) DTC

1st trip DTC

–

1st trip DTC

DTC (=MIL “ON”)

SRT of EGR

“incomplete”

“incomplete”

“incomplete”

“complete”

LC

Case 1 SRT of EGR

FE

Case 2 SRT of EGR NG exists

Case 3

P1402

CL MT

OK: Self-diagnosis is carried out and the result is OK. NG: Self-diagnosis is carried out and the result is OK. – : Self-diagnosis is not carried out.

AT TF PD

When all SRT related self-diagnoses showed OK results in a same cycle (Ignition OFF – ON – OFF), the SRT will indicate “complete”. , Case 1 above When all SRT related self-diagnoses show OK results through several different cycles, the SRT will indicate “complete” at the time the respective self-diagnoses have at least one OK result. , Case 2 above If one or more SRT related self-diagnoses showed NG results in 2 consecutive cycles, the SRT will also indicate “complete”. , Case 3 above The previous table shows that the minimum number of cycles for setting SRT as “incomplete” is one (1) for each self-diagnosis (Case 1 and 2) or two (2) for one self-diagnosis (Case 3). However, in preparation for the State emissions inspection, it is unnecessary of each self-diagnosis to be executed twice (Case 3) because of the following reasons; 쐌 The SRT will indicate “complete” at the time the respective self-diagnoses have one (1) OK result. 쐌 The emissions inspection requires “complete” of the SRT only with OK self-diagnosis result. 쐌 When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to “complete” of SRT, the self-diagnosis memory must be erased from ECM after repair. 쐌 If the 1st trip DTC is erased, all the SRT will indicate “incomplete”. NOTE: SRT can be set as “complete” together with the DTC(s). Therefore, DTC check must always be carried out prior to the State emission inspection even though the SRT indicates “complete”.

AX SU BR ST RS BT HA SC

How to Display SRT Code 1.

GI

NGEC0031S0301

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.

EC-77

EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d)

2.

With GST Selecting Mode 1 with GST (Generic Scan Tool) A sample of CONSULT-II display for SRT code is shown below. “INCMP” means the self-diagnosis is incomplete and SRT is not set. “CMPLT” means the self-diagnosis is complete and SRT is set.

SEF713Y

EC-78

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d)

SRT Service Procedure

=NGEC0031S0311

If a vehicle has been rejected for the State emissions inspection due to one or more SRT items indicating “incomplete”, review the following flowchart diagnostic sequence.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS SEF170Z

*1

EC-74

*2

EC-77

*3

EC-80

BT HA SC EL

EC-79

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d)

How to Set SRT Code

=NGEC0031S0302

To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each diagnosis may require a long period of actual driving under various conditions. With CONSULT-II Perform corresponding DTC confirmation procedure one by one based on “Performance Priority” in the table on EC-76. Without CONSULT-II The most efficient driving pattern in which SRT codes can be properly set is explained on EC-81. The driving pattern should be performed one or more times to set all SRT codes.

EC-80

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d)

Driving Pattern

NGEC0031S0303

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEC746C

EC-81

EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d)

쐌

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: 쐌 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 59 and ground is 3.0 - 4.3V). 쐌 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 59 and ground is lower than 1.4V). 쐌 The engine is started at the tank fuel temperature of warmer than 0°C (32°F) (where the voltage between the ECM terminal 60 and ground is less than 4.1V). Pattern 2: 쐌 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. Pattern 3: 쐌 The driving pattern outlined in *2 must be repeated at least 3 times. Pattern 4: 쐌 Tests are performed after the engine has been operated for at least 17 minutes. 쐌 The accelerator pedal must be held very steady during steady-state driving. 쐌 If the accelerator pedal is moved, the test must be conducted all over again. *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: Operate the vehicle in the following driving pattern. 1) Decelerate vehicle to 0 km/h (0 MPH) and let engine idle. 2) Repeat driving pattern shown below at least 10 times. 쐌 During acceleration, hold the accelerator pedal as steady as possible. 3) Repeat steps 1 and 2 until the EGR system SRT is set.

SEF414S

*3: Checking the vehicle speed with GST is advised. 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.

EC-82

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d) For normal acceleration in low altitude areas [less than 1,219 m (4,000 ft)]:

For quick acceleration in low altitude areas and high altitude areas [over 1,219 m (4,000 ft)]:

ACCEL shift point km/h (MPH)

CRUISE shift point km/h (MPH)

km/h (MPH)

1st to 2nd

24 (15)

24 (15)

24 (15)

2nd to 3rd

40 (25)

29 (18)

40 (25)

3rd to 4th

58 (36)

48 (30)

64 (40)

4th to 5th

64 (40)

63 (39)

72 (45)

Gear change

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)

MA EM LC NGEC0031S04

The following is the information specified in Mode 6 of SAE J1979. 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 (9 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

GI

—: Not applicable

FE CL MT

Test value (GST display) SRT item

CATALYST

Self-diagnostic test item

Test limit

Application

01H

Max.

X

02H

81H

Min.

X

EVAP control system (Small leak)

05H

03H

Max.

X

EVAP control system purge flow monitoring

06H

83H

Min.

X

09H

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

01H

AT

Three way catalyst function

PD

EVAP SYSTEM

Heated oxygen sensor 1

HO2S

TF

AX SU BR ST

Heated oxygen sensor 2

Heated oxygen sensor 1 heater

RS BT

HO2S HTR Heated oxygen sensor 2 heater

HA SC EL

EC-83

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d) Test value (GST display) SRT item

Self-diagnostic test item

EGR function EGR SYSTEM

Test limit

Application

8CH

Min.

X

32H

8CH

Min.

X

33H

8CH

Min.

X

34H

8CH

Min.

X

35H

0CH

Max.

X

36H

0CH

Max.

X

37H

8CH

Min.

X

TID

CID

31H

EGRC-BPT valve function

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS

NGEC0031S05

X: Applicable DTC*1*2

—: Not applicable

CONSULT-II GST

SRT code

Test value/Test limit (GST only)

1st trip DTC

Reference page

NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED.

P0000

—

—

—

—

HO2S1 HTR (B1)

P0031

X

X

X*5

EC-158

HO2S1 HTR (B1)

P0032

X

X

X*5

EC-158

HO2S2 HTR (B1)

P0037

X

X

X*5

EC-163

HO2S2 HTR (B1)

P0038

X

X

X*5

EC-163

MAF SEN/CIRCUIT

P0101

—

—

X

EC-168

MAF SEN/CIRCUIT

P0102*3

—

—

—

EC-168

MAF SEN/CIRCUIT

P0103*3

—

—

—

EC-168

ABSL PRES SEN/CIRC

P0107

—

—

X

EC-178

ABSL PRES SEN/CIRC

P0108

—

—

X

EC-178

IAT SEN/CIRCUIT

P0112*3

—

—

—

EC-180

IAT SEN/CIRCUIT

P0113*3

—

—

—

EC-180

ECT SEN/CIRCUIT

P0117*3

—

—

—

EC-185

ECT SEN/CIRCUIT

P0118*3

—

—

—

EC-185

TP SEN/CIRCUIT

P0121

—

—

X

EC-190

TP SEN/CIRCUIT

P0122*3

—

—

—

EC-190

TP SEN/CIRCUIT

P0123*3

—

—

—

EC-190

ECT SENSOR

P0125

—

—

X

EC-204

IAT SENSOR

P0127

—

—

X

EC-180

THERMSTAT FNCTN

P0128

—

—

X

EC-209

HO2S1 (B1)

P0132

X

X

X*5

EC-211

HO2S1 (B1)

P0133

X

X

X*5

EC-218

HO2S1 (B1)

P0134

X

X

X*5

EC-229

HO2S2 (B1)

P0138

X

X

X*5

EC-237

Items (CONSULT-II screen terms)

EC-84

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d) DTC*1*2 CONSULT-II GST

SRT code

Test value/Test limit (GST only)

1st trip DTC

Reference page

HO2S2 (B1)

P0139

X

X

X*5

EC-245

FUEL SYS-LEAN-B1

P0171

—

—

X

EC-255

FUEL SYS-RICH-B1

P0172

—

—

X

EC-262

FTT SENSOR

P0181

—

—

X

EC-269

FTT SEN/CIRCUIT

P0182

—

—

X

EC-269

FTT SEN/CIRCUIT

P0183

—

—

X

EC-269

ENG OVER TEMP

P0217

—

—

X

EC-275

MULTI CYL MISFIRE

P0300

—

—

X

EC-281

CYL1 MISFIRE

P0301

—

—

X

EC-281

CYL2 MISFIRE

P0302

—

—

X

EC-281

CYL3 MISFIRE

P0303

—

—

X

EC-281

CYL4 MISFIRE

P0304

—

—

X

EC-281

KNOCK SEN/CIRC-B1

P0327

—

—

—

EC-290

KNOCK SEN/CIRC-B1

P0328

—

—

—

EC-290

CKP SEN/CIRCUIT

P0335

—

—

X

EC-294

CMP SEN/CIRCUIT

P0340

—

—

X

EC-300

EGR SYSTEM

P0400

X

X

X*5

EC-308

EGRC-BPT VALVE

P0402

X

X

X*5

EC-320

EGR TEMP SEN/CIRC

P0405

—

—

X

EC-328

EGR TEMP SEN/CIRC

P0406

—

—

X

EC-328

TW CATALYST SYS-B1

P0420

X

X

X*5

EC-334

EVAP PURG FLOW/MON

P0441

X

X

X*5

EC-339

EVAP SMALL LEAK

P0442

X

X

X*5

EC-350

PURG VOLUME CONT/V

P0444

—

—

X

EC-366

PURG VOLUME CONT/V

P0445

—

—

X

EC-366

VENT CONTROL VALVE

P0447

—

—

X

EC-373

EVAP SYS PRES SEN

P0452

—

—

X

EC-380

EVAP SYS PRES SEN

P0453

—

—

X

EC-380

EVAP GROSS LEAK

P0455

X

X

X*5

EC-393

EVAP VERY SML LEAK

P0456

X*4

X

X*5

EC-405

FUEL LEV SEN SLOSH

P0460

—

—

X

EC-420

FUEL LEVEL SENSOR

P0461

—

—

X

EC-424

FUEL LEVL SEN/CIRC

P0462

—

—

X

EC-426

FUEL LEVL SEN/CIRC

P0463

—

—

X

EC-426

VEH SPEED SEN/CIRC

P0500

—

—

X

EC-430

ISC SYSTEM/CIRC

P0505

—

—

X

EC-434

Items (CONSULT-II screen terms)

EC-85

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d) DTC*1*2 CONSULT-II GST

SRT code

Test value/Test limit (GST only)

1st trip DTC

Reference page

CLOSED TP SW/CIRC

P0510

—

—

X

EC-440

ECM

P0605

—

—

X

EC-447

HO2S1 (B1)

P1143

X

X

X*5

EC-449

HO2S1 (B1)

P1144

X

X

X*5

EC-456

HO2S2 (B1)

P1146

X

X

X*5

EC-463

HO2S2 (B1)

P1147

X

X

X*5

EC-473

CLOSED LOOP-B1

P1148

—

—

X

EC-483

ENG OVER TEMP

P1217

—

—

X

EC-485

CKP SENSOR (COG)

P1336

—

—

X

EC-490

EGRC SOLENOID/V

P1400

—

—

X

EC-496

EGR SYSTEM

P1402

X

X

X*5

EC-503

PURG VOLUME CONT/V

P1444

—

—

X

EC-512

VENT CONTROL VALVE

P1446

—

—

X

EC-523

VENT CONTROL VALVE

P1448

—

—

X

EC-529

EVAP VERY SML LEAK

P1456

X*4

X

X*5

EC-405

FUEL LEVEL SEN/CIRC

P1464

—

—

X

EC-536

VC/V BYPASS/V

P1490

—

—

X

EC-539

VC CUT/V BYPASS/V

P1491

—

—

X

EC-546

P-N POS SW/CIRCUIT

P1706

—

—

X

EC-556

Items (CONSULT-II screen terms)

*1: *2: *3: *4: *5:

1st trip DTC No. is the same as DTC No. These numbers are prescribed by SAE J2012. When the fail-safe operation occurs, the MIL illuminates. SRT code will not be set if the self-diagnostic result is NG. These are not displayed with GST.

HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC (With CONSULT-II)

NGEC0031S06 NGEC0031S0601

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 “ENGINE”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. (The DTC in the ECM will be erased.)

EC-86

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Emission-related Diagnostic Information (Cont’d)

GI MA EM LC

FE SEC747C

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)

CL MT

NGEC0031S0602

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. Select Mode 4 with GST (Generic Scan Tool). The emission-related diagnostic information in the ECM can be erased by selecting Mode 4 with GST (Generic Scan Tool). NOTE: 쐌 If the battery is disconnected, the emission-related diagnostic information will be lost after approx. 24 hours. 쐌 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) 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.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-87

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Malfunction Indicator Lamp (MIL)

Malfunction Indicator Lamp (MIL) DESCRIPTION

NGEC0032

SEF217U

The MIL is located on the instrument panel. 1. The MIL will light up when the ignition switch is turned ON without the engine running. This is a bulb check. 쐌 If the MIL does not light up, refer to “WARNING LAMPS”, EL-94 or see EC-598. 2. When the engine is started, the MIL should go off. If the MIL remains on, the on board diagnostic system has detected an engine system malfunction.

On Board Diagnostic System Function

NGEC0032S01

The on board diagnostic system has the following two functions. Diagnostic Test Mode

KEY and ENG. Status

Function

Explanation of Function

Mode I

Ignition switch in “ON” position

BULB CHECK

This function checks the MIL bulb for damage (blown, open circuit, etc.). If the MIL does not come on, check MIL circuit.

MALFUNCTION WARNING

This is a usual driving condition. When a malfunction is detected twice in two consecutive driving cycles (two trip detection logic), the MIL will light up to inform the driver that a malfunction has been detected. The following malfunctions will light up or blink the MIL in the 1st trip. 쐌 “Coolant overtemperature enrichment protection” 쐌 “Misfire (Possible three way catalyst damage)” 쐌 “Closed loop control” 쐌 Fail-safe mode

Engine stopped

Engine running

Diagnostic Test Mode I — Bulb Check

NGEC0032S03

In this mode, the MIL on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to EL-94, “WARNING LAMPS” or see EC-598.

Diagnostic Test Mode I — Malfunction Warning MIL

NGEC0032S04

Condition

ON

When the malfunction is detected or the ECM’s CPU is malfunctioning.

OFF

No malfunction.

OBD System Operation Chart RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DETECTABLE ITEMS 쐌

NGEC0033 NGEC0033S01

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.

EC-88

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

OBD System Operation Chart (Cont’d)

쐌 쐌 쐌

쐌

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 MIL will come on. For details, refer to “Two Trip Detection Logic” on EC-73. The MIL 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 MIL (goes off) DTC, Freeze Frame Data (no display) 1st Trip DTC (clear) 1st Trip Freeze Frame Data (clear)

GI MA EM LC

NGEC0033S02

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-91. For details about patterns “A” and “B” under “Other”, see EC-93. *1: Clear timing is at the moment OK is detected. *2: Clear timing is when the same malfunction is detected in the 2nd trip.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-89

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

OBD System Operation Chart (Cont’d)

RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE” , “FUEL INJECTION SYSTEM”

NGEC0033S03

SEF392S

*1: When the same malfunction is detected in two consecutive trips, MIL will light up. *2: MIL 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-90

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

KA24DE

OBD System Operation Chart (Cont’d)

EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” Driving Pattern B

NGEC0033S04

Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. 쐌 The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. 쐌 The B counter will be counted up when driving pattern B is satisfied without any malfunction. 쐌 The MIL will go off when the B counter reaches 3. (*2 in “OBD SYSTEM OPERATION CHART”)

Driving Pattern C

GI

NGEC0033S0401

NGEC0033S0402

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: 쐌 When the freeze frame data shows lower than 70°C (158°F), “T” should be lower than 70°C (158°F). 쐌 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) 쐌 The C counter will be cleared when the malfunction is detected regardless of (1). 쐌 The C counter will be counted up when (1) is satisfied without the same malfunction. 쐌 The DTC will not be displayed after C counter reaches 80. 쐌 The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC is stored in ECM.

MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-91

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

OBD System Operation Chart (Cont’d)

RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”NGEC0033S05

SEF393S

*1: When the same malfunction is detected in two consecutive trips, MIL will light up. *2: MIL 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-92

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

KA24DE

OBD System Operation Chart (Cont’d)

EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” NGEC0033S06 GI Driving Pattern A NGEC0033S0601

MA EM LC

FE CL AEC574

쐌 쐌 쐌

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

MT AT TF

NGEC0033S0602

Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. 쐌 The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. 쐌 The B counter will be counted up when driving pattern B is satisfied without any malfunctions. 쐌 The MIL will go off when the B counter reaches 3 (*2 in “OBD SYSTEM OPERATION CHART”).

PD AX SU BR ST RS BT HA SC EL

EC-93

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

CONSULT-II

CONSULT-II CONSULT-II INSPECTION PROCEDURE

=NGEC0034 NGEC0034S01

1. 2.

Turn ignition switch OFF. Connect “CONSULT-II” to data link connector which is located behind the fuse box cover.

3. 4.

Turn ignition switch ON. Touch “START”.

5.

Touch “ENGINE”.

SEF163X

PBR455D

PEF895K

6.

Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual.

SEF824Y

EC-94

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE CONSULT-II (Cont’d)

ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION NGEC0034S02

GI

DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS Item

ENGINE CONTROL COMPONENT PARTS

DATA MONITOR

DATA MONITOR (SPEC)

X

X

X

X

X

X

ACTIVE TEST

DTC*1

Camshaft position sensor

X

X

Mass air flow sensor

X

Engine coolant temperature sensor

X

Heated oxygen sensor 1

X

X

X

X

X

Heated oxygen sensor 2

X

X

X

X

X

Vehicle speed sensor

X

X

X

X

X

X

Fuel tank temperature sensor

X

X

X

EVAP control system pressure sensor

X

X

X

Absolute pressure sensor

X

X

X

EGR temperature sensor

X

X

X

Intake air temperature sensor

X

X

X

Crankshaft position sensor (OBD)

X

Knock sensor

X

Fuel level sensor

X

X

X

X

X

X

X

X

X

X

Closed throttle position switch (throttle position sensor signal)

X

X

Air conditioner switch

X

X

X

X

Power steering oil pressure switch

X

X

Air conditioner pressure switch

X

X

Battery voltage

X

X

Ambient air temperature switch

X

X

Closed throttle position switch

Park/Neutral position (PNP) switch

X

X

MA EM LC

X

FE CL

X

MT AT TF PD AX

X

Ignition switch (start signal)

SRT STATUS

DTC WORK SUPPORT

FREEZE FRAME DATA*2

Throttle position sensor

INPUT

WORK SUPPORT

DTC & SRT CONFIRMATION

SU BR ST RS BT HA

EC-95

SC EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

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

X

X

X

IACV-AAC valve

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

EVAP canister purge volume control solenoid valve Air conditioner relay Fuel pump relay OUTPUT

DTC & SRT CONFIRMATION

X

SRT STATUS

X

EGRC-solenoid valve

X

X

X

Heated oxygen sensor 1 heater

X

X

X

X

Heated oxygen sensor 2 heater

X

X

X

X

EVAP canister vent control valve

X

X

X

X

Vacuum cut valve bypass valve

X

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-74.

FUNCTION Diagnostic test mode

NGEC0034S03

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 of the specification for the basic fuel schedule, AFM, A/F, feedback control valve 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.

Function test

This mode is used to inform customers when their vehicle condition requires periodic maintenance.

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-96

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE CONSULT-II (Cont’d)

4) 5) 6) 7)

1st trip freeze frame data System readiness test (SRT) codes Test values Others

GI WORK SUPPORT MODE

WORK ITEM

CONDITION

NGEC0034S04

TP SW/TP SEN IDLE POSI ADJ

쐌 FOLLOW THE BASIC INSPECTION IN THE SERVICE MANUAL.

IGNITION TIMING ADJ

쐌 IGNITION TIMING FEEDBACK CONTROL WILL BE When adjusting initial ignition timHELD BY TOUCHING “START”. AFTER DOING SO, ing ADJUST IGNITION TIMING WITH A TIMING LIGHT BY TURNING THE CRANKSHAFT POSITION SENSOR.

FUEL PRESSURE RELEASE

쐌 FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure from fuel line

SELF-LEARNING CONT

쐌 THE COEFFICIENT OF SELF-LEARNING CONTROL MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT.

When releasing fuel pressure from fuel line

OPEN THE VACUUM CUT VALVE BYPASS VALVE AND CLOSE THE EVAP CANISTER VENT CONTROL VALVE IN ORDER TO MAKE EVAP SYSTEM CLOSE UNDER THE FOLLOWING CONDITIONS. 쐌 BATTERY VOLTAGE IS SUFFICIENT. 쐌 IGN SW “ON” 쐌 ENGINE NOT RUNNING 쐌 AMBIENT TEMPERATURE IS ABOVE 0°C (32°F). 쐌 NO VACUUM AND NO HIGH PRESSURE IN EVAP SYSTEM 쐌 TANK FUEL TEMP. IS MORE THAN 0°C (32°F). 쐌 WITHIN 10 MINUTES AFTER STARTING “EVAP SYSTEM CLOSE” WHEN TRYING TO EXECUTE “EVAP SYSTEM CLOSE” UNDER THE CONDITIONS ABOVE, CONSULT-II WILL DISCONTINUE AND DISPLAY INSTRUCTIONS. NOTE: WHEN STARTING ENGINE, CONSULT-II MAY DISPLAY “BATTERY VOLTAGE IS LOW. CHARGE BATTERY”, EVEN WHEN USING A CHARGED BATTERY.

When detecting EVAP vapor leak point of EVAP system

쐌 IDLE CONDITION

When setting target idle speed

EVAP SYSTEM CLOSE

TARGET IDLE RPM ADJ*

MA

USAGE When adjusting the idle throttle position

EM LC

FE CL MT AT TF PD AX SU BR

*: This function is not necessary in the usual service procedure.

SELF DIAGNOSTIC MODE DTC and 1st Trip DTC

NGEC0034S05 NGEC0034S0501

Regarding items of “DTC and 1st trip DTC”, refer to “TROUBLE DIAGNOSIS — INDEX”, EC-18.

Freeze Frame Data and 1st Trip Freeze Frame Data NGEC0034S0502 Freeze frame data item* DIAG TROUBLE CODE [PXXXX]

ST RS BT

Description 쐌 Engine Control component part/control system has a trouble code, it is displayed as “PXXXX”. [Refer to “Alphabetical & P No. Index for DTC” (EC-18).]

HA SC EL

EC-97

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

CONSULT-II (Cont’d) Freeze frame data item*

Description

FUEL SYS-B1

쐌 “Fuel injection system status” at the moment a malfunction is detected is displayed. 쐌 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 [%]

쐌 The calculated load value at the moment a malfunction is detected is displayed.

COOLANT TEMP [°C] 쐌 The engine coolant temperature at the moment a malfunction is detected is displayed. or [°F] S-FUEL TRIM-B1 [%]

쐌 “Short-term fuel trim” at the moment a malfunction is detected is displayed. 쐌 The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule.

L-FUEL TRIM-B1 [%]

쐌 “Long-term fuel trim” at the moment a malfunction is detected is displayed. 쐌 The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim.

ENGINE SPEED [rpm]

쐌 The engine speed at the moment a malfunction is detected is displayed.

VEHICLE SPEED [km/h] or [mph]

쐌 The vehicle speed at the moment a malfunction is detected is displayed.

ABSOL TH-P/S [%]

쐌 The throttle valve opening angle at the moment a malfunction is detected is displayed.

B/FUEL SCHDL [msec]

쐌 The base fuel schedule at the moment a malfunction is detected is displayed.

INT/A TEMP SE [°C] or [°F]

쐌 The intake air temperature at the moment a malfunction is detected is displayed.

*: The items are the same as those of 1st trip freeze frame data.

DATA MONITOR MODE Monitored item [Unit]

ECM input signals

Main signals

Description

NGEC0034S06

Remarks

ENG SPEED [rpm]

쎻

쎻

쐌 Accuracy becomes poor if engine 쐌 Indicates the engine speed computed speed drops below the idle rpm. from the REF signal (180° signal) of the 쐌 If the signal is interrupted while the engine is running, an abnormal value camshaft position sensor. may be indicated.

MAS A/F SE-B1 [V]

쎻

쎻

쐌 The signal voltage of the mass air flow sensor is displayed.

쎻

쐌 “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction.

B/FUEL SCHDL [msec]

쐌 When the engine is stopped, a certain value is indicated.

A/F ALPHA-B1 [%]

쐌 Indicates the mean value of the air-fuel ratio feedback correction factor per cycle.

쐌 When the engine is stopped, a certain value is indicated. 쐌 This data also includes the data for the air-fuel ratio learning control.

COOLAN TEMP/S [°C] or [°F]

쐌 The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed.

쐌 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.

쎻

쎻

EC-98

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE CONSULT-II (Cont’d)

ECM input signals

Main signals

HO2S1 (B1) [V]

쎻

쎻

쐌 The signal voltage of the heated oxygen sensor 1 is displayed.

HO2S2 (B1) [V]

쎻

쎻

쐌 The signal voltage of the heated oxygen sensor 2 is displayed.

쎻

쐌 Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control: RICH ... means the mixture became “rich”, and control is being affected toward a leaner mixture. LEAN ... means the mixture became “lean”, and control is being affected toward a rich mixture.

쐌 After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. 쐌 When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously.

쐌 Display of heated oxygen sensor 2 signal: RICH ... means the amount of oxygen after three way catalyst is relatively small. LEAN ... means the amount of oxygen after three way catalyst is relatively large.

쐌 When the engine is stopped, a certain value is indicated.

Monitored item [Unit]

HO2S1 MNTR (B1) [RICH/LEAN]

HO2S2 MNTR (B1) [RICH/LEAN]

쎻

쎻

Description

Remarks

GI MA EM LC

FE CL MT AT

VHCL SPEED SE [km/h] or [mph]

쎻

쎻

쐌 The vehicle speed computed from the vehicle speed sensor signal is displayed.

BATTERY VOLT [V]

쎻

쎻

쐌 The power supply voltage of ECM is displayed.

THRTL POS SEN [V]

쎻

쎻

쐌 The throttle position sensor signal voltage is displayed.

PD

FUEL T/TMP SE [°C] or [°F]

쎻

쐌 The fuel temperature judged from the fuel tank temperature sensor signal voltage is displayed.

AX

INT/A TEMP SE [°C] or [°F]

쎻

쐌 The intake air temperature determined by the signal voltage of the intake air temperature sensor is indicated.

SU

EGR TEMP SEN [V]

쎻

쐌 The signal voltage of the EGR temperature sensor is displayed.

BR

쐌 The signal voltage of EVAP control system pressure sensor is displayed.

ST

ABSOL PRES/SE [V]

쐌 The signal voltage of the absolute pressure sensor is displayed.

RS

FULL LEVEL SE [V]

쐌 The signal voltage of the fuel level sensor is displayed.

쎻

EVAP SYS PRES [V]

TF

BT 쐌 After starting the engine, [OFF] is displayed regardless of the starter signal.

START SIGNAL [ON/OFF]

쎻

쎻

쐌 Indicates [ON/OFF] condition from the starter signal.

CLSD THL POS [ON/OFF]

쎻

쎻

쐌 Indicates idle position [ON/OFF] computed by ECM according to the throttle position sensor signal.

SC

쐌 Indicates mechanical contact [ON/OFF] condition of the closed throttle position switch.

EL

CLSD THL/P SW [ON/OFF]

EC-99

HA

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

CONSULT-II (Cont’d) ECM input signals

Main signals

Description

AIR COND SIG [ON/OFF]

쎻

쎻

쐌 Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioning signal.

P/N POSI SW [ON/OFF]

쎻

쎻

쐌 Indicates [ON/OFF] condition from the PNP switch signal.

쎻

쐌 Indicates [ON/OFF] condition of the power steering oil pressure switch determined by the power steering oil pressure switch signal.

Monitored item [Unit]

PW/ST SIGNAL [ON/OFF]

쎻

IGNITION SW [ON/OFF]

쎻

쐌 Indicates [ON/OFF] condition from ignition switch.

INJ PULSE-B1 [msec]

쎻

쐌 Indicates the actual fuel injection pulse width compensated by ECM according to the input signals.

IGN TIMING [BTDC]

쎻

쐌 Indicates the ignition timing computed by ECM according to the input signals.

CAL/LD VALUE [%]

쐌 “Calculated load value” indicates the value of the current airflow divided by peak airflow.

ABSOL TH·P/S [%]

쐌 “Absolute throttle position sensor” indicates the throttle opening computed by ECM according to the signal voltage of the throttle position sensor.

MASS AIRFLOW [g·m/s]

쐌 Indicates the mass airflow computed by ECM according to the signal voltage of the mass air flow sensor.

IACV-AAC/V [%]

PURG VOL C/V [%]

Remarks

쎻

쐌 Indicates the IACV-AAC valve control value computed by ECM according to the input signals.

쎻

쐌 Indicates the EVAP canister purge volume control value computed by the ECM according to the input signals. 쐌 The opening becomes larger as the value increases.

AIR COND RLY [ON/OFF]

쐌 Indicates the air conditioner relay control condition determined by ECM according to the input signals.

EGRC SOL/V [ON/OFF] (FLOW/CUT)

쐌 Indicates the control condition of the EGRC-solenoid valve determined by ECM according to the input signals. 쐌 ON ... EGR valve is operational OFF ... EGR valve operation is cut-off

FUEL PUMP RLY [ON/OFF]

쐌 Indicates the fuel pump relay control condition determined by ECM according to the input signals.

VC/V BYPASS/V [ON/OFF]

쐌 The control condition of the vacuum cut valve bypass valve (determined by ECM according to the input signal) is indicated. 쐌 ON ... Open OFF ... Closed

EC-100

쐌 When the engine is stopped, a certain computed value is indicated.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE CONSULT-II (Cont’d)

Monitored item [Unit]

VENT CONT/V [ON/OFF]

ECM input signals

Main signals

Description 쐌 The control condition of the EVAP canister vent control valve (determined by ECM according to the input signal) is indicated. 쐌 ON ... Closed OFF ... Open

HO2S1 HTR (B1) [ON/OFF]

쐌 Indicates [ON/OFF] condition of heated oxygen sensor 1 heater determined by ECM according to the input signals.

HO2S2 HTR (B1) [ON/OFF]

쐌 Indicates [ON/OFF] condition of heated oxygen sensor 2 heater determined by ECM according to the input signals.

VOLTAGE [V]

쐌 Voltage measured by the voltage probe.

Frequency [msec] or [Hz] or [%]

Remarks

쐌 Pulse width, frequency or duty cycle measured by the pulse probe.

GI MA EM LC

FE 쐌 Only “#” is displayed if item is unable to be measured. 쐌 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.

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-101

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

CONSULT-II (Cont’d)

DATA MONITOR (SPEC) MODE

=NGEC0034S11

ECM input signals

Main signals

Description

ENG SPEED [rpm]

쎻

쎻

쐌 Indicates the engine speed computed from the REF signal (180° signal) of the camshaft position sensor.

MAS A/F SE-B1 [V]

쎻

쎻

쐌 The signal voltage of the mass air flow sensor specification is displayed.

쐌 When engine is running specification range is indicated.

쐌 “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction.

쐌 When engine is running specification range is indicated.

쐌 The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.

쐌 When engine is running specification range is indicated. 쐌 This data also includes the data for the air-fuel ratio learning control.

Monitored item [Unit]

B/FUEL SCHDL [msec]

A/F ALPHA-B1 [%]

쎻

Remarks

NOTE: 쐌 Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

ACTIVE TEST MODE TEST ITEM

CONDITION

NGEC0034S07

JUDGEMENT

CHECK ITEM (REMEDY)

쐌 Engine: Return to the original 쐌 Harness and connector If trouble symptom disappears, see trouble condition FUEL INJECTION 쐌 Fuel injectors 쐌 Change the amount of fuel injec- CHECK ITEM. 쐌 Heated oxygen sensor 1 tion using CONSULT-II. 쐌 Engine: Return to the original trouble condition IGNITION TIMING 쐌 Timing light: Set 쐌 Retard the ignition timing using CONSULT-II.

IACV-AAC/V OPENING

쐌 Engine: After warming up, idle the engine. 쐌 Change the IACV-AAC valve opening percent using CONSULT-II.

If trouble symptom disappears, see 쐌 Adjust initial ignition timing CHECK ITEM.

Engine speed changes according to the opening percent.

쐌 Harness and connector 쐌 IACV-AAC valve

POWER BALANCE

쐌 Engine: After warming up, idle the engine. 쐌 Air conditioner switch “OFF” 쐌 Shift lever “N” 쐌 Cut off each injector signal one at a time using CONSULT-II.

Engine runs rough or dies.

쐌 쐌 쐌 쐌 쐌 쐌

ENG COOLANT TEMP

쐌 Engine: Return to the original trouble condition 쐌 Change the engine coolant temperature indication using CONSULT-II.

쐌 Harness and connector If trouble symptom disappears, see 쐌 Engine coolant temperature senCHECK ITEM. sor 쐌 Fuel injectors

FUEL PUMP RELAY

쐌 Ignition switch: ON (Engine stopped) 쐌 Turn the fuel pump relay “ON” and “OFF” using CONSULT-II and listen to operating sound.

Fuel pump relay makes the operat- 쐌 Harness and connector ing sound. 쐌 Fuel pump relay

EGRC SOLENOID VALVE

쐌 Ignition switch: ON 쐌 Turn EGRC-solenoid valve “ON” and “OFF” using CONSULT-II and listen to operating sound.

EGRC-solenoid valve makes an operating sound.

EC-102

Harness and connector Compression Injectors Power transistor Spark plugs Ignition coils

쐌 Harness and connector 쐌 EGRC-solenoid valve

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE CONSULT-II (Cont’d)

TEST ITEM

CONDITION

JUDGEMENT

CHECK ITEM (REMEDY)

PURG VOL CONT/V

쐌 Engine: After warming up, run engine at 1,500 rpm. Engine speed changes according 쐌 Change the EVAP canister purge to the opening step. volume control valve opening step using CONSULT-II.

FUEL T/TEMP SEN

쐌 Change the fuel tank temperature using CONSULT-II.

VENT CONTROL/V

쐌 Ignition switch: ON (Engine stopped) 쐌 Turn solenoid valve “ON” and “OFF” using CONSULT-II and listen to operating sound.

Solenoid valve makes an operating 쐌 Harness and connector sound. 쐌 Solenoid valve

VC/V BYPASS/V

쐌 Ignition switch: ON (Engine stopped) 쐌 Turn solenoid valve “ON” and “OFF” using CONSULT-II and listen to operating sound.

Solenoid valve makes an operating 쐌 Harness and connector sound. 쐌 Solenoid valve

쐌 Harness and connector 쐌 EVAP canister purge volume control valve

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-103

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

CONSULT-II (Cont’d)

DTC & SRT CONFIRMATION MODE SRT STATUS Mode

=NGEC0034S08 NGEC0034S0801

For details, refer to “SYSTEM READINESS TEST (SRT) CODE”, EC-75.

SRT Work Support Mode

NGEC0034S0803

This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status.

DTC Work Support Mode TEST MODE

EVAP SYSTEM

TEST ITEM

CONDITION

EC-339

EVAP SML LEAK P0442/P1442

EC-350

EVAP V/S LEAK P0456/P1456

EC-405

PURG VOL CN/V P1444

EC-512

VC CUT/V BP/V P1491

EC-546

HO2S1 (B1) P0133

EC-218

HO2S1 (B1) P0134

Refer to corresponding trouble diagnosis for DTC.

HO2S1 (B1) P1143 HO2S1 (B1) P1144

EGR SYSTEM

REFERENCE PAGE

PURG FLOW P0441

HO2S1

HO2S2

NGEC0034S0802

EC-229 EC-449 EC-456

HO2S2 (B1) P0139

EC-245

HO2S2 (B1) P1146

EC-463

HO2S2 (B1) P1147

EC-473

EGR SYSTEM P0400

EC-308

EGRC-BPT/VLV P0402

EC-320

EGR SYSTEM P1402

EC-503

REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA) NGEC0034S10 CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1) “AUTO TRIG” (Automatic trigger): 쐌 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 the percentage reached 100%, “REALTIME DIAG” screen is displayed. If “STOP” is touched on the screen during “Recording Data ... xx%”, “REAL-TIME DIAG” screen is also displayed. The recording time after the malfunction detection and the recording speed can be changed by “TRIGGER POINT” and “RECORDING Speed”. Refer to CONSULT-II OPERATION MANUAL. 2) “MANU TRIG” (Manual trigger): 쐌 DTC/1st trip DTC and malfunction item will not be displayed automatically on CONSULT-II screen even though a malfunction is detected by ECM.

EC-104

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE CONSULT-II (Cont’d)

DATA MONITOR can be performed continuously even though a malfunction is detected. Use these triggers as follows: 1) “AUTO TRIG” 쐌 While trying to detect the DTC/1st trip DTC by performing the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE”, be sure to select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected. 쐌 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 “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE”, the moment a malfunction is found the DTC/ 1st trip DTC will be displayed. (Refer to “Incident Simulation Tests” in “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”, GI-22. 2) “MANU TRIG” 쐌 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.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA

SEF720X

SC EL

EC-105

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Generic Scan Tool (GST)

Generic Scan Tool (GST) DESCRIPTION

NGEC0035 NGEC0035S01

Generic Scan Tool (OBDII scan tool) complying with SAE J1978 has 8 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.

NGEC0035S02

Turn ignition switch OFF. Connect “GST” to data link connector for GST which is located under LH dash panel near the fuse box cover.

SEF163X

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-106

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

KA24DE

Generic Scan Tool (GST) (Cont’d)

FUNCTION Diagnostic test mode

NGEC0035S03

Function

READINESS TESTS

This mode gains access to current emission-related data values, including analog inputs and outputs, digital inputs and outputs, 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-97).]

MODE 3

DTCs

This mode gains access to emission-related power train trouble codes which were stored by ECM.

CLEAR DIAG INFO

This mode can clear all emission-related diagnostic information. This includes: 쐌 Clear number of diagnostic trouble codes (MODE 1) 쐌 Clear diagnostic trouble codes (MODE 3) 쐌 Clear trouble code for freeze frame data (MODE 1) 쐌 Clear freeze frame data (MODE 2) 쐌 Reset status of system monitoring test (MODE 1) 쐌 Clear on board monitoring test results (MODE 6 and 7)

(ON BOARD TESTS)

This mode accesses the results of on board diagnostic monitoring tests of specific components/systems that are not continuously monitored.

(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 1

MODE 4

MODE 6

MODE 7

MODE 8

MODE 9

—

(CALIBRATION ID)

This mode can close EVAP system in ignition switch “ON” position (Engine stopped). When this mode is performed, the following parts can be opened or closed. 쐌 EVAP canister vent control valve open 쐌 Vacuum cut valve bypass valve closed In the following conditions, this mode cannot function. 쐌 Low ambient temperature 쐌 Low battery voltage 쐌 Engine running 쐌 Ignition switch OFF 쐌 Low fuel temperature 쐌 Too much pressure is applied to EVAP system This mode is to enable the off-board to request vehicle specific information such as Vehicle Identification Number (VIN) and Calibration ID.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-107

IDX

TROUBLE DIAGNOSIS — INTRODUCTION

KA24DE

Introduction

Introduction

MEF036D

SEF233G

NGEC0036

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-110. 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

SEF907L

NGEC0036S01

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 lamp to come on steady or blink and DTC to be detected. Examples: 쐌 Vehicle ran out of fuel, which caused the engine to misfire. 쐌 Fuel filler cap was left off or incorrectly screwed on, allowing fuel to evaporate into the atmosphere.

EC-108

TROUBLE DIAGNOSIS — INTRODUCTION

KA24DE Introduction (Cont’d)

Worksheet Sample

NGEC0036S0101

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST MTBL0017

RS BT HA SC EL

EC-109

IDX

TROUBLE DIAGNOSIS — INTRODUCTION

KA24DE

Work Flow

Work Flow

NGEC0037

SEF510ZF

*1: EC-127 *2: If time data of “SELF-DIAG RESULTS” is other than “0” or “1t” refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT”, EC-150. *3: If the incident cannot be duplicated, refer to “TROUBLE

DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. *4: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to “TROUBLE DIAGNOSIS FOR POWER SUPPLY”, EC-151.

EC-110

*5: If the malfunctioning part cannot be found, refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. *6: EC-81 *7: EC-146

TROUBLE DIAGNOSIS — INTRODUCTION

KA24DE Work Flow (Cont’d)

DESCRIPTION FOR WORK FLOW STEP

NGEC0037S01

DESCRIPTION

STEP I

Get detailed information about the conditions and the environment when the incident/symptom occurred using the “DIAGNOSTIC WORK SHEET”, EC-109.

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-86.) 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-128.) 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”, GI-23. 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”, GI-23. 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

STEP VI

STEP VII

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-112.) If CONSULT-II is available, perform “DATA MONITOR (SPEC)” mode with CONSULT-II and proceed to the “TROUBLE DIAGNOSIS — SPECIFICATION VALUE”, EC-146. (If malfunction is detected, proceed to “REPAIR/REPLACE”.) Then perform inspections according to the Symptom Matrix Chart. (Refer to EC-128.) 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-137. 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 “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”, “Circuit Inspection”, GI-25. Repair or replace the malfunction parts. 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] 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-86.)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-111

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE

Basic Inspection

Basic Inspection

NGEC0038

Precaution: Perform Basic Inspection without electrical or mechanical loads applied; 쐌 Headlamp switch is OFF, 쐌 Air conditioner switch is OFF, 쐌 Rear window defogger switch is OFF, 쐌 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: 쐌 Harness connectors for improper connections 쐌 Vacuum hoses for splits, kinks, or improper connections 쐌 Wiring for improper connections, pinches, or cuts

SEF142I

With CONSULT-II

䊳

GO TO 2.

With GST

䊳

GO TO 4.

No tools

䊳

GO TO 5.

2

CONNECT CONSULT-II TO THE VEHICLE

Connect “CONSULT-II” to the data link connector and select “ENGINE” from the menu. Refer to EC-94.

SEF163X

䊳

GO TO 3.

EC-112

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE Basic Inspection (Cont’d)

3 1. 2. 3. 4. 5.

CHECK FI CAM FUNCTION With CONSULT-II Adjust accelerator wire. Refer to “Adjust Accelerator Wire”, FE-3. Warm up engine to 75°C (167°F). Stop engine and wait at least 5 seconds, then turn ignition switch ON. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. When the engine coolant temp is 75 to 85°C (167 to 185°F), confirm the clearance is less than 0.05mm (0.002in), between stopper and throttle drum as shown in the figure.

GI MA EM LC

FE AEC871A

CL

OK or NG OK

䊳

GO TO 6.

NG

䊳

1. Replace throttle body assembly. Refer to “OUTER COMPONENT PARTS”, EM-12. 2. GO TO 6.

4 1. 2. 3. 4. 5.

MT AT

CHECK FI CAM FUNCTION With GST Adjust accelerator wire. Refer to “Adjust Accelerator Wire”, FE-3. Warm up engine to 75°C (167°F). Stop engine and wait at least 10 seconds, then turn ignition switch ON. Select “MODE 1” with GST. When the engine coolant temp is 75 to 85°C (167 to 185°F), confirm the clearance is less than 0.05mm (0.002in), between stopper and throttle drum as shown in the figure.

TF PD AX SU BR ST

AEC871A

RS

OK or NG

BT

OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 14.

NG

䊳

1. Replace throttle body assembly. Refer to “OUTER COMPONENT PARTS”, EM-12. 2. With CONSULT-II: GO TO 6. Without CONSULT-II: GO TO 14.

HA SC EL

EC-113

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE

Basic Inspection (Cont’d)

5

CHECK FI CAM FUNCTION

No Tools 1. Adjust accelerator wire. Refer to “Adjust Accelerator Wire”, FE-3. 2. Disconnect engine coolant temperature sensor harness connector and check resistance as shown in the figure.

SEF536H

3. Warm up engine until the resistance of coolant temperature sensor is 0.26 to 0.39 kΩ. 4. Turn ignition switch OFF. 5. When engine coolant temperature is 75 to 85°C (167 to 185°F), with the voltage between 1.10 to 1.36V, make sure that the clearance is less than 0.05 mm (0.002 in), between stopper and throttle adjusting screw as shown in figure.

AEC871A

OK or NG OK

䊳

GO TO 14.

NG

䊳

1. Replace throttle body assembly. Refer to “OUTER COMPONENT PARTS”, EM-12. 2. GO TO 14.

EC-114

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE Basic Inspection (Cont’d)

6

CHECK IGNITION TIMING

With CONSULT-II 1. Warm up engine to normal operating temperature. 2. Select “IGNITION TIMING ADJ” in “WORK SUPPORT” mode. 3. Touch “START”.

GI MA EM LC

FE

PEF546N

CL

4. Check ignition timing at idle using timing light.

MT AT TF PD SEF320V

Ignition timing: MT: 20°±2° BTDC

AX OK or NG

OK

䊳

GO TO 7.

SU

NG

䊳

1. Adjust ignition timing by turning distributor. Refer to “Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment”, EC-59. 2. GO TO 7.

BR ST RS BT HA SC EL

EC-115

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE

Basic Inspection (Cont’d)

7

CHECK BASE IDLE SPEED

With CONSULT-II 1. Select “IGNITION TIMING ADJ” in “WORK SUPPORT” mode and touch “START”.

SEF714Z

2. Check idle speed. MT: 750±50 rpm OK or NG OK

䊳

GO TO 8.

NG

䊳

1. Adjust base idle speed by turning idle speed adjusting screw. Refer to “Idle Speed/ Ignition Timing/Idle Mixture Ratio Adjustment”, EC-59. 2. GO TO 8.

EC-116

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE Basic Inspection (Cont’d)

8

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION (CHECK THROTTLE POSITION SENSOR IDLE POSITION)

With CONSULT-II NOTE: Always check ignition timing and base idle speed before performing the following. 1. Warm up engine to normal operating temperature. 2. Check FI cam. Refer to procedure 3. 3. Stop engine. 4. Turn ignition switch ON. 5. Select “DATA MONITOR” mode with CONSULT-II. 6. Select “CLSD THL/P SW” from the menu. 7. Read “CLSD THL/P SW” signal under the following conditions. 쐌 Insert a 0.1 mm (0.004 in) and 0.3 mm (0.012 in) feeler gauge alternately between the throttle adjust screw (TAS) and throttle drum as shown in the figure and check the signal.

GI MA EM LC

FE CL MT AEC871A

AT TF PD AX

SEF197Y

“CLSD THL/P SW” signal should remain “ON” while inserting 0.1 mm (0.004 in) feeler gauge. “CLSD THL/P SW” signal should remain “OFF” while inserting 0.3 mm (0.012 in) feeler gauge. OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 9.

SU BR ST RS BT HA SC EL

EC-117

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE

Basic Inspection (Cont’d)

9

ADJUSTMENT THROTTLE POSITION SENSOR IDLE POSITION-1

With CONSULT-II NOTE: 쐌 Never adjust throttle adjust screw (TAS). 쐌 Do not touch throttle drum when checking “CLSD THL/P SW” signal. Doing so may cause an incorrect adjustment. 1. Warm engine up to normal operating temperature. 2. Check FI cam. Refer to procedure 3. 3. Stop engine. 4. Loosen throttle position sensor fixing bolts. 5. Turn ignition switch ON. 6. Select “CLSD THL/P SW” in “DATA MONITOR” mode. 7. Insert a 0.1 mm (0.004 in) feeler gauge between throttle adjust screw and throttle drum as shown in the figure.

AEC871A

8. Open throttle valve and then close. 9. Check “CLSD THL/P SW” signal.

SEF197Y

“CLSD THL/P SW” signal should remain “OFF” when the throttle valve is closed. If it is impossible to adjust closed throttle position switch, replace throttle position sensor. OK or NG OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

EC-118

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE Basic Inspection (Cont’d)

10

ADJUSTMENT THROTTLE POSITION SENSOR IDLE POSITION-2

With CONSULT-II Turn throttle position sensor body counterclockwise until “CLSD THL/P SW” signal switches to “OFF”.

GI MA EM LC

AEC872A

䊳

11

GO TO 11.

FE

ADJUSTMENT THROTTLE POSITION SENSOR IDLE POSITION-3

With CONSULT-II 1. Temporarily tighten sensor body fixing bolts as follows. 쐌 Gradually move the sensor body clockwise and stop it when “CLSD THL/P SW” signal switches from “OFF” to “ON” when tightening sensor body fixing bolts.

CL MT AT TF PD AX

AEC872A

2. 3. 4. 5. 6.

Make sure two or three times that the signal is “ON” when the throttle valve is closed and “OFF” when it is opened. Remove 0.1 mm (0.004 in) feeler gauge then insert 0.3 mm (0.012 in) feeler gauge. Make sure two or three times that the signal remains “OFF” when the throttle valve is closed. Tighten throttle position sensor. Check “CLSD THL/P SW” signal again. The signal remains “OFF” while closing throttle valve. OK or NG

OK

䊳

1. Remove 0.3 mm (0.012 in) feeler gauge. 2. GO TO 12.

NG

䊳

GO TO 9.

SU BR ST RS BT HA SC EL

EC-119

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE

Basic Inspection (Cont’d)

12

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. 2. Warm up engine to normal operating temperature. 3. Select “CLSD THL POS” in “DATA MONITOR” mode manual trigger. 4. Stop engine. (Turn ignition switch OFF.) 5. Turn ignition switch ON and wait at least 5 seconds.

SEF864V

6. Turn ignition switch OFF and wait at least 5 seconds. 7. Repeat steps 5 and 6 until “CLSD THL POS” in “DATA MONITOR” mode with CONSULT-II changes to “ON”.

SEF715Z

䊳

13

GO TO 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. 3. Check idle speed. MT: 800±50 rpm OK or NG OK

䊳

INSPECTION END

NG

䊳

Adjust idle speed. Refer to “Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment”, EC-59. Inspection end after adjust idle speed.

EC-120

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE Basic Inspection (Cont’d)

14

CHECK IGNITION TIMING

Without CONSULT-II 1. Warm up engine to normal operating temperature. 2. Stop engine and disconnect throttle position sensor harness connector.

GI MA EM LC

SEF265S

FE

3. Start engine. 4. Rev engine (2,000 to 3,000 rpm) two or three times under no-load and then run engine at idle speed. 5. Check ignition timing at idle using timing light.

CL MT AT TF SEF320V

Ignition timing: MT: 20°±2° BTDC

PD OK or NG

OK

䊳

GO TO 15.

NG

䊳

1. Adjust ignition timing by turning distributor. Refer to “Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment”, EC-59. 2. GO TO 15.

15

AX SU BR

CHECK BASE IDLE SPEED

Without CONSULT-II Make sure that engine speed falls to the following speed. M/T: 750±50 rpm OK or NG OK

䊳

GO TO 16.

NG

䊳

1. Adjust base idle speed by turning idle speed adjusting screw. Refer to “Idle Speed/ Ignition Timing/Idle Mixture Ratio Adjustment”, EC-59. 2. GO TO 16.

ST RS BT HA SC EL

EC-121

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE

Basic Inspection (Cont’d)

16

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION (CHECK THROTTLE POSITION SENSOR IDLE POSITION)

Without CONSULT-II NOTE: Always check ignition timing and base idle speed before performing the following. 1. Warm up engine to normal operating temperature. 2. Check FI cam. Refer to procedure 5. 3. Stop engine. 4. Disconnect closed throttle position switch harness connector . 5. Connect the tester probe to closed throttle position switch terminals 5 and 6. 6. Check harness continuity under the following conditions.

SEF862V

쐌 Insert the 0.1 mm (0.004 in) and 0.3 mm (0.012 in) feeler gauge alternately between the throttle adjust screw (TAS) and throttle drum as shown in the figure.

AEC871A

“Continuity should exist” while inserting 0.1 mm (0.004 in) feeler gauge. “Continuity should not exist” while inserting 0.3 mm (0.012 in) feeler gauge. OK or NG OK

䊳

GO TO 20.

NG

䊳

GO TO 17.

EC-122

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE Basic Inspection (Cont’d)

17

ADJUSTMENT THROTTLE POSITION SENSOR IDLE POSITION-1

Without CONSULT-II NOTE: 쐌 Never adjust throttle adjust screw (TAS). 쐌 Do not touch throttle drum when checking “continuity”. Doing so may cause an incorrect adjustment. 1. Warm engine up to normal operating temperature. 2. Check FI cam. Refer to procedure 5. 3. Stop engine. 4. Loosen throttle position sensor fixing bolts. 5. Disconnect closed throttle position sensor harness connector. 6. Insert 0.1 mm (0.004 in) feeler gauge between the throttle adjust screw and throttle drum as shown in the figure.

GI MA EM LC

FE CL MT AEC871A

7. Open throttle valve then close. 8. Check continuity between closed throttle position switch terminal 5 and 6.

AT TF PD AX SEF862V

The continuity should not exist while closing the throttle position sensor body. If it is impossible to adjust closed throttle position switch, replace throttle position sensor. OK or NG OK

䊳

GO TO 19.

NG

䊳

GO TO 18.

SU BR ST RS BT HA SC EL

EC-123

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE

Basic Inspection (Cont’d)

18

ADJUSTMENT THROTTLE POSITION SENSOR IDLE POSITION-2

Without CONSULT-II Turn throttle position sensor body counterclockwise until continuity does not exist.

AEC872A

䊳

19

GO TO 19.

ADJUSTMENT THROTTLE POSITION SENSOR IDLE POSITION-3

Without CONSULT-II 1. Temporarily tighten sensor body fixing bolts as follows. 쐌 Gradually move the sensor body clockwise and stop it when the continuity comes to exist, then tighten sensor body fixing bolts.

AEC872A

2. Make sure two or three times that the continuity exists when the throttle valve is closed and continuity does not exist when it is opened. 3. Remove 0.1 mm (0.004 in) feeler gauge then insert 0.3 mm (0.012 in) feeler gauge. 4. Make sure two or three times that continuity does not exist when the throttle valve is closed. 5. Tighten throttle position sensor. 6. Check the continuity again. Continuity does not exist while closing the throttle valve. OK or NG OK

䊳

GO TO 20.

NG

䊳

GO TO 17.

20

REINSTALLATION

Without CONSULT-II 1. Remove 0.3 mm (0.012 in) feeler gauge. 2. Reconnect throttle position sensor harness connector and closed throttle position switch harness connector. 3. Rev engine (2,000 to 3,000 rpm) two or three times under no-load and then run engine at idle speed. 䊳

GO TO 21.

EC-124

TROUBLE DIAGNOSIS — BASIC INSPECTION

KA24DE Basic Inspection (Cont’d)

21

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. 2. Warm up engine to normal operating temperature. 3. Stop engine. (Turn ignition switch “OFF”.) 4. Turn ignition switch “ON” and wait at least 5 seconds.

GI MA EM LC

FE CL SEF864V

5. Turn ignition switch “OFF” and wait at least 5 seconds. 6. Repeat steps 4 and 5, 20 times. 䊳

MT

GO TO 22.

AT 22

CHECK TARGET IDLE SPEED

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. MT: 800±50 rpm OK or NG OK

䊳

GO TO 23.

NG

䊳

1. Adjust target idle speed. Refer to “Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment”, EC-59. 2. GO TO 23.

23

ERASE UNNECESSARY DTC

After this inspection, unnecessary DTC No. might be displayed. Erase the stored memory in ECM and TCM. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, (EC-86) . 䊳

TF PD AX SU BR ST

INSPECTION END

RS BT HA SC EL

EC-125

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

DTC Inspection Priority Chart

DTC Inspection Priority Chart

NGEC0039

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

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

P0101, P0102, P0103 MAF sensor P0112, P0113, P0127 IAT sensor P0117, P0118, P0125 ECT sensor P0121, P0122, P0123 TP sensor P0128 Thermostat function P0181, P0182, P0183 FTT sensor P0327, P0328 KS P0340 CMP sensor P0460, P0461, P0462, P0463, P1464 Fuel level sensor P0500 VSS P0605 ECM P1400 EGRC-solenoid valve P1706 PNP switch

2

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

P0031, P0032 HO2S1 heater P0037, P0038 HO2S2 heater P0107, P0108 Absolute pressure sensor P0132, P0133, P0134, P1143, P1144 HO2S1 P0138, P0139, P1146, P1147 HO2S2 P0335, P1336 CKP sensor P0405, P0406 EGRT sensor P0441 EVAP control system purge flow monitoring P0444, P0445, P1444 EVAP canister purge volume control solenoid valve P0447, P1446, P1448 EVAP canister vent control valve P0452, P0453 EVAP control system pressure sensor P0510 CTP switch P1490, P1491 Vacuum cut valve bypass valve

3

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

P0171, P0172 Fuel injection system function P0300 — P0304 Misfire P0400, P1402 EGR function P0402 EGRC-BPT valve P0420 Three way catalyst function P0442, P0455, P0456, P1456 EVAP control system P0505 ISC system P1148 Closed loop control

EC-126

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE Fail-safe Chart

Fail-safe Chart

=NGEC0040

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 MIL illuminates.

GI

DTC No. Detected items

CONSULT-II GST

Engine operating condition in fail-safe mode

P0102 P0103

Mass air flow sensor circuit

Engine speed will not rise more than 2,400 rpm due to the fuel cut.

P0112 P0113

Intake air temperature sen- The ECM functions on the assumption that the intake air temperature is 25°C (77°F). sor

P0117 P0118

Engine coolant temperature sensor circuit

FE

Just as ignition switch is turned to ON or Start

40°C (104°F)

CL

More than approx. 4 minutes after ignition ON or Start

80°C (176°F)

MT 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

Driving condition

When engine is idling When accelerating Unable to ECM access ECM

LC

Engine coolant temperature decided (CONSULTII display)

Except as shown above Throttle position sensor circuit

EM

Engine coolant temperature will be determined by ECM based on the time after turning ignition switch to ON or START. CONSULT-II displays the engine coolant temperature decided by ECM. Condition

P0122 P0123

MA

AT TF

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 MIL 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.

PD AX SU BR

ECM fail-safe operation Engine speed will not rise more than 3,000 rpm

Engine speed Fuel injection

Simultaneous multiport fuel injection system

Ignition timing

Ignition timing is fixed at the preset valve Fuel pump relay is “ON” when engine is running and “OFF” when engine stalls

Fuel pump IACV-AAC valve

Replace ECM, if ECM fail-safe condition is confirmed.

ST RS BT

Full open

HA SC EL

EC-127

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

Symptom Matrix Chart

Symptom Matrix Chart

NGEC0041

SYSTEM — ENGINE CONTROL SYSTEM

NGEC0041S01

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

AF

AG

AH

AJ

AK

AL

AM

HA

AB

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

IACV-FICD solenoid valve circuit

2

2

3

Incorrect ignition timing adjustment

3

3

Ignition circuit

1

HESITATION/SURGING/FLAT SPOT

ENGINE STALL

AE

HARD/NO START/RESTART (EXCP. HA)

AC AD

AA

Warranty symptom code Fuel

SPARK KNOCK/DETONATION

SYMPTOM

2

2

4

4

2

2

4

4

4

4

4

1 3

3

3

1

1

1

2

2 2

Main power supply and ground circuit Air conditioner circuit

Air

Ignition

EGR

EGR system

EC-580 EC-58

2

EC-571

4

4

EC-40

4

4

4

1

1

1

1

2

2

2

2

2

3

3

3

3

3

EC-592

1

1

1

1

EC-59

2

2

2

2

2

EC-562

2

3

3

3

EC-496

1

2

3

3

3

EC-308, 320, 503

2

2

3

3

3

2

2

3

3

3

1 - 6: The numbers refer to the order of inspection. (continued on next page)

EC-128

3

3

2

2

3

3

3

3

4

2

4

EGRC-solenoid valve circuit

4

3

Reference page

3 2 3

1

EC-55 EC-59 2

EC-434

3

2

EC-151

3

2

HA-26

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

Symptom Matrix Chart (Cont’d) SYMPTOM

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-300

2

2

2

2

2

EC-168

2

3

2

2

2

2

EC-229, 449

1

2

3

2

3

2

2

3

2

EC-185, 204

Throttle position sensor circuit

1

2

2

2

2

2

2

2

EC-190

Incorrect throttle position sensor adjustment

3

1

1

1

1

1

1

1

EC-112

Vehicle speed sensor circuit

2

3

3

3

EC-430

3

EC-290

3

EC-447, 127

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

GI

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

EM Reference page

LC

FE

EC-576

PNP switch circuit Power steering oil pressure switch circuit

3

MA

3

3

2

1 - 6: The numbers refer to the order of inspection. (continued on next page)

3

3

3

3

3

CL MT AT TF PD AX SU

EC-556 EC-588

BR ST RS BT HA SC EL

EC-129

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

Symptom Matrix Chart (Cont’d)

SYSTEM — ENGINE MECHANICAL & OTHER

NGEC0041S03

Fuel

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

AB

SPARK KNOCK/DETONATION

AA

AC AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

HESITATION/SURGING/FLAT SPOT

ENGINE STALL

Warranty symptom code

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Fuel tank

Reference page

FE-5 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-3

Air leakage from intake manifold/Collector/Gasket Cranking

—

Battery

SC-4 1

1

1

1

1

1

1

Alternator circuit

SC-26

Starter circuit

3

Flywheel

6

EM-52

PNP switch

4

—

1

1 - 6: The numbers refer to the order of inspection. (continued on next page)

EC-130

SC-10

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

Symptom Matrix Chart (Cont’d)

Engine

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

5

HIGH IDLE/LOW IDLE

5

LACK OF POWER/POOR ACCELERATION

AB

GI

SPARK KNOCK/DETONATION

AA

AC AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

HESITATION/SURGING/FLAT SPOT

ENGINE STALL

Warranty symptom code

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

MA EM Reference page

LC

FE CL

Cylinder head 5

5

5

5

5

5

Cylinder head gasket

4

3

MT

Cylinder block Piston

4

Piston ring 6

6

6

6

6

6

6

EM-29, EM-44

AT

6

Connecting rod

TF

Bearing Crankshaft Valve mechanism

PD

Timing chain Camshaft 5

5

5

5

5

5

5

EM-18, EM-29

5

Intake valve

AX

3 Exhaust valve Exhaust

Exhaust manifold/Tube/ Muffler/Gasket

SU 5

5

5

5

5

5

5

5

FE-9

5

5

5

5

5

5

5

5

MA-21, LC-6

Three way catalyst Lubrication

Oil pan/Oil strainer/Oil pump/ Oil filter/Oil gallery

BR ST

Oil level (Low)/Filthy oil Cooling

RS

Radiator/Hose/Radiator filler cap Thermostat Water pump

5 5

5

5

5

5

5

5

LC-11 4

BT

5

HA

Water gallery Coolant level (low)/ Contaminated coolant

MA-17

SC

1 - 6: The numbers refer to the order of inspection.

EL

EC-131

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NGEC0042

Remarks: 쐌 Specification data are reference values. 쐌 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.) 쐌 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

SPECIFICATION

ENG SPEED

쐌 Tachometer: Connect 쐌 Run engine and compare tachometer indication with the CONSULT-II value. Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

Idle

0.9 - 1.8V

MAS A/F SE-B1

쐌 쐌 쐌 쐌

2,500 rpm

1.9 - 2.3V

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

0.8 - 1.2 msec

2,000 rpm

0.8 - 1.2 msec

Maintaining engine speed at 2,000 rpm

50 - 159%

B/FUEL SCHDL

A/F ALPHA-B1

쐌 Engine: After warming up

COOLAN TEMP/S

쐌 Engine: After warming up

More than 70°C (158°F) 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1) HO2S2 (B1) HO2S2 MNTR (B1)

Almost the same speed as the CONSULT-II value.

쐌 Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

쐌 Engine: After warming up

Revving engine from idle to 3,000 rpm quickly

0 - 0.3V +, Approx. 0.6 - 1.0V LEAN +, RICH

VHCL SPEED SE

쐌 Turn drive wheels and compare speedometer indication with the CONSULT-II value

Almost the same speed as the CONSULT-II value

BATTERY VOLT

쐌 Ignition switch: ON (Engine stopped)

11 - 14V

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

Throttle valve fully closed

0.2 - 0.8V

THRTL POS SEN

Throttle valve fully opened

3.5 - 4.5V

EGR TEMP SEN

쐌 Engine: After warming up

Less than 4.5V

EVAP SYS PRES

쐌 Ignition switch: ON

Approx. 3.4V

ABSOL PRES/SE

쐌 Ignition switch: ON

Approx. 4.4V

START SIGNAL

쐌 Ignition switch: ON , START , ON

OFF , ON , OFF

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

Throttle valve: Idle position

ON

CLSD THL POS

Throttle valve: Slightly open

OFF

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

Throttle valve: Idle position

ON

Throttle valve: Slightly open

OFF

CLSD THL/P SW

EC-132

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM

AIR COND SIG

P/N POSI SW

PW/ST SIGNAL

CONDITION 쐌 Engine: After warming up, idle the engine

쐌 Ignition switch: ON

쐌 Engine: After warming up, idle the engine

SPECIFICATION

A/C switch: OFF

OFF

A/C switch: ON (Compressor operates.)

ON

Shift lever: Neutral

ON

Except above

OFF

Steering wheel in neutral position (forward direction)

OFF

The steering wheel is turned

ON

MA

IGNITION SW

쐌 Ignition switch: ON , OFF , ON Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

2.5 - 3.3 msec

INJ PULSE-B1

쐌 쐌 쐌 쐌

2,000 rpm

2.4 - 3.2 msec

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

Approx. 20° BTDC

2,000 rpm

More than 25° BTDC

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

9.5 - 34.0%

2,500 rpm

13.9 - 24.9%

Throttle valve: fully closed

0.0%

Throttle valve: fully opened

Approx. 80%

IGN TIMING

CAL/LD VALUE

ABSOL TH·P/S

MASS AIRFLOW

IACV-AAC/V

PURG VOL C/V

쐌 Engine: After warming up, engine stopped 쐌 Ignition switch: ON

Idle

0.9 - 5.8 g·m/s

2,500 rpm

7.5 - 13.2 g·m/s

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

Approx. 30%

2,000 rpm

—

쐌 Engine: After warming up 쐌 Air conditioner switch: OFF 쐌 No-load

Idle

0%

2,000 rpm (More than 200 seconds after starting engine)

—

EGRC SOL/V

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

FE CL

AT TF PD AX

OFF , ON Idle

ON (Cut)

Engine speed: Revving engine from idle to 3,000 rpm quickly.

OFF (Flow)

SU BR ST RS

쐌 Ignition switch is turned to ON (Operates for 5 seconds) 쐌 Engine running and cranking

ON

쐌 Except as shown above

OFF

VC/V BYPASS/V

쐌 Ignition switch: ON

OFF

VENT CONT/V

쐌 Ignition switch: ON

OFF

FUEL PUMP RLY

LC

MT

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

쐌 Air conditioner switch: OFF , ON

EM

ON , OFF , ON

쐌 쐌 쐌 쐌

AIR COND RLY

GI

BT HA SC EL

EC-133

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM

HO2S1 HTR (B1)

HO2S2 HTR (B1)

CONDITION

SPECIFICATION

쐌 Engine speed: Below 3,000 rpm (All models) For 6 seconds after engine speed exceeds 3,000 rpm (4WD models only)

ON

쐌 Engine speed: Above 3,000 rpm (2WD models) More than 6 seconds after engine speed exceeds 3,000 rpm (4WD models)

OFF

쐌 Engine speed: Idle after driving for 2 minutes at 70 km/h (43 MPH) or more

ON

쐌 Ignition switch: ON (Engine stopped)

OFF

Major Sensor Reference Graph in Data Monitor Mode

NGEC0043

The following are the major sensor reference graphs in “DATA MONITOR” mode. (Select “MANU TRIG” in “DATA MONITOR” with CONSULT-II. “Trigger Point” is set to 100%, “Recording Speed” is set to MAX..)

THRTL POS SEN, ABSOL TH·P/S, CLSD THL POS

NGEC0043S01

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”.

SEF306Y

ENG SPEED, MAS A/F SE-B1, THRTL POS SEN, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1 NGEC0043S02 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-134

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

Major Sensor Reference Graph in Data Monitor Mode (Cont’d)

GI MA EM LC

FE SEF241Y

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-135

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

Major Sensor Reference Graph in Data Monitor Mode (Cont’d)

SEF242YA

EC-136

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

ECM Terminals and Reference Value

ECM Terminals and Reference Value PREPARATION 1. 쐌

NGEC0044 NGEC0044S01

ECM is located behind the instrument lower cover. For this inspection: Remove instrument lower cover.

GI MA EM LC

SEF324V

2.

Remove ECM harness protector.

FE CL MT

AEC913

3. 쐌 쐌 쐌

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.

AT TF PD AX SU BR ST RS

SEF367I

BT HA SC EL

EC-137

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

ECM Terminals and Reference Value (Cont’d)

ECM HARNESS CONNECTOR TERMINAL LAYOUTNGEC0044S02

SEF533P

ECM INSPECTION TABLE

NGEC0044S03

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) 0 - 0.5V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

1

PU/W

Ignition signal 0.2 - 1.0V

[Engine is running] 쐌 Engine speed is 2,000 rpm

EC-138

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

GI

12 - 14V

MA [Engine is running] 쐌 Warm-up condition 쐌 Idle speed

EM LC

2

B

Ignition check 12 - 13V

[Engine is running] 쐌 Engine speed is 2,000 rpm

FE CL 0 - 1V

MT [Engine is running] 쐌 Warm-up condition 쐌 Idle speed

AT TF

3

P/L

Tachometer 0.5 - 2V

PD [Engine is running] 쐌 Engine speed is 2,000 rpm

AX SU

4

LG/R

ECM relay (Self shutoff)

[Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

0 - 1V

[Ignition switch OFF] 쐌 More than a few seconds after turning ignition switch OFF

BATTERY VOLTAGE (11 - 14V)

BR ST RS BT HA SC EL

EC-139

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed

5

R/Y

EVAP canister purge volume control solenoid valve

12 - 13V

[Engine is running] 쐌 Engine speed is 2,000 rpm (More than 200 seconds after starting engine)

10

11

12

B/R

W/R

P

ECM ground

Air conditioner relay

R/W

Malfunction indicator lamp

19

B/R

ECM ground

21

22

L/OR

G/R

L/B

Engine ground

[Ignition switch ON] 쐌 For 5 seconds after turning ignition switch ON. [Engine is running]

0 - 1V

[Ignition switch ON] 쐌 More than 5 seconds after turning ignition switch ON

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Both A/C switch and blower switch are ON* *: Any mode except “OFF”, ambient air temperature above 10°C (50°F).

Approximately 0V

[Engine is running] 쐌 A/C switch is OFF

BATTERY VOLTAGE (11 - 14V)

[Ignition switch ON]

0 - 1V

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed

Engine ground

[Ignition switch ON]

Approximately 0V

[Ignition switch START]

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Both air conditioner switch and blower switch are ON (Compressor operates)

Approximately 0V

[Engine is running] 쐌 Air conditioner switch is OFF

BATTERY VOLTAGE (11 - 14V)

[Ignition switch ON] 쐌 Gear position is “Neutral”

Approximately 0V

[Ignition switch ON] 쐌 Except the above gear position

Approximately 5V

Fuel pump relay

18

20

[Engine is running] 쐌 Idle speed

Start signal

Air conditioner dualpressure switch

Park/neutral position (PNP) switch

EC-140

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

23

24

25

28

WIRE COLOR

L

W/G

ITEM

CONDITION

[Ignition switch ON] 쐌 Warm-up condition Throttle position sensor 쐌 Accelerator pedal fully released

DATA (DC Voltage)

0.2 - 0.8V

MA

[Ignition switch ON] 쐌 Accelerator pedal fully depressed

3.5 - 4.5V

EM

[Ignition switch OFF]

0V

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed

Engine ground

Ignition switch

B/Y

ECM ground

BR/W

[Ignition switch ON] 쐌 Warm-up condition Throttle position switch 쐌 Accelerator pedal released (Closed position) [Ignition switch ON] 쐌 Accelerator pedal depressed

G/B

Vehicle speed sensor

LC

BATTERY VOLTAGE (11 - 14V)

FE

Approximately 0V

CL

1 - 4V

29

GI

[Engine is running] 쐌 Lift up the vehicle 쐌 In 2nd gear position 쐌 40 km/h (25 MPH)

MT AT TF

32

39

B/Y

GY/R

ECM ground

Power steering oil pressure switch

[Engine is running] 쐌 Idle speed

Engine ground

[Engine is running] 쐌 Steering wheel is fully turned

Approximately 0V

[Engine is running] 쐌 Steering wheel is not turned

Approximately 5V

PD AX SU

42

BR

Sensors’ power supply

[Ignition switch ON]

Approximately 5V

43

B/W

Sensors’ ground

[Engine is running] 쐌 Idle speed

Approximately 0V

BR

0.2 - 0.5V

ST [Engine is running] 쐌 Warm-up condition 쐌 Idle speed

44

PU

RS BT

Camshaft position sensor (Reference signal)

0 - 0.5V

HA [Engine is running] 쐌 Engine speed is 2,000 rpm

SC EL

EC-141

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

45

B/R

Absolute pressure sen[Ignition switch ON] sor

Approximately 4.4V

46

OR/B

Fuel level sensor

Approximately 0 - 4.8V Output voltage varies with fuel level.

[Ignition switch ON]

Approximately 0V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

47

L

Crankshaft position sensor (OBD)

Approximately 0V

[Engine is running] 쐌 Engine speed is 2,000 rpm

Approximately 2.6V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

49

LG

Camshaft position sensor (Position signal)

Approximately 2.5 - 2.6V

[Engine is running] 쐌 Engine speed is 2,000 rpm

0 - Approximately 1.0V

50

54

B

R

Heated oxygen sensor 1

Mass air flow sensor

[Engine is running] 쐌 After warning up to normal operating temperature and engine speed is 2,000 rpm.

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

0.9 - 1.8V

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm

1.8 - 2.3V

EC-142

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

GI

G

Mass air flow sensor ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

OR

Heated oxygen sensor 2

[Engine is running] 쐌 After warming up to normal operating temperature and revving engine from idle to 3,000 rpm quickly

0 - Approximately 1.0V

59

LG/R

Engine coolant temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with engine coolant temperature

60

Y/B

Fuel tank temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with fuel temperature

FE CL

55

56

MA EM LC

61

PU/R

Intake air temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with intake air temperature

62

Y

EVAP control system pressure sensor

[Ignition switch ON]

Approximately 3.4V

MT

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Less than 4.5V

AT

[Engine is running] 쐌 Warm-up condition 쐌 EGR system is operating

0 - 1.5V

TF PD

63

G/OR

EGR temperature sensor

64

W

Knock sensor

[Engine is running] 쐌 Idle speed

Approximately 2.4V

66

B

Fuel level sensor ground

[Engine is running] 쐌 Idle speed

Approximately 0V

67

B/P Power supply for ECM

[Ignition switch ON]

72

B/P

BATTERY VOLTAGE (11 - 14V)

69

LG/R

Data link connector

[Ignition switch ON] 쐌 CONSULT-II or GST is disconnected.

Approximately 2V

SB

Power supply (Backup)

[Ignition switch OFF]

BATTERY VOLTAGE (11 - 14V)

80

AX SU BR ST RS BT HA SC EL

EC-143

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 10.5 - 11.5V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

101

OR/L

IACV-AAC valve 1 - 13V

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

BATTERY VOLTAGE (11 - 14V) 102

W/B

Injector No. 1 [Engine is running] 쐌 Warm-up condition 쐌 Idle speed

104

W/R

Injector No. 3

BATTERY VOLTAGE (11 - 14V) 109

W/L

Injector No. 2 [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

111

103

W/PU

G/W

Injector No. 4

EGRC-solenoid valve

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

0 - 1V

[Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle to 3,000 rpm quickly

BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V)

108

R/G

EVAP canister vent control valve

[Ignition switch ON]

116

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

117

B/P

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

EC-144

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

KA24DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

119

120

122

124

WIRE COLOR

BR/Y

P/B

R/B

B/R

ITEM

Heated oxygen sensor heater 1

Vacuum cut valve bypass valve

Heated oxygen sensor heater 2

ECM ground

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Engine speed is below 3,000 rpm. (All models)

Approximately 0.4V

[Engine is running] 쐌 Engine speed is above 3,000 rpm. (2WD models) 쐌 More than 6 seconds after engine speed exceeds 3,000 rpm (4WD models)

BATTERY VOLTAGE (11 - 14V)

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed after driving 2 minutes at 70 km/h (43 MPH) or more

Approximately 0.4V

[Ignition switch ON] 쐌 Engine is not running

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed

Engine ground

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-145

IDX

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

KA24DE

Description

Description

NGEC1003

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: 쐌 B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction) 쐌 A/F ALPHA-B1/B2 (The mean value of air-fuel ratio feedback correction factor per cycle) 쐌 MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)

Testing Condition

NGEC1004

쐌 Vehicle driven distance: More than 5,000 km (3,107 miles) 쐌 Barometric pressure: 101.3 kPa (760.0 mmHg, 29.92 inHg)±3 kPa (22.5 mmHg, 0.89 inHg) 쐌 Atmospheric temperature: 20 - 30°C (68 - 86°F) 쐌 Engine coolant temperature: 75 - 95°C (167 - 203°F) 쐌 Transmission: Warmed-up*1 쐌 Electrical load: Not applied*2 쐌 Engine speed: Idle *1: For M/T models, drive vehicle for 5 minutes after the engine is warmed up to normal operating temperature. *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

NGEC1005

NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform “Basic Inspection”, EC-112. 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-147.

EC-146

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

KA24DE Diagnostic Procedure

Diagnostic Procedure

NGEC1006

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEF613ZD

EC-147

EL IDX

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

KA24DE

Diagnostic Procedure (Cont’d)

SEF768Z

EC-148

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

KA24DE

Diagnostic Procedure (Cont’d)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEF615ZA

EL

EC-149

IDX

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT

KA24DE

Description

Description

NGEC0045

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

NGEC0045S01

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

NGEC0046

INSPECTION START

Erase (1st trip) DTCs. Refer to “HOW TO ERASE EMISSION-RELATED INFORMATION”, EC-86. 䊳

2

GO TO 2.

CHECK GROUND TERMINALS

Check ground terminals for corroding or loose connection. Refer to “Circuit Inspection”, “GROUND INSPECTION”, GI-28. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace.

3

SEARCH FOR ELECTRICAL INCIDENT

Perform “Incident Simulation Tests”, GI-23. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace.

4

CHECK CONNECTOR TERMINALS

Refer to “How to Check Enlarged Contact Spring of Terminal”, GI-20. OK or NG OK

䊳

INSPECTION END

NG

䊳

Repair or replace connector.

EC-150

TROUBLE DIAGNOSIS FOR POWER SUPPLY

KA24DE

Main Power Supply and Ground Circuit

Main Power Supply and Ground Circuit WIRING DIAGRAM

NGEC0047

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC113A

EC-151

IDX

TROUBLE DIAGNOSIS FOR POWER SUPPLY

KA24DE

Main Power Supply and Ground Circuit (Cont’d)

ECM TERMINALS AND REFERENCE VALUE

NGEC0048

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

LG/R

ITEM

ECM relay (Self shut-off)

CONDITION [Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

DATA (DC Voltage)

0 - 1V

[Ignition switch OFF] BATTERY VOLTAGE 쐌 A few seconds passed after turning ignition switch (11 - 14V) OFF 10

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

19

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

[Ignition switch OFF]

0V

24

W/G

Ignition switch [Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

25

B/Y

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

32

B/Y

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

67

B/P Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

72

B/P

80

SB

Power supply (Back-up)

[Ignition switch OFF]

BATTERY VOLTAGE (11 - 14V)

116

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

117

B/P

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

124

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

EC-152

TROUBLE DIAGNOSIS FOR POWER SUPPLY

KA24DE

Main Power Supply and Ground Circuit (Cont’d)

DIAGNOSTIC PROCEDURE 1

=NGEC0049

INSPECTION START

GI

Start engine. Is engine running?

MA

Yes or No Yes

䊳

GO TO 4.

No

䊳

GO TO 2.

2

EM LC

CHECK POWER SUPPLY-I

1. Turn ignition switch OFF and then ON. 2. Check voltage between ECM terminal 24 and ground with CONSULT-II or tester.

FE CL MT SEF600P

Voltage: Battery voltage OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 3.

3

AT TF PD

DETECT MALFUNCTIONING PART

AX

Check the following. 쐌 Harness connectors M65, E43 쐌 Harness connectors M59, F27 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between ECM and fuse 䊳

SU

Repair harness or connectors.

BR ST RS BT HA SC EL

EC-153

IDX

TROUBLE DIAGNOSIS FOR POWER SUPPLY

KA24DE

Main Power Supply and Ground Circuit (Cont’d)

4

CHECK POWER SUPPLY-II

1. Stop engine. 2. Check voltage between ECM terminal 80 and ground with CONSULT-II or tester.

MEC698B

Voltage: Battery voltage OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Fuse block (J/B) connector M27 쐌 10A fuse 쐌 Harness for open or short between ECM and fuse 䊳

6

Repair harness or connectors.

CHECK POWER SUPPLY-III

1. Turn ignition switch ON and then OFF. 2. Check voltage between ECM terminals 67, 72, 117 and ground with CONSULT-II or tester.

SEF121V

Voltage: After turning ignition switch OFF, battery voltage will exist for a few seconds, then drop to approximately 0V. OK or NG OK

䊳

GO TO 12.

NG (Battery voltage does not exist.)

䊳

GO TO 7.

NG (Battery voltage exists for more than a few seconds.)

䊳

GO TO 11.

EC-154

TROUBLE DIAGNOSIS FOR POWER SUPPLY

KA24DE

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.

GI MA EM LC SEF323VA

3. Check harness continuity between ECM terminals 67, 72, 117 and ECM relay terminal 3.

FE CL MT AT SEF122V

Continuity should exist. 4. Also check harness for short to ground and short to power.

TF

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

PD AX

8

CHECK VOLTAGE BETWEEN ECM RELAY AND GROUND

SU

Check voltage between ECM relay terminals 2, 5 and ground with CONSULT-II or tester.

BR ST RS SEF120V

BT

Voltage: Battery voltage OK or NG OK

䊳

GO TO 10.

NG

䊳

GO TO 9.

HA SC EL

EC-155

IDX

TROUBLE DIAGNOSIS FOR POWER SUPPLY

KA24DE

Main Power Supply and Ground Circuit (Cont’d)

9

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between ECM relay and harness connector F36 䊳

10

Repair harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Check harness continuity between ECM terminal 4 and ECM relay terminal 1.

SEF605P

Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 11.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

11

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.

SEF511P

12V (1 - 2) applied: Continuity exists. No voltage applied: No continuity OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace ECM relay.

EC-156

TROUBLE DIAGNOSIS FOR POWER SUPPLY

KA24DE

Main Power Supply and Ground Circuit (Cont’d)

12

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 10, 19, 25, 32, 116, 124 and engine ground.

GI MA EM LC

SEF119V

FE

Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 13.

NG

䊳

Repair open circuit or short to power in harness or connectors.

13

CL MT

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

AT

INSPECTION END

TF PD AX SU BR ST RS BT HA SC EL

EC-157

IDX

DTC P0031, P0032 HO2S1 HEATER

KA24DE

Description

Description

NGEC0136

SYSTEM DESCRIPTION

NGEC0136S01

Sensor

ECM function

Input Signal to ECM

Camshaft position sensor

Actuator

Heated oxygen sensor 1 Heated oxygen sensor 1 heater heater control

Engine speed

The ECM performs ON/OFF control of the heated oxygen sensor 1 heater corresponding to the engine operating condition.

OPERATION

NGEC0136S02

Engine speed

Heated oxygen sensor 1 heater

Above 3,000 rpm

OFF

Below 3,000 rpm

ON

CONSULT-II Reference Value in Data Monitor Mode

NGEC0137

Specification data are reference values. MONITOR ITEM HO2S1 HTR (B1)

CONDITION

SPECIFICATION

쐌 Engine speed: Below 3,000 rpm

ON

쐌 Engine speed: Above 3,000 rpm

OFF

ECM Terminals and Reference Value

NGEC0138

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.

119

WIRE COLOR

BR/Y

ITEM

Heated oxygen sensor 1 heater

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Engine speed is below 3,000 rpm.

Approximately 0.4V

[Engine is running] 쐌 Engine speed is above 3,000 rpm.

BATTERY VOLTAGE (11 - 14V)

On Board Diagnosis Logic DTC No. P0031 P0032

Malfunction is detected when ... 쐌 The current amperage in the heated oxygen sensor 1 heater circuit is out of the normal range. [An excessively low (P0031) or high (P0032) voltage signal is sent to ECM through the heated oxygen sensor 1 heater.]

EC-158

NGEC0139

Check Items (Possible Cause) 쐌 Harness or connectors (The heated oxygen sensor 1 heater circuit is open or shorted.) 쐌 Heated oxygen sensor 1 heater

DTC P0031, P0032 HO2S1 HEATER

KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC0140

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. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle.

GI MA EM LC

1) 2) 3) 4) 5)

SEF058Y

1) 2) 3) 4) 5) 6) 7) 쐌

With CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 5 seconds. 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”, EC-161. With GST Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 5 seconds. Start engine and run it for at least 6 seconds at idle speed. Turn ignition switch OFF and wait least 5 seconds. Start engine and run it for at least 6 seconds at idle speed. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-161. 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.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-159

IDX

DTC P0031, P0032 HO2S1 HEATER

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0141

WEC966

EC-160

DTC P0031, P0032 HO2S1 HEATER

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0142

CHECK POWER SUPPLY

GI

1. Turn ignition switch OFF. 2. Disconnect heated oxygen sensor 1 harness connector.

MA EM LC

SEF331VB

FE

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

CL MT AT SEF213W

Voltage: Battery voltage

TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

PD AX

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M59, F27 쐌 15A fuse 쐌 Fuse block (J/B) connector M26 쐌 Harness for open or short between heated oxygen sensor 1 and 15A fuse 䊳

3

SU BR

Repair harness or connectors.

ST

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between heated oxygen sensor 1 terminal 3 and ECM terminal 119. Refer to the wiring diagram. Continuity should exist. 4. Also check harness for short to ground or short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

RS BT HA SC EL

EC-161

IDX

DTC P0031, P0032 HO2S1 HEATER

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK HEATED OXYGEN SENSOR 1 HEATER

Check resistance between terminals 3 and 1.

SEF220W

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. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace heated oxygen sensor 1.

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-162

DTC P0037, P0038 HO2S2 HEATER

KA24DE Description

Description

NGEC0180

SYSTEM DESCRIPTION

NGEC0180S01

Sensor

ECM function

Input Signal to ECM

Camshaft position sensor

Actuator

Heated oxygen sensor 2 Heated oxygen sensor 2 heater heater control

Engine speed

GI

The ECM performs ON/OFF control of the heated oxygen sensor 2 heater corresponding to the engine speed.

OPERATION

MA EM LC

NGEC0180S02

Engine condition

Heated oxygen sensor 2 heater

Ignition switch ON Engine stopped

OFF

Engine is running.

ON

FE CL

CONSULT-II Reference Value in Data Monitor Mode

NGEC0181

Specification data are reference values. MONITOR ITEM

HO2S2 HTR (B1)

CONDITION

SPECIFICATION

쐌 Engine speed: Idle [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]

ON

쐌 Ignition switch ON (Engine stopped)

OFF

AT TF

ECM Terminals and Reference Value

NGEC0182

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.

122

WIRE COLOR

R/B

P0141

PD AX SU

ITEM

Heated oxygen sensor 2 heater

CONDITION

DATA (DC Voltage)

BR

[Engine is running] 쐌 After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more

Approximately 0.4V

[Ignition switch “ON”] 쐌 Engine stopped

BATTERY VOLTAGE (11 - 14V)

ST

On Board Diagnosis Logic DTC No.

MT

Malfunction is detected when ... 쐌 The current amperage in the heated oxygen sensor 2 heater circuit is out of the normal range. [An excessively low (P0037) or high (P0038) voltage signal is sent to ECM through the heated oxygen sensor 2 heater.]

RS NGEC0183

Check Items (Possible Cause) 쐌 Harness or connectors (The heated oxygen sensor 2 heater circuit is open or shorted.) 쐌 Heated oxygen sensor 2 heater

BT HA SC EL

EC-163

IDX

DTC P0037, P0038 HO2S2 HEATER

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC0184

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is in between 10.5V at idle.

SEF175Y

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) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-166. With GST 1) Start engine. 2) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 3) Stop vehicle and let engine idle for at least 6 seconds. 4) Turn ignition switch OFF and wait at least 10 seconds. 5) Start engine. 6) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes 7) Stop vehicle and let engine idle for at least 6 seconds. 8) Select “MODE 3” with GST. 9) If DTC is detected, go to “Diagnostic Procedure”, EC-166. 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-164

DTC P0037, P0038 HO2S2 HEATER

KA24DE Wiring Diagram

Wiring Diagram

NGEC0185

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC968

EC-165

EL IDX

DTC P0037, P0038 HO2S2 HEATER

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4.

NGEC0186

CHECK POWER SUPPLY Turn ignition switch OFF. Disconnect heated oxygen sensor 2 harness connector. Turn ignition switch ON. Check voltage between terminal 2 and ground.

SEF218W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuse block (J/B) connector M26 쐌 15A fuse 쐌 Harness for open or short between heated oxygen sensor 2 and 15A fuse 䊳

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 terminal 3 and ECM terminal 122. Refer to the wiring diagram. Continuity should exist. 4. Also check harness for short to ground or short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness for open or short between heated oxygen sensor 2 and ECM 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-166

DTC P0037, P0038 HO2S2 HEATER

KA24DE Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 2 HEATER

Check the following. 1. Check resistance between terminals 2 and 3.

GI MA EM LC

FE CL MT AT SEF221W

Resistance: 2.3 - 4.3Ω at 25°C (77°F) 2. Check continuity.

TF PD MTBL0330

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

SU

OK or NG

BR ST

OK

䊳

GO TO 6.

NG

䊳

Replace heated oxygen sensor 2.

6

AX

RS

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

BT

INSPECTION END

HA SC EL

EC-167

IDX

DTC P0101, P0102, P0103 MAF SENSOR

KA24DE

Component Description

Component Description

NGEC0050

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.

SEF893J

CONSULT-II Reference Value in Data Monitor Mode

NGEC0051

Specification data are reference values. MONITOR ITEM

MAS AIR/FL SE

CAL/LD VALUE

MASS AIRFLOW

CONDITION

SPECIFICATION

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

0.9 - 1.8V

2,500 rpm

1.9 - 2.3V

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

9.5 - 34.0%

2,500 rpm

13.9 - 24.9%

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

0.9 - 5.8 g·m/s

2,500 rpm

7.5 - 13.2 g·m/s

ECM Terminals and Reference Value

NGEC0052

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO.

54

55

WIRE COLOR

R

ITEM

Mass air flow sensor

Mass air flow sensor ground

G

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

0.9 - 1.8V

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm

1.9 - 2.3V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

On Board Diagnosis Logic DTC No.

Malfunction is detected when ...

P0103

A)

P0101

C)

Check Items (Possible Cause)

An excessively high voltage from the sensor is sent 쐌 Harness or connectors to ECM when engine is not running. (The sensor circuit is open or shorted.) 쐌 Mass air flow sensor A high voltage from the sensor is sent to ECM under light load driving condition.

EC-168

NGEC0053

DTC P0101, P0102, P0103 MAF SENSOR

KA24DE

On Board Diagnosis Logic (Cont’d) DTC No.

Malfunction is detected when ...

P0102

B)

P0101

D)

Check Items (Possible Cause)

GI

쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Intake air leaks A low voltage from the sensor is sent to ECM under 쐌 Mass air flow sensor heavy load driving condition. An excessively low voltage from the sensor is sent to ECM* when engine is running.

MA

*: When this malfunction is detected, the ECM enters fail-safe mode and the MIL lights up. Detected items

EM

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

LC

FE CL MT

DTC Confirmation Procedure

NGEC0054

Perform “PROCEDURE FOR MALFUNCTION A” first. If the 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. If there is no problem on “PROCEDURE FOR MALFUNCTION B”, perform “PROCEDURE FOR MALFUNCTION C”. If there is no problem on “PROCEDURE FOR MALFUNCTION C”, perform “PROCEDURE FOR MALFUNCTION D”. 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 5 seconds before conducting the next test.

AT TF PD AX SU BR ST RS

PROCEDURE FOR MALFUNCTION A 1) 2) 3) 4)

SEF058Y

5) 6)

NGEC0054S01

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 6 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-173. If 1st trip DTC is not deteeted, go to next step. Start engine and let it idle for at least 6 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-173.

EC-169

BT HA SC EL IDX

DTC P0101, P0102, P0103 MAF SENSOR

KA24DE

DTC Confirmation Procedure (Cont’d)

With GST Follow the procedure “With CONSULT-II”.

PROCEDURE FOR MALFUNCTION B

SEF058Y

PROCEDURE FOR MALFUNCTION C

SEF174Y

NGEC0054S02

With CONSULT-II 1) Turn ignition switch ON. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and wait 5 seconds at most. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-173. With GST Follow the procedure “With CONSULT-II”. NOTE: If 1st trip DTC is confirmed after more than 5 seconds, there may be malfunction C.

NGEC0054S03

NOTE: If engine will not start or stops soon, wait at least 10 seconds with engine stopped (Ignition switch “ON”) instead of running engine at idle speed. 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) Run engine for at least 10 seconds at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-173. With GST Follow the procedure “With CONSULT-II”.

EC-170

DTC P0101, P0102, P0103 MAF SENSOR

KA24DE

DTC Confirmation Procedure (Cont’d)

PROCEDURE FOR MALFUNCTION D 1) 2)

3) 4) 5) 6)

7)

NGEC0054S04

With CONSULT-II Turn ignition switch ON. Start engine and warm it up to normal operating temperature. If engine cannot be started, go to “Diagnostic Procedure”, EC-173. Select “DATA MONITOR” mode with CONSULT-II. Check the voltage of “MAS A/F SE-B1” with “DATA MONITOR”. Increases engine speed to about 4,000 rpm. Monitor the linear voltage rise in response to engine speed increases. If NG, go to “Diagnostic Procedure”, EC-173. If OK, go to following step. Maintain the following conditions for at least 10 consecutive seconds. More than 2,000 rpm

THRTL POS SEN

More than 3V

Selector lever

Suitable position

Driving location

Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test.

8)

MA EM LC

FE

ENG SPEED

SEF243Y

GI

CL

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-173.

MT AT TF PD AX

SEF175Y

Overall Function Check

NGEC0055

Use this procedure to check the overall function of the mass air flow sensor circuit. During this check, a 1st trip DTC might not be confirmed.

PROCEDURE FOR MALFUNCTION D

SEF534P

1) 2) 3) 4) 5) 6)

SU BR

NGEC0055S01

With GST Turn ignition switch ON. Start engine and warm it up to normal operating temperature. Select “MODE 1” with GST. Check the mass air flow sensor signal with “MODE 1”. Check for linear mass air flow rise in response to increases to about 4,000 rpm in engine speed. If NG, go to “Diagnostic Procedure”, EC-173.

ST RS BT HA SC EL

EC-171

IDX

DTC P0101, P0102, P0103 MAF SENSOR

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0056

LEC963

EC-172

DTC P0101, P0102, P0103 MAF SENSOR

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0057

INSPECTION START

GI

Which malfunction (A, B, C or D) is duplicated?

MA MTBL0063

EM

Type I or Type II Type I

䊳

GO TO 3.

Type II

䊳

GO TO 2.

2

LC

CHECK INTAKE SYSTEM

Check the followings for connection. 쐌 Air duct 쐌 Air cleaner 쐌 Vacuum hoses 쐌 Intake air passage between air duct to collector

FE CL OK or NG

OK

䊳

GO TO 3.

NG

䊳

Reconnect the parts.

MT AT

3

RETIGHTEN GROUND SCREWS

TF

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

PD AX SU BR SEF325V

䊳

ST

GO TO 4.

RS BT HA SC EL

EC-173

IDX

DTC P0101, P0102, P0103 MAF SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK POWER SUPPLY

1. Disconnect mass air flow sensor harness connector.

AEC131A

2. Turn ignition switch ON. 3. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF126V

Voltage: Battery voltage OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between ECM relay and mass air flow sensor 쐌 Harness for open or short between mass air flow sensor and ECM 䊳

Repair harness or connectors.

EC-174

DTC P0101, P0102, P0103 MAF SENSOR

KA24DE Diagnostic Procedure (Cont’d)

6

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between mass air flow sensor terminal 3 and ECM terminal 55. Refer to EC-172.

GI MA EM LC

SEF124V

FE

Continuity should exist. 4. Also check harness for short to ground or short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

7

CL MT

CHECK INPUT SIGNAL CIRCUIT

AT

1. Reconnect all harness connectors. 2. Check harness continuity between terminal 4 and ECM terminal 54.

TF PD AX SU SEF125V

Continuity should exist. 3. Also check harness for short to ground and short to power.

BR

OK or NG

ST

OK

䊳

GO TO 8.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

RS BT HA SC EL

EC-175

IDX

DTC P0101, P0102, P0103 MAF SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK MASS AIR FLOW SENSOR Reconnect all harness connectors. Turn ignition switch ON. Start engine and warm it up to normal operating temperature. Check voltage between ECM terminal 54 (mass air flow sensor signal) and ground.

SEF326V

MTBL0326

5. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Repeat above check. 6. If NG, remove mass air flow sensor from air duct. Check hot wire for damage or dust.

SEF893J

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace mass air flow sensor.

EC-176

DTC P0101, P0102, P0103 MAF SENSOR

KA24DE Diagnostic Procedure (Cont’d)

9

CHECK SHIELD CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect joint connector-2. 3. Check the following. 쐌 Continuity between joint connector-1 terminal 1 and ground 쐌 Joint connector-2 (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

GI MA EM LC

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

FE

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-177

IDX

DTC P0107, P0108 ABSOLUTE PRESSURE SENSOR

KA24DE

Component Description

Component Description

NGEC1007

The absolute pressure sensor detects ambient barometric pressure and sends the voltage signal to the ECM. As the pressure increases, the voltage rises. The absolute pressure sensor is built into ECM.

On Board Diagnosis Logic DTC No. P0107 P0108

Malfunction is detected when ... An excessively low (P0107) or high (P0108) voltage from the sensor is sent to the micro computer.

Check Items (Possible Cause) 쐌 ECM

DTC Confirmation Procedure

SEF058Y

NGEC1008

NGEC1009

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”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 6 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-179. With GST Follow the procedure “With CONSULT-II” above.

EC-178

DTC P0107, P0108 ABSOLUTE PRESSURE SENSOR

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4. 5.

INSPECTION START

NGEC1011

GI

With CONSULT-II Turn ignition switch ON. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See previous page. Is the 1st trip DTC P0107 or P0108 displayed again?

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 P0107 or P0108 displayed again? 1. 2. 3. 4.

MA EM LC

FE

Yes or No Yes

䊳

Replace ECM.

No

䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-179

IDX

DTC P0112, P0113, P0127 IAT SENSOR

KA24DE

Component Description

Component Description

NGEC0066

The intake air temperature sensor is mounted to the air duct housing. 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.

SEF329V

Intake air temperature °C (°F)

Voltage* V

Resistance kΩ

20 (68)

3.5

2.1 - 2.9

80 (176)

1.23

0.27 - 0.38

*: These data are reference values and are measured between ECM terminal 61 (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.

Malfunction is detected when ...

P0112 P0113

A)

P0127

B)

Check Items (Possible Cause)

An excessively low (P0112) or high (P0113) voltage 쐌 Harness or connectors from the sensor is sent to ECM. (The sensor circuit is open or shorted.) 쐌 Intake air temperature sensor Rationally incorrect voltage from the sensor is sent to ECM, compared with the voltage signal from engine coolant temperature sensor.

Engine operating condition in fail-safe mode The ECM functions on the assumption that the intake air temperature is 25°C (77°F).

EC-180

NGEC0067

DTC P0112, P0113, P0127 IAT SENSOR

KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC0068

Perform “PROCEDURE FOR MALFUNCTION A” first. If the 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 5 seconds before conducting the next test.

GI MA EM LC

PROCEDURE FOR MALFUNCTION A

NGEC0068S01

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”, EC-183. With GST Follow the procedure “With CONSULT-II”.

CL MT

SEF058Y

PROCEDURE FOR MALFUNCTION B

SEF176Y

FE

NGEC0068S02

CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: 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. With CONSULT-II 1) Wait until engine coolant temperature is less than 90°C (194°F). a) Turn ignition switch ON. b) Select “DATA MONITOR” mode with CONSULT-II. c) Check the engine coolant temperature. d) If the engine coolant temperature is not less than 90°C (194°F), turn ignition switch “OFF” and cool down engine. 쐌 Perform the following steps before engine coolant temperature is above 90°C (194°F). 2) Turn ignition switch ON. 3) Select “DATA MONITOR” mode with CONSULT-II. 4) Start engine. 5) Hold vehicle speed more than 70 km/h (43 MPH) for 100 consecutive seconds. 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-183. With GST Follow the procedure “With CONSULT-II”.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-181

IDX

DTC P0112, P0113, P0127 IAT SENSOR

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0069

AEC983A

EC-182

DTC P0112, P0113, P0127 IAT SENSOR

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0070

CHECK POWER SUPPLY

GI

1. Turn ignition switch OFF. 2. Disconnect intake air temperature sensor harness connector.

MA EM LC

SEF329V

FE

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

CL MT AT TF AEC570A

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

AX SU

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and intake air temperature sensor 䊳

3

Repair harness or connectors.

CHECK GROUND CIRCUIT

OK or NG 䊳

GO TO 5.

NG

䊳

GO TO 4.

BR ST RS

1. Turn ignition switch OFF. 2. Check harness continuity between intake air temperature sensor terminal 2 and engine ground. Refer to the wiring diagram. Continuity should exist. 3. Also check harness for short to power.

OK

PD

BT HA SC EL

EC-183

IDX

DTC P0112, P0113, P0127 IAT SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and intake air temperature sensor 䊳

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTAKE AIR TEMPERATURE SENSOR

Check resistance as shown in the figure.

SEF302X

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace intake air temperature sensor.

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-184

DTC P0117, P0118 ECT SENSOR

KA24DE Component Description

Component Description

NGEC0072

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.

GI MA EM LC

SEF594K



SEF012P

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

FE

*: These data are reference values and are measured between ECM terminal 59 (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.

CL MT AT TF PD AX

CONSULT-II Reference Value in Data Monitor Mode

SU

CONDITION

BR

NGEC0073

MONITOR ITEM COOLAN TEMP/S

SPECIFICATION

쐌 Engine: After warming up

More than 70°C (158°F)

On Board Diagnosis Logic DTC No. P0117 P0118

Malfunction is detected when ...

Check Items (Possible Cause)

쐌 An excessively low (P0117) or high (P0118) voltage from 쐌 Harness or connectors the sensor is sent to ECM.* (The sensor circuit is open or shorted.) 쐌 Engine coolant temperature sensor

ST NGEC0074

RS BT

*: When this malfunction is detected, the ECM enters fail-safe mode and the MIL lights up.

HA SC EL

EC-185

IDX

DTC P0117, P0118 ECT SENSOR

KA24DE

On Board Diagnosis Logic (Cont’d) 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 to 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 to 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

DTC Confirmation Procedure

SEF058Y

NGEC0075

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. 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”, EC-188. With GST Follow the procedure “With CONSULT-II”.

EC-186

DTC P0117, P0118 ECT SENSOR

KA24DE Wiring Diagram

Wiring Diagram

NGEC0076

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC AEC984A

EC-187

EL IDX

DTC P0117, P0118 ECT SENSOR

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0077

CHECK POWER SUPPLY

1. Turn ignition switch OFF. 2. Disconnect engine coolant temperature sensor harness connector.

SEF330V

3. Turn ignition switch ON. 4. Check voltage between engine coolant temperature sensor terminal 1 and ground with CONSULT-II or tester.

SEF206W

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and engine coolant temperature sensor. 䊳

3

Repair harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Check harness continuity between engine coolant temperature sensor terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and engine coolant temperature sensor. 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-188

DTC P0117, P0118 ECT SENSOR

KA24DE Diagnostic Procedure (Cont’d)

5

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

GI MA EM LC SEF152P



FE CL MTBL0285

MT AT TF PD SEF012P

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace engine coolant temperature sensor.

6

AX SU BR

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

ST

INSPECTION END

RS BT HA SC EL

EC-189

IDX

DTC P0121, P0122, P0123 TP SENSOR

KA24DE

Component Description

Component Description

NGEC0079

NOTE: If DTC P0121, P0122 or P0123 is displayed with DTC P0510, first perform trouble diagnosis for DTC P0510, EC-440. The throttle position sensor responds to the accelerator pedal movement. This sensor is a type 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.

SEF105S

CONSULT-II Reference Value in Data Monitor Mode

NGEC0080

Specification data are reference values. MONITOR ITEM THRTL POS SEN

ABSOL TH·P/S

CONDITION

SPECIFICATION

쐌 Ignition switch: ON (Engine stopped) 쐌 Engine: After warming up

Throttle valve: fully closed

0.2 - 0.8V

Throttle valve: fully opened

3.5 - 4.5V

쐌 Ignition switch: ON (Engine stopped) 쐌 Engine: After warming up

Throttle valve: fully closed

0.0%

Throttle valve: fully opened

Approx. 80%

EC-190

DTC P0121, P0122, P0123 TP SENSOR

KA24DE

ECM Terminals and Reference Value

ECM Terminals and Reference Value

=NGEC0081

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.

23

WIRE COLOR

L

ITEM

CONDITION

Throttle position sensor

DATA (DC Voltage)

[Ignition switch ON] 쐌 Warm-up condition 쐌 Accelerator pedal fully released

0.2 - 0.8V

[Ignition switch ON] 쐌 Accelerator pedal fully depressed

3.5 - 4.5V

42

BR

Sensors’ power supply

[Ignition switch ON]

Approximately 5V

43

B/W

Sensors’ ground

[Engine is running] 쐌 Idle speed

Approximately 0V

P0122 P0123

P0121

Malfunction is detected when ... A)

B)

C)

FE

NGEC0082

Check Items (Possible Cause)

쐌 Harness or connectors (The throttle position sensor circuit is open or shorted.) 쐌 Throttle position sensor 쐌 Fuel injector 쐌 Camshaft position sensor 쐌 Mass air flow sensor

A low voltage from the sensor is sent to ECM under 쐌 Harness or connectors heavy load driving condition. (The throttle position sensor circuit is open or shorted.) 쐌 Intake air leaks 쐌 Throttle position sensor

*: When this malfunction is detected, the ECM enters fail-safe mode and the MIL lights up. Detected items

EM LC

An excessively low (P0122) or high (P0123) voltage 쐌 Harness or connectors from the sensor is sent to ECM.* (The throttle position sensor circuit is open or shorted.) 쐌 Throttle position sensor A high voltage from the sensor is sent to ECM under light load driving condition.

MA

CL

On Board Diagnosis Logic DTC No.

GI

MT AT TF PD AX SU BR

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

ST RS

Normal

When accelerating

Poor acceleration

BT HA SC EL

EC-191

IDX

DTC P0121, P0122, P0123 TP SENSOR

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC0083

Perform “PROCEDURE FOR MALFUNCTION A” first. If the 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. If there is no problem on “PROCEDURE FOR MALFUNCTION B”, perform “PROCEDURE FOR MALFUNCTION C”. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A

NGEC0083S01

CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: 쐌 Before performing the following procedure, confirm that battery voltage is more than 10V at idle. 쐌 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.

With CONSULT-II 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. 1)

SEF065Y

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”, EC-196. With GST Follow the procedure “With CONSULT-II”.

PROCEDURE FOR MALFUNCTION B

NGEC0083S02

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 10 seconds. If idle speed is over 1,100 rpm, maintain the following conditions for at least 10 seconds to keep engine speed below 1,100 rpm.

SEF058Y

EC-192

DTC P0121, P0122, P0123 TP SENSOR

KA24DE

DTC Confirmation Procedure (Cont’d) Selector lever

Suitable position except “N” (Higher gear position such as 3rd or 4th is better to keep low engine rpm.)

Accelerator pedal

Released

Vehicle speed

As slow as possible

MA

4)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-196. With GST Follow the procedure “With CONSULT-II”.

PROCEDURE FOR MALFUNCTION C

SEF177Y

GI

EM LC

NGEC0083S03

CAUTION: Always drive vehicle at a safe speed. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “MANU TRIG” in “DATA MONITOR” mode with CONSULT-II. 5) Select “THRTL POS SEN” and “ABSOL TH·P/S” in “DATA MONITOR” mode with CONSULT-II. 6) Press RECORD on CONSULT-II SCREEN at the same time accelerator pedal is depressed. 7) Print out the recorded graph and check the following: 쐌 The voltage rise is linear in response to accelerator pedal depression. 쐌 The voltage when accelerator pedal is fully depressed is approximately 4V. If NG, go to “Diagnostic Procedure”, EC-196. If OK, go to following step.

FE CL MT AT TF PD AX SU BR ST RS BT HA

SEF245Y

SC EL

EC-193

IDX

DTC P0121, P0122, P0123 TP SENSOR

KA24DE

DTC Confirmation Procedure (Cont’d)

8) 9)

SEF178Y

Select “AUTO TRIG” in “DATA MONITOR” mode with CONSULT-II. Maintain the following conditions for at least 10 consecutive seconds.

ENG SPEED

More than 2,000 rpm

MAS A/F SE-B1

More than 3V

COOLAN TEMP/S

More than 70°C (158°F)

Selector lever

Suitable position

Driving location

Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test.

10) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-196. With GST Follow the procedure “With CONSULT-II”.

EC-194

DTC P0121, P0122, P0123 TP SENSOR

KA24DE Wiring Diagram

Wiring Diagram

NGEC0084

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC964

EC-195

EL IDX

DTC P0121, P0122, P0123 TP SENSOR

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0085

INSPECTION START

Which malfunction A, B or C is duplicated?

MTBL0066

Type A, B or C Type A or B

䊳

GO TO 4.

Type C

䊳

GO TO 2.

2

ADJUST THROTTLE POSITION SENSOR

1. Check the following items. Refer to “Basic Inspection”, EC-112.

MTBL0328

OK or NG OK

3

䊳

GO TO 3.

CHECK INTAKE SYSTEM

Check the following for connection. 쐌 Air duct 쐌 Air cleaner 쐌 Vacuum hoses 쐌 Intake air passage between air duct to intake manifold collector OK or NG OK

䊳

GO TO 4.

NG

䊳

Reconnect the parts.

EC-196

DTC P0121, P0122, P0123 TP SENSOR

KA24DE Diagnostic Procedure (Cont’d)

4

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

GI MA EM LC SEF325V

䊳

5

FE

GO TO 5.

CHECK POWER SUPPLY

CL

1. Disconnect throttle position sensor harness connector.

MT AT TF PD SEF265S

2. Turn ignition switch ON. 3. Check voltage between terminal 1 and ground with CONSULT-II or tester.

AX SU BR ST SEF564P

RS

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair harness or connectors.

BT HA SC EL

EC-197

IDX

DTC P0121, P0122, P0123 TP SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

6

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Check harness continuity between throttle position sensor terminal 3 and engine ground. Refer to the wiring diagram.

SEF565P

Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check harness for open or short between ECM and throttle position sensor. 䊳

8

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 23 and 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 (With CONSULT-II)

䊳

GO TO 9.

OK (Without CONSULTII)

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-198

DTC P0121, P0122, P0123 TP SENSOR

KA24DE Diagnostic Procedure (Cont’d)

9 1. 2. 3. 4. 5.

CHECK THROTTLE POSITION SENSOR With CONSULT-II Reconnect all harness connectors. Start engine and warm it up to normal operating temperature. Stop engine and turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check voltage of “THRTL POS SEN” under the following conditions.

GI MA EM LC

FE SEF179Y

NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle.

CL MT AT MTBL0579

If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-112. OK or NG OK (Type B in step 1)

䊳

GO TO 11.

OK (Type A or C in step 1)

䊳

GO TO 14.

NG

䊳

Replace throttle position sensor. To adjust it, perform “Basic Inspection”, EC-112.

TF PD AX SU BR ST RS BT HA SC EL

EC-199

IDX

DTC P0121, P0122, P0123 TP SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

10 1. 2. 3. 4.

CHECK THROTTLE POSITION SENSOR Without CONSULT-II Reconnect all harness connectors. Start engine and warm it up to normal operating temperature. Stop engine and turn ignition switch ON. Check voltage between ECM terminal 23 (Throttle position sensor signal) and ground under the following conditions.

SEF767W

NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle.

MTBL0579

If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-112. OK or NG OK (Type B in step 1)

䊳

GO TO 11.

OK (Type A or C in step 1)

䊳

GO TO 14.

NG

䊳

Replace throttle position sensor. To adjust it, perform “Basic Inspection”, EC-112.

EC-200

DTC P0121, P0122, P0123 TP SENSOR

KA24DE Diagnostic Procedure (Cont’d)

11

CHECK MASS AIR FLOW SENSOR

1. Turn ignition switch ON. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 54 (Mass air flow sensor signal) and ground.

GI MA EM LC

SEF326V

FE CL MT MTBL0326

4. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Repeat above check. 5. If NG, remove mass air flow sensor from air duct. Check hot wire for damage or dust.

AT TF PD AX SU

SEF893J

BR

OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace mass air flow sensor.

ST RS BT HA SC EL

EC-201

IDX

DTC P0121, P0122, P0123 TP SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

12

CHECK CAMSHAFT POSITION SENSOR

1. Start engine and warm it up to normal operating temperature. 2. Check voltage between ECM terminals 49 and engine ground, ECM terminal 44 and engine ground.

SEF868Z

OK or NG OK

䊳

GO TO 13.

NG

䊳

Replace distributor assembly with camshaft position sensor.

13

CHECK FUEL INJECTOR

1. Disconnect injector harness connector. 2. Check resistance between terminals as shown in the figure.

SEF273W

Resistance: 10 - 14Ω [at 25°C (77°F)] OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace fuel injector.

EC-202

DTC P0121, P0122, P0123 TP SENSOR

KA24DE Diagnostic Procedure (Cont’d)

14

CHECK SHIELD CIRCUIT

1. Turn ignition switch OFF. 2. Remove joint connector-1. 3. Check the following. 쐌 Continuity between joint connector-1 terminal 1 and ground 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 15.

NG

䊳

Repair open circuit or short to power in harness or connectors.

15

CHECK INTERMITTENT INCIDENT

GI MA EM LC

FE

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-203

IDX

DTC P0125 ECT SENSOR

KA24DE

Component Description

Component Description

NGEC0087

NOTE: If DTC P0125 is displayed with P0117 or P0118, first perform trouble diagnosis for DTC P0117 or P0118, EC-185. 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



SEF012P

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

*: These data are reference values and are measured between ECM terminal 59 (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.

On Board Diagnosis Logic DTC No. P0125

Malfunction is detected when ... 쐌 Voltage sent to ECM from the sensor is not practical, even when some time has passed after starting the engine. 쐌 Engine coolant temperature is insufficient for closed loop fuel control.

Check Items (Possible Cause) 쐌 Harness or connectors (High resistance in the circuit) 쐌 Engine coolant temperature sensor 쐌 Thermostat

DTC Confirmation Procedure

SEF174Y

NGEC0089

NGEC0090

CAUTION: Be careful not to overheat engine. 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. 2) Select “DATA MONITOR” mode with CONSULT-II.

EC-204

DTC P0125 ECT SENSOR

KA24DE DTC Confirmation Procedure (Cont’d)

3)

Start engine and run it for 65 minutes at idle speed. If “COOLAN TEMP/S” increases to more than 10°C (50°F) within 65 minutes, stop engine because the test result will be OK. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-207. With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-205

IDX

DTC P0125 ECT SENSOR

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0091

AEC984A

EC-206

DTC P0125 ECT SENSOR

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0092

CHECK POWER SUPPLY

GI

1. Turn ignition switch OFF. 2. Disconnect engine coolant temperature sensor harness connector.

MA EM LC

SEF330V

FE

3. Turn ignition switch ON. 4. Check voltage between engine coolant temperature sensor terminal 1 and ground with CONSULT-II or tester.

CL MT AT SEF206W

Voltage: Approximately 5V

TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

PD AX

2

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and engine coolant temperature sensor. 䊳

3

SU

Repair harness or connectors.

BR

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Check harness continuity between engine coolant temperature sensor terminal 2 and engine ground. Refer to the wiring diagram. Continuity should exist. 3. Also check harness for short to power.

ST RS

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

BT HA

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and engine coolant temperature sensor. 䊳

SC

Repair open circuit or short to ground or short to power in harness or connectors.

EL

EC-207

IDX

DTC P0125 ECT SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

5

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

SEF152P



MTBL0285

SEF012P

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace engine coolant temperature sensor.

6

CHECK THERMOSTAT OPERATION

When the engine is cooled [lower than 76.5°C (170°F)], condition grasp lower radiator hose and confirm the engine coolant does not flow. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair or replace thermostat. Refer to “Thermostat”, “ENGINE COOLING SYSTEM”, LC-13.

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-208

DTC P0128 THERMOSTAT FUNCTION

KA24DE On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1028

Engine coolant temperature has not risen enough to open the thermostat even though the engine has run long enough. This is due to a leak in the seal or the thermostat open stuck. Malfunction is detected when the engine coolant temperature does not reach to specified temperature even though the engine has run long enough.

GI MA EM LC

Possible Cause 쐌 쐌 쐌

NGEC1029

Thermostat function Leakage from sealing portion of thermostat Engine coolant temperature sensor

FE CL MT

DTC Confirmation Procedure

NGEC1030

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. TESTING CONDITION: 쐌 For best results, perform at ambient temperature of –10°C (14°F) or higher. 쐌 For best results, perform at engine coolant temperature of –10°C (14°F) to 60°C (140°F).

WITH CONSULT-II 1)

2) 3) 4)

5)

NGEC1030S01

Replace thermostat with new one. Refer to LC-13, “Thermostat”. Use only a genuine NISSAN thermostat as a replacement. If an incorrect thermostat is used, the MIL may come on. Turn ignition switch “ON”. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Check that the “COOLAN TEMP/S” is above 60°C (140°F). If it is below 60°C (140°F), go to following step. If it is above 60°C (140°F), stop engine and cool down the engine to less than 60°C (140°F), then retry from step 1. Drive vehicle for 10 consecutive minutes under the following conditions.

VHCL SPEED SE

TF PD AX SU BR ST RS BT

80 - 120 km/h (50 - 75 MPH)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-210.

WITH GST 1)

AT

HA SC

NGEC1030S02

Follow the prodedure “WITH CONSULT-II” above.

EL

EC-209

IDX

DTC P0128 THERMOSTAT FUNCTION

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1031

CHECK ENGINE COOLANT TEMPERATURE SENSOR

1. Turn ignition switch OFF. 2. Remove engine coolant temperature sensor. 3. Check resistance between engine coolant temperature sensor terminals under the following conditions.

SEF304X

OK or NG OK

䊳

INSPECTION END

NG

䊳

Replace engine coolant temperature sensor.

EC-210

DTC P0132 HO2S1

KA24DE Component Description

Component Description

NGEC0128

The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V.

GI MA EM LC

SEF463R

FE CL MT

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

AT

CONDITION

TF

NGEC0129

Specification data are reference values. MONITOR ITEM

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

쐌 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

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1

AX

NGEC0130

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.

PD

[Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

SU BR ST RS BT

SEF008W

HA SC EL

EC-211

IDX

DTC P0132 HO2S1

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0131

To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high.

SEF301UA

DTC No. P0132

Malfunction is detected when ... 쐌 An excessively high voltage from the sensor is sent to ECM.

Check Items (Possible Cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 1

DTC Confirmation Procedure

SEF174Y

NGEC0132

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) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Restart engine and let it idle for 35 seconds. 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-214. With GST 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Restart engine and let it idle for 35 seconds. 4) Turn ignition switch OFF and wait at least 5 seconds. 5) Restart engine and let it idle for 35 seconds. 6) Select “MODE 3” with GST. 7) If DTC is detected, go to “Diagnostic Procedure”, EC-214. 쐌 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-212

DTC P0132 HO2S1

KA24DE Wiring Diagram

Wiring Diagram

NGEC0133

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC965

EC-213

EL IDX

DTC P0132 HO2S1

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0134

RETIGHTEN HEATED OXYGEN SENSOR 1

1. Turn ignition switch OFF. 2. Loosen and retighten heated oxygen sensor 1.

SEF332VB

Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 1 harness connector and ECM harness connector.

SEF331VB

2. Check harness continuity between ECM terminal 50 and terminal 2.

SEF141V

Continuity should exist. 3. Check harness continuity between ECM terminal 50 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-214

DTC P0132 HO2S1

KA24DE Diagnostic Procedure (Cont’d)

3

CHECK HARNESS CONNECTOR

Check heated oxygen sensor 1 harness connector for water. Water should not exist. OK or NG OK (With CONSULT-II)

䊳

GO TO 4.

OK (Without CONSULTII)

䊳

GO TO 5.

NG

䊳

Repair or replace harness connector.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-215

IDX

DTC P0132 HO2S1

KA24DE

Diagnostic Procedure (Cont’d)

4 1. 2. 3. 4. 5. 6.

CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Reconnect all harness connectors. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode, and the trigger point is adjusted to 100%. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)” in item selection. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “START” on CONSULT-II screen.

SEF646Y

7. Check the following. 쐌 “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:

SEF217YA

쐌 “HO2S1 (B1)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)” voltage never exceeds 1.0V.

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace heated oxygen sensor 1.

EC-216

DTC P0132 HO2S1

KA24DE Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Reconnect all harness connectors. 2. Start engine and warm it up to normal operating temperature. 3. Set voltmeter probes between ECM terminal 50 (Heated oxygen sensor 1 signal) and engine ground.

GI MA EM LC

AEC873A

4. Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than five times within 10 seconds. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 쐌 The maximum voltage is over 0.6V at least one time. 쐌 The minimum voltage is below 0.3V at least one time. 쐌 The voltage never exceeds 1.0V. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

FE CL MT AT TF

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace heated oxygen sensor 1.

6

PD AX

CHECK SHIELD CIRCUIT

1. Turn ignition switch OFF. 2. Remove joint connector-1. 3. Check the following. 쐌 Continuity between joint connector-1 terminal 1 and ground 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to ground and short to power. Then reconnect joint connector.

SU BR ST

OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit, short to power in harness or connectors.

RS BT

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

HA

INSPECTION END

SC EL

EC-217

IDX

DTC P0133 HO2S1

KA24DE

Component Description

Component Description

NGEC0119

The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NGEC0120

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

쐌 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

NGEC0121

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) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1

[Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-218

DTC P0133 HO2S1

KA24DE On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0122

To judge the malfunction of heated oxygen sensor 1, this diagnosis measures response time of heated oxygen sensor 1 signal. The time is compensated by engine operating (speed and load), fuel feedback control constant, and heated oxygen sensor 1 temperature index. Judgment is based on whether the compensated time (heated oxygen sensor 1 cycling time index) is inordinately long or not.

P0133

Malfunction is detected when ...

DTC Confirmation Procedure

SEF657Y

EM

Check Items (Possible Cause)

쐌 The response of the voltage signal from the sensor takes 쐌 Harness or connectors more than the specified time. (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 1 쐌 Heated oxygen sensor 1 heater 쐌 Fuel pressure 쐌 Injectors 쐌 Intake air leaks 쐌 Exhaust gas leaks 쐌 PCV 쐌 Mass air flow sensor

SEF656Y

MA

LC

SEF298U

DTC No.

GI

FE CL MT NGEC0123

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 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 5 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 3.0 minutes. NOTE: Never raise engine speed above 3,000 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.) ENG SPEED

1,750 - 3,750 rpm

Vehicle speed

More than 80 km/h (50 MPH)

B/FUEL SCHDL

3.5 - 15.5 msec

Selector lever

Suitable position

AT TF PD AX SU BR ST RS BT HA SC EL

SEF658Y

EC-219

IDX

DTC P0133 HO2S1

KA24DE

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-222.

Overall Function Check

AEC873A

NGEC0124

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. With GST 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (Heated oxygen sensor 1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than five times within 10 seconds. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 4) If NG, go to “Diagnostic Procedure”, EC-222.

EC-220

DTC P0133 HO2S1

KA24DE Wiring Diagram

Wiring Diagram

NGEC0125

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC965

EC-221

EL IDX

DTC P0133 HO2S1

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0126

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

SEF325V

䊳

2

GO TO 2.

RETIGHTEN HEATED OXYGEN SENSOR 1

Loosen and retighten heated oxygen sensor 1.

SEF332VB

Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

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

䊳

GO TO 4.

NG

䊳

Repair or replace.

EC-222

DTC P0133 HO2S1

KA24DE Diagnostic Procedure (Cont’d)

4

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak between the mass air flow sensor and the intake manifold.

GI

OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair or replace.

5

MA EM

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 “CLEAR”.

LC

FE CL MT SEF215Z

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?

AT

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.

TF PD AX SU BR

AEC131A

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure 1st trip DTC P0102 is displayed. 6. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-86. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? Is it difficult to start engine?

ST RS BT

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171, P0172. Refer to EC-255, 262.

No

䊳

GO TO 6.

HA SC EL

EC-223

IDX

DTC P0133 HO2S1

KA24DE

Diagnostic Procedure (Cont’d)

6

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 harness connector and ECM harness connector. 3. Check harness continuity between ECM terminal 50 and terminal 2.

SEF141V

Continuity should exist. 4. Check harness continuity between ECM terminal 50 (or terminal 2) and ground. Continuity should not exist. 5. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

7

CHECK HEATED OXYGEN SENSOR 1 HEATER

Check resistance between terminals 3 and 1.

SEF220W

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. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK (With CONSULT-II)

䊳

GO TO 8.

OK (Without CONSULTII)

䊳

GO TO 9.

NG

䊳

Replace heated oxygen sensor 1.

EC-224

DTC P0133 HO2S1

KA24DE Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4. 5. 6.

CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Reconnect all harness connectors. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode, and the trigger point is adjusted to 100%. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)” in item selection. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “START” on CONSULT-II screen.

GI MA EM LC

FE SEF646Y

7. Check the following. 쐌 “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:

CL MT AT TF PD

SEF217YA

쐌 “HO2S1 (B1)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)” voltage never exceeds 1.0V.

AX SU BR ST RS

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BT HA

OK or NG

SC EL

OK

䊳

GO TO 10.

NG

䊳

Replace heated oxygen sensor 1.

EC-225

IDX

DTC P0133 HO2S1

KA24DE

Diagnostic Procedure (Cont’d)

9

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Reconnect all harness connectors. 2. Start engine and warm it up to normal operating temperature. 3. Set voltmeter probes between ECM terminal 50 (Heated oxygen sensor 1 signal) and engine ground.

AEC873A

4. Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than five times within 10 seconds. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 쐌 The maximum voltage is over 0.6V at least one time. 쐌 The minimum voltage is below 0.3V at least one time. 쐌 The voltage never exceeds 1.0V. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace heated oxygen sensor 1.

EC-226

DTC P0133 HO2S1

KA24DE Diagnostic Procedure (Cont’d)

10

CHECK MASS AIR FLOW SENSOR

1. Turn ignition switch ON. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 54 (Mass air flow sensor signal) and ground.

GI MA EM LC

SEF326V

FE CL MT MTBL0326

4. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Repeat above check. 5. If NG, remove mass air flow sensor from air duct. Check hot wire for damage or dust.

AT TF PD AX SU

SEF893J

BR

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace mass air flow sensor.

ST RS BT HA SC EL

EC-227

IDX

DTC P0133 HO2S1

KA24DE

Diagnostic Procedure (Cont’d)

11

CHECK PCV VALVE

1. With engine running at idle, remove PCV valve from breather separator. 2. 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

OK or NG OK

䊳

GO TO 12.

NG

䊳

Repair or replace PCV valve.

12

CHECK SHIELD CIRCUIT

1. Turn ignition switch OFF. 2. Remove joint connector-1. 3. Check the following. 쐌 Continuity between joint connector-1 terminal 1 and ground 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 13.

NG

䊳

Repair open circuit, short to power in harness or connectors.

13

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-228

DTC P0134 HO2S1

KA24DE Component Description

Component Description

NGEC0094

The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V.

GI MA EM LC

SEF463R

FE CL MT

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

AT

CONDITION

TF

NGEC0095

Specification data are reference values. MONITOR ITEM

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

쐌 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

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1

AX

NGEC0096

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.

PD

[Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

SU BR ST RS BT

SEF008W

HA SC EL

EC-229

IDX

DTC P0134 HO2S1

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0097

Under the condition in which the heated oxygen sensor 1 signal is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output voltage is within 200 to 400 mV range is monitored, and the diagnosis checks that this time is not inordinately long.

SEF237U

DTC No. P0134

Malfunction is detected when ... 쐌 The voltage from the sensor is constantly approx. 0.3V.

EC-230

Check Items (Possible Cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 1

DTC P0134 HO2S1

KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

SEC748C

SEC749C

SEC750C

=NGEC0098

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 5 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “HO2S1 (B1) P0134” of “HO2S1” 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 3,000 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

1,400 - 4,000 rpm

Vehicle speed

64 - 130 km/h (40 - 81 MPH)

B/FUEL SCHDL

3.5 - 17 msec

Selector lever

Suitable position

If “TESTING” is not displayed after 5 minutes, retry from step 2. 6) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-234. During this test, P1148 may be displayed on CONSULT-II screen.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-231

IDX

DTC P0134 HO2S1

KA24DE

Overall Function Check

Overall Function Check

AEC873A

=NGEC0099

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (Heated oxygen sensor 1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage does not remain in the range of 0.2 - 0.4V. 4) If NG, go to “Diagnostic Procedure”, EC-234.

EC-232

DTC P0134 HO2S1

KA24DE Wiring Diagram

Wiring Diagram

NGEC0100

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC965

EC-233

EL IDX

DTC P0134 HO2S1

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0101

INSPECTION START

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

SEF325V

3. Disconnect heated oxygen sensor 1 harness connector.

SEF331VB

䊳

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 50 and terminal 2.

SEF141V

Continuity should exist. 3. Check harness continuity between ECM terminal 50 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to power. OK or NG OK (With CONSULT-II)

䊳

GO TO 3.

OK (Without CONSULTII)

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-234

DTC P0134 HO2S1

KA24DE Diagnostic Procedure (Cont’d)

3 1. 2. 3. 4. 5. 6.

CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Reconnect all harness connectors. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode, and the trigger point is adjusted to 100%. Select “HO2S1 (B1)” AND “HO2S1 MNTR (B1)” in Item Selection. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “START” on CONSULT-II screen.

GI MA EM LC

FE SEF646Y

7. Check the following. 쐌 “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:

CL MT AT TF PD

SEF217YA

쐌 “HO2S1 (B1)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)” voltage never exceeds 1.0V.

AX SU BR ST RS

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BT HA

OK or NG

SC EL

OK

䊳

GO TO 5.

NG

䊳

Replace heated oxygen sensor 1.

EC-235

IDX

DTC P0134 HO2S1

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Reconnect all harness connectors. 2. Start engine and warm it up to normal operating temperature. 3. Set voltmeter probes between ECM terminal 50 (Heated oxygen sensor 1 signal) and engine ground.

AEC873A

4. Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than five times within 10 seconds. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 쐌 The maximum voltage is over 0.6V at least one time. 쐌 The minimum voltage is below 0.3V at least one time. 쐌 The voltage never exceeds 1.0V. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace heated oxygen sensor 1.

5

CHECK SHIELD CIRCUIT

1. Turn ignition switch OFF. 2. Remove joint connector-1. 3. Check the following. 쐌 Continuity between joint connector-1 terminal 1 and ground 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair open circuit, short to power in harness or connectors.

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-236

DTC P0138 HO2S2

KA24DE Component Description

Component Description

SEF327R

NGEC0171

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

GI MA EM LC

CONSULT-II Reference Value in Data Monitor Mode

NGEC0172

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

FE

0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) 쐌 Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

CL

LEAN +, RICH

ECM Terminals and Reference Value

NGEC0173

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. 56

WIRE COLOR

OR

MT AT TF

ITEM

CONDITION

Heated oxygen sensor 2

DATA (DC Voltage)

[Engine is running] 쐌 After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 3,000 rpm

On Board Diagnosis Logic

NGEC0174

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether or not the voltage is too high during various driving conditions such as fuel-cut.

PD AX SU BR ST RS

SEF305UA

DTC No. P0138

Malfunction is detected when ... 쐌 An excessively high voltage from the sensor is sent to ECM.

Check Items (Possible Cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 2

BT HA SC EL

EC-237

IDX

DTC P0138 HO2S2

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF189Y

ENG SPEED

1,100 - 3,600 rpm

VHCL SPEED SE

32 - 120 km/h (20 - 75 MPH)

B/FUEL SCHDL

3.5 - 15.5 msec

COOLAN TEMP/S

More than 70°C (158°F)

Selector lever

Suitable position

4)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-240.

Overall Function Check

AEC874A

NGEC0175

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 drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 3) Maintain the following conditions for at least 5 consecutive seconds.

NGEC0176

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. 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 56 (Heated oxygen sensor 2 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 1.4V during this procedure. 5) If NG, go to “Diagnostic Procedure”, EC-240.

EC-238

DTC P0138 HO2S2

KA24DE Wiring Diagram

Wiring Diagram

NGEC0177

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC967

EC-239

EL IDX

DTC P0138 HO2S2

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0178

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

SEF325V

䊳

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 2 harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 56 and terminal 1.

SEF157V

Continuity should exist. 3. Check harness continuity between ECM terminal 56 (or terminal 1) and ground. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness for open or short between heated oxygen sensor 2 and ECM 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-240

DTC P0138 HO2S2

KA24DE Diagnostic Procedure (Cont’d)

4

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

GI MA EM

DETECT MALFUNCTIONING PART

LC

Check the following. 쐌 Harness connectors M58, F28 쐌 Joint connector-1 쐌 Harness for open or short between heated oxygen sensor 2 and engine ground 䊳

6

Repair open circuit or short to power in harness or connectors.

CHECK HARNESS CONNECTOR

Check heated oxygen sensor 2 harness connector for water. Water should not exist. OK or NG

FE CL MT

OK (With CONSULT-II)

䊳

GO TO 7.

OK (Without CONSULTII)

䊳

GO TO 8.

AT

NG

䊳

Repair or replace harness connector.

TF PD AX SU BR ST RS BT HA SC EL

EC-241

IDX

DTC P0138 HO2S2

KA24DE

Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4. 5.

CHECK HEATED OXYGEN SENSOR 2 With CONSULT-II Reconnect all harness connectors. 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%.

SEF662Y

“HO2S2 (B1)” should be above 0.56V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.54V at least once when the “FUEL INJECTION” is −25%. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

SEF244Y

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace heated oxygen sensor 2.

EC-242

DTC P0138 HO2S2

KA24DE Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without CONSULT-II Reconnect all harness connectors. 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. Set voltmeter probes between ECM terminals 56 (Heated oxygen sensor 2 signal) and engine ground.

GI MA EM LC

FE AEC874A

5. 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 0.56V at least once. If the voltage is above 0.56V at step 4, step 5 is not necessary. 6. Check the voltage when revving up to 5,000 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 0.54V at least once. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace heated oxygen sensor 2.

9

CL MT AT TF PD AX

CHECK SHIELD CIRCUIT

SU

1. Turn ignition switch OFF. 2. Disconnect harness connectors M58, F28. 3. Check harness continuity between harness connector F28 terminal 4 and ground.

BR ST RS BT SEF698Z

Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect harness connectors.

HA OK or NG

OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

SC EL

EC-243

IDX

DTC P0138 HO2S2

KA24DE

Diagnostic Procedure (Cont’d)

10

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) 쐌 Harness for open or short between harness connector F28 and engine ground 䊳

11

Repair open circuit, short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-244

DTC P0139 HO2S2

KA24DE Component Description

Component Description

SEF327R

NGEC0162

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

GI MA EM LC

CONSULT-II Reference Value in Data Monitor Mode

NGEC0163

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

FE

0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) 쐌 Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

CL

LEAN +, RICH

ECM Terminals and Reference Value

NGEC0164

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. 56

WIRE COLOR

OR

MT AT TF

ITEM

CONDITION

Heated oxygen sensor 2

DATA (DC Voltage)

[Engine is running] 쐌 After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 3,000 rpm

On Board Diagnosis Logic

NGEC0165

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the switching response of the sensor’s voltage is faster than specified during various driving conditions such as fuel-cut.

PD AX SU BR ST RS

SEF302U

DTC No. P0139

Malfunction is detected when ... 쐌 It takes more than the specified time for the sensor to respond between rich and lean.

Check Items (Possible Cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 2 쐌 Fuel pressure 쐌 Injectors 쐌 Intake air leaks

BT HA SC EL

EC-245

IDX

DTC P0139 HO2S2

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF666Y

SEF667Y

NGEC0166

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. TESTING CONDITION: Open engine hood before conducting following procedure With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Make sure the “COOLANT TEMP/S” is more then 70°C (158°F). 6) Select “HO2S2 (B1) P0139” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 7) Start engine and follow the instructions of CONSULT-II. 8) Make sure the “OK” is displayed after touching “SELF-DIAG RESULTS”. If NG is displayed, refer to “Diagnostic Procedure”, EC-249. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. a) Stop engine and cool down “COOLANT TEMP/S” to less then 70°C (158°F). b) Turn ignition switch ON c) Select “DATA MONITOR” mode with CONSULT-II. d) Start engine. e) Perform from step 6) again when the “COOLANT TEMP/S” reach to 70°C (158°F).

SEF668Y

EC-246

DTC P0139 HO2S2

KA24DE Overall Function Check

Overall Function Check

AEC874A

=NGEC0167

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 56 (Heated oxygen sensor 2 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-249.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-247

IDX

DTC P0139 HO2S2

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0168

WEC967

EC-248

DTC P0139 HO2S2

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0169

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

SEF325V

FE 䊳

GO TO 2.

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-249

IDX

DTC P0139 HO2S2

KA24DE

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 “CLEAR”.

SEF215Z

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.

AEC131A

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure 1st trip DTC P0102 is displayed. 6. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-86. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? Is it difficult to start engine? Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171 or P0172. Refer to EC-255 or EC-262.

No

䊳

GO TO 3.

EC-250

DTC P0139 HO2S2

KA24DE Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 2 harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 56 and terminal 1.

GI MA EM LC

SEF157V

Continuity should exist. 3. Check harness continuity between ECM terminal 56 (or terminal 1) and ground. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

CL MT AT

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness for open or short between heated oxygen sensor 2 and ECM 䊳

FE

TF

Repair open circuit or short to ground or short to power in harness or connectors.

PD 5

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 terminal 4 and engine ground. Refer to the wiring diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG

AX SU

OK (With CONSULT-II)

䊳

GO TO 7.

OK (Without CONSULTII)

䊳

GO TO 8.

BR

NG

䊳

GO TO 6.

ST

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Joint connector-1 쐌 Harness for open or short between heated oxygen sensor 2 and engine ground 䊳

RS BT

Repair open circuit or short to power in harness or connectors.

HA SC EL

EC-251

IDX

DTC P0139 HO2S2

KA24DE

Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4. 5.

CHECK HEATED OXYGEN SENSOR 2 With CONSULT-II Reconnect all harness connectors. 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%.

SEF662Y

“HO2S2 (B1)” should be above 0.56V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.54V at least once when the “FUEL INJECTION” is −25%. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

SEF244Y

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace heated oxygen sensor 2.

EC-252

DTC P0139 HO2S2

KA24DE Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without CONSULT-II Reconnect all harness connectors. 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. Set voltmeter probes between ECM terminals 56 (Heated oxygen sensor 2 signal) and engine ground.

GI MA EM LC

FE AEC874A

5. 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 0.56V at least once. If the voltage is above 0.56V at step 4, step 5 is not necessary. 6. Check the voltage when revving up to 5,000 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 0.54V at least once. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace heated oxygen sensor 2.

9

CL MT AT TF PD AX

CHECK SHIELD CIRCUIT

SU

1. Turn ignition switch OFF. 2. Disconnect harness connectors M58, F28. 3. Check harness continuity between harness connector F28 terminal 4 and ground.

BR ST RS BT SEF698Z

Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect harness connectors.

HA OK or NG

OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

SC EL

EC-253

IDX

DTC P0139 HO2S2

KA24DE

Diagnostic Procedure (Cont’d)

10

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) 쐌 Harness for open or short between harness connector F28 and engine ground 䊳

11

Repair open circuit, short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-254

DTC P0171 FUEL INJECTION SYSTEM FUNCTION

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0188

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensor 1. The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the ECM judges the condition as the fuel injection system malfunction and lights up the MIL (2 trip detection logic). Sensor

Heated oxygen sensor 1

DTC No. P0171

ECM function

Input Signal to ECM

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Malfunction is detected when ... 쐌 Fuel injection system does not operate properly. 쐌 The amount of mixture ratio compensation is too large. (The mixture ratio is too lean.)

Fuel injection & mixture ratio control

Actuator

MA EM LC

Injectors

Check Items (Possible Cause) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

FE

Intake air leaks Heated oxygen sensor 1 Injectors Exhaust gas leaks Incorrect fuel pressure Lack of fuel Mass air flow sensor Incorrect PCV hose connection

DTC Confirmation Procedure

SEF215Z

GI

CL MT NGEC0189

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) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 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-258. 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-258. If engine does not start, visually check for exhaust and intake air leak.

AT

With GST Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 5 seconds. Disconnect mass air flow sensor harness connector. Then restart and run engine for at least 3 seconds at idle speed. 4) Stop engine and reconnect mass air flow sensor harness connector. 5) Select “MODE 7” with GST. Make sure 1st trip DTC P0102 is detected. 6) Select “MODE 4” with GST and erase the 1st trip DTC P0102.

BT

TF PD AX SU BR ST RS

SEF058Y

1) 2) 3)

HA SC EL

AEC131A

EC-255

IDX

DTC P0171 FUEL INJECTION SYSTEM FUNCTION

KA24DE

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-258. 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-258. If engine does not start, visually check for exhaust and intake air leak.

EC-256

DTC P0171 FUEL INJECTION SYSTEM FUNCTION

KA24DE Wiring Diagram

Wiring Diagram

NGEC0190

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC969

EC-257

EL IDX

DTC P0171 FUEL INJECTION SYSTEM FUNCTION

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0191

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

䊳

GO TO 2.

NG

䊳

Repair or replace.

2

CHECK FOR INTAKE AIR LEAK AND PCV HOSE

1. Listen for an intake air leak between the mass air flow sensor and the intake manifold. 2. Check PCV hose connection. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace.

EC-258

DTC P0171 FUEL INJECTION SYSTEM FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

3

CHECK HEATED OXYGEN SENSOR 1 CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect heated oxygen sensor 1 harness connector and ECM harness connector.

GI MA EM LC SEF331VB

3. Check harness continuity between ECM terminal 50 and terminal 2.

FE CL MT AT SEF141V

Continuity should exist. 4. Check harness continuity between ECM terminal 50 (or terminal 2) and ground. Continuity should not exist. 5. Also check harness for short to ground and short to power.

TF PD

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

4

AX SU

CHECK FUEL PRESSURE

1. Release fuel pressure to zero. Refer to EC-57. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (3.0 kg/cm2, 43 psi)

BR ST RS

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

BT HA

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuel pump and circuit, refer to EC-580. 쐌 Fuel pressure regulator, refer to EC-58. 쐌 Fuel lines, refer to “Checking Fuel Lines”, MA-19. 쐌 Fuel filter for clogging 䊳

SC EL

Repair or replace.

EC-259

IDX

DTC P0171 FUEL INJECTION SYSTEM FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

6

CHECK MASS AIR FLOW SENSOR

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 0.9 - 5.8 g·m/sec at 2,500 rpm: 7.5 - 13.2 g·m/sec With GST 1. Start engine and warm it up to normal operating temperature. 2. Check mass air flow sensor signal in MODE 1 with GST. at idling: 0.9 - 5.8 g·m/sec at 2,500 rpm: 7.5 - 13.2 g·m/sec OK or NG OK

䊳

GO TO 7.

NG

䊳

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-168.

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.

SEF190Y

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

䊳

GO TO 8.

NG

䊳

Perform trouble diagnosis for “INJECTORS”, EC-571.

EC-260

DTC P0171 FUEL INJECTION SYSTEM FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

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-58. Keep fuel hose and all injectors connected to injector gallery. The injector harness connectors should remain connected. 䊳

9

GO TO 9.

GI MA EM

CHECK INJECTOR

LC

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.

FE CL MT SEF595Q

Fuel should be sprayed evenly for each cylinder.

AT

OK or NG OK

䊳

GO TO 10.

TF

NG

䊳

Replace injectors from which fuel does not spray out. Always replace O-ring with new one.

PD

10

CHECK INTERMITTENT INCIDENT

AX

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

SU BR ST RS BT HA SC EL

EC-261

IDX

DTC P0172 FUEL INJECTION SYSTEM FUNCTION

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0192

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensor 1. The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the ECM judges the condition as the fuel injection system malfunction and lights up the MIL (2 trip detection logic). Sensor

Heated oxygen sensor 1

DTC No. P0172

ECM function

Input Signal to ECM

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Malfunction is detected when ... 쐌 Fuel injection system does not operate properly. 쐌 The amount of mixture ratio compensation is too large. (The mixture ratio is too rich.)

Fuel injection & mixture ratio control

Actuator

Injectors

Check Items (Possible Cause) 쐌 쐌 쐌 쐌 쐌

Heated oxygen sensor 1 Injectors Exhaust gas leaks Incorrect fuel pressure Mass air flow sensor

DTC Confirmation Procedure

SEF215Z

NGEC0193

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) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 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 P0172 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-265. 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-265. If engine does not start, remove ignition plugs and check for fouling, etc.

SEF058Y

With GST Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 5 seconds. Disconnect mass air flow sensor harness connector. Then restart and run engine for at least 3 seconds at idle speed. 4) Stop engine and reconnect mass air flow sensor harness connector. 5) Select “MODE 7” with GST. Make sure 1st trip DTC P0102 is detected. 6) Select “MODE 4” with GST and erase the 1st trip DTC P0102. 1) 2) 3)

AEC131A

EC-262

DTC P0172 FUEL INJECTION SYSTEM FUNCTION

KA24DE

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-265. 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-265. If engine does not start, remove ignition plugs and check for fouling, etc.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-263

IDX

DTC P0172 FUEL INJECTION SYSTEM FUNCTION

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0194

WEC969

EC-264

DTC P0172 FUEL INJECTION SYSTEM FUNCTION

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0195

CHECK FOR EXHAUST AIR LEAK

GI

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.

MA EM LC

SEF099P

FE

OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair or replace.

2

CL MT

CHECK HEATED OXYGEN SENSOR 1 CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect heated oxygen sensor 1 harness connector and ECM harness connector.

AT TF PD AX SEF331VB

3. Check harness continuity between ECM terminal 50 and terminal 2.

SU BR ST RS BT

SEF141V

Continuity should exist. 4. Check harness continuity between ECM terminal 50 (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

䊳

GO TO 3.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-265

HA SC EL IDX

DTC P0172 FUEL INJECTION SYSTEM FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

3

CHECK FUEL PRESSURE

1. Release fuel pressure to zero. Refer to EC-57. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. Approximately 235 kPa (2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. Approximately 294 kPa (3.0 kg/cm2, 43 psi) OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuel pump and circuit (Refer to EC-580.) 쐌 Fuel pressure regulator (Refer to EC-58.) 䊳

5

Repair or replace.

CHECK MASS AIR FLOW SENSOR

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 0.9 - 5.8 g·m/sec at 2,500 rpm: 7.5 - 13.2 g·m/sec With GST 1. Start engine and warm it up to normal operating temperature. 2. Check mass air flow sensor signal in MODE 1 with GST. at idling: 0.9 - 5.8 g·m/sec at 2,500 rpm: 7.5 - 13.2 g·m/sec OK or NG OK

䊳

GO TO 6.

NG

䊳

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-168.

EC-266

DTC P0172 FUEL INJECTION SYSTEM FUNCTION

KA24DE

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.

GI MA EM LC

SEF190Y

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.

FE CL MT AT TF PD

MEC703B

Clicking noise should be heard.

AX

OK or NG

SU

OK

䊳

GO TO 7.

NG

䊳

Perform trouble diagnosis for “INJECTORS”, EC-571.

BR 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-58. Keep fuel hose and all injectors connected to injector gallery. 䊳

ST RS

GO TO 8.

BT 8 1. 2. 3. 4.

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.

HA SC OK or NG

EL

OK (Does not drip)

䊳

GO TO 9.

NG (Drips)

䊳

Replace the injectors from which fuel is dripping. Always replace O-ring with new one.

EC-267

IDX

DTC P0172 FUEL INJECTION SYSTEM FUNCTION Diagnostic Procedure (Cont’d)

9

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-268

KA24DE

DTC P0181, P0182, P0183 FTT SENSOR

KA24DE Component Description

Component Description

NGEC0196

The fuel tank temperature sensor is used to detect the fuel temperature inside the fuel tank. 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.

GI MA EM LC

AFE095

Fluid temperature °C (°F)

Voltage* V

Resistance kΩ

20 (68)

3.5

2.3 - 2.7

50 (122)

2.2

0.79 - 0.90

FE

*: These data are reference values and are measured between ECM terminal 60 (Fuel tank 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.

CL MT AT TF PD AX

On Board Diagnosis Logic DTC No.

Malfunction is detected when ...

P0182 P0183

쐌 An excessively low (P0182) or high (P0183) voltage is sent to ECM.

P0181

쐌 Rationally incorrect voltage is sent to ECM, compared with the voltage signals from engine coolant temperature sensor and intake air temperature sensor.

NGEC0197

SU

Check Items (Possible Cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Fuel tank temperature sensor

BR ST RS BT HA SC EL

EC-269

IDX

DTC P0181, P0182, P0183 FTT SENSOR

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF174Y

=NGEC0198

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. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 10 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-272. If the result is OK, go to following step. NOTE: If “COOLAN TEMP/S” is already less than 60°C (140°F) before step 4), the result will be OK. If “COOLAN TEMP/S” is above 60°C (140°F), go to the following step. 4) Check “COOLAN TEMP/S” signal. If the signal is less than 60°C (140°F), the result will be OK. If the signal is above 60°C (140°F), go to the following step. 5) Cool engine down until “COOLAN TEMP/S” signal is less than 60°C (140°F). 6) Wait at least 10 seconds. 7) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-272. With GST Follow the procedure “With CONSULT-II”.

EC-270

DTC P0181, P0182, P0183 FTT SENSOR

KA24DE Wiring Diagram

Wiring Diagram

NGEC0199

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC970

EC-271

EL IDX

DTC P0181, P0182, P0183 FTT SENSOR

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0200

CHECK POWER SUPPLY

1. Turn ignition switch OFF. 2. Disconnect fuel level sensor unit harness connector.

AFE095

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

SEF708Z

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors B101, M67 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuel tank temperature sensor 䊳

Repair harness or connector.

EC-272

DTC P0181, P0182, P0183 FTT SENSOR

KA24DE Diagnostic Procedure (Cont’d)

3

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Check harness continuity between terminal 4 and body ground.

GI MA EM LC SEF709Z

Continuity should exist. 3. Also check harness for short to power.

FE OK or NG

OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to power in harness or connectors.

4

CL MT

CHECK FUEL TANK TEMPERATURE SENSOR

1. Remove fuel level sensor unit.

AT TF PD AX AFE095

2. Check resistance by heating with hot water or heat gun as shown in the figure.

SU BR ST RS SEF710Z

BT HA MTBL0291

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace fuel tank temperature sensor.

EC-273

SC EL IDX

DTC P0181, P0182, P0183 FTT SENSOR Diagnostic Procedure (Cont’d)

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-274

KA24DE

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1492

This diagnosis checks whether the engine coolant temperature is extraordinary high, even when the load is not heavy. When malfunction is detected, the MIL will light up even in the first trip. DTC No. P0217

Check Items (Possible Cause)

MA

Cooling fan (Crankshaft driven) Thermostat Improper ignition timing Engine coolant temperature sensor Blocked radiator Blocked front end (Improper fitting of nose mask) Crushed vehicle frontal area (Vehicle damage from a collision but not repaired) 쐌 Blocked air passage by improper installation of front fog lamp or fog lamps. 쐌 Improper mixture ratio of coolant 쐌 Damaged bumper For more information, refer to “MAIN 11 CAUSES OF OVERHEATING”, EC-280.

EM

Malfunction is detected when ... 쐌 Engine coolant temperature is excessively high under normal engine speed.

GI

쐌 쐌 쐌 쐌 쐌 쐌 쐌

CAUTION: When a malfunction is indicated, be sure to replace the coolant. Refer to MA-17, “Changing Engine Coolant”. 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-15, “Anti-freeze Coolant Mixture Ratio”. 2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.

LC

FE CL MT AT TF PD AX

Overall Function Check

SEF621W

NGEC1493

Use this procedure to check the overall function of the coolant overtemperature enrichment protection 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 and mixture ratio (using coolant tester) in the reservoir tank and radiator. Allow engine to cool before checking coolant level and mixture ratio. 쐌 If the coolant level in the reservoir and/or radiator is below the proper range, go to “Diagnostic Procedure”, EC-277. 쐌 If the coolant mixture ratio is out of the range of 45 to 55%, replace the coolant in the following procedure MA-17, “Changing Engine Coolant”. a) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pouring coolant from a kettle. Be sure to use coolant with the proper mixture ratio. Refer to MA-15,

EC-275

SU BR ST RS BT HA SC EL IDX

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

KA24DE

Overall Function Check (Cont’d)

b) c) 2)

3) 4)

5)

6) a)

7) a) b) c)

8)

9)

“Anti-freeze Coolant Mixture Ratio”. After refilling coolant, run engine to ensure that no water-flow noise is emitted. After checking or replacing coolant, go to step 3 below. Ask the customer if engine coolant has been added. If it has been added, go to “Diagnostic Procedure”, EC-277. After repair, go to the next step. Start engine and let it idle. Make sure that A/C switch is “OFF” and air conditioner is not operating. If NG, check air conditioner circuit. Refer to HA-85 or HA-85, “TROUBLE DIAGNOSES”. After repair, go to the next step. Start engine and make sure that cooling fan operates. Be careful not to overheat engine. If NG, check cooling fan. Refer to LC-16, “Cooling Fan (Crankshaft driven)”. After repair, go to the next step. Check for blocked coolant passage. Warm up engine to normal operating temperature, then grasp radiator upper hose and lower hose and make sure that coolant flows. If NG, go to “Diagnostic Procedure”, EC-277. After repair, go to the next step. Be extremely careful not to touch any moving or adjacent parts. Check for blocked radiator air passage. When market fog lamps have been installed, check for damaged fans and clogging in the condenser and radiator. Check the front end for clogging caused by insects or debris. Check for improper fitting of front-end cover, damaged radiator grille or bumper, damaged vehicle front. If NG, take appropriate action and then go to the next step. Check function of ECT sensor. Refer to step 4 of “Diagnostic Procedure”, EC-277. If NG, replace ECT sensor and go to the next step. Check ignition timing. Refer to basic inspection, EC-277. Make sure that ignition timing is 20°±2° at idle. If NG, adjust ignition timing and then recheck.

EC-276

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1494

CHECK COOLING SYSTEM FOR LEAK

GI

Apply pressure to the cooling system with a tester, and check if the pressure drops. Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage.

MA EM LC

FE SLC754A

Pressure should not drop.

CL

OK or NG OK

䊳

GO TO 2.

NG

䊳

Check the following for leak. 쐌 Hose 쐌 Radiator 쐌 Water pump Refer to LC-12, “Water Pump”.

2

MT AT TF

CHECK RADIATOR CAP

Apply pressure to cap with a tester.

PD AX SU BR SLC755A

Radiator cap relief pressure: 78 - 98 kPa (0.8 - 1.0 kg/cm2, 11 - 14 psi) OK or NG OK

䊳

GO TO 3.

NG

䊳

Replace radiator cap.

ST RS BT HA SC EL

EC-277

IDX

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

KA24DE

Diagnostic Procedure (Cont’d)

3

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-13, “Thermostat”. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace thermostat

EC-278

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

GI MA EM LC SEF152P



FE CL MTBL0285

MT AT TF PD SEF012P

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace engine coolant temperature sensor.

5

AX SU BR

CHECK COOLING FAN

Refer to LC-16, “Cooling Fan (Crankshaft driven)”. OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace cooling fan.

6

ST RS

CHECK MAIN 11 CAUSES

BT

If the cause cannot be isolated, go to “MAIN 11 CAUSES OF OVERHEATING”, EC-280. 䊳

INSPECTION END

HA

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

EC-279

SC EL IDX

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

KA24DE

Diagnostic Procedure (Cont’d)

3.

systems for leaks by listening for noise or visually inspecting the components. Allow engine to cool and visually check for oil and coolant leaks. Then, perform “OVERALL FUNCTION CHECK”.

Main 11 Causes of Overheating Engine

Step

Inspection item

OFF

1

쐌 쐌 쐌 쐌

2

Equipment

Standard

NGEC1495

Reference page

쐌 Visual

No blocking

쐌 Coolant mixture

쐌 Coolant tester

50 - 50% coolant mixture See MA-13, “RECOMMENDED FLUIDS AND LUBRICANTS”.

3

쐌 Coolant level

쐌 Visual

Coolant up to MAX level in reservoir tank and radiator filler neck

See MA-17, “Changing Engine Coolant”.

4

쐌 Radiator cap

쐌 Pressure tester

78 - 98 kPa (0.8 - 1.0 kg/cm2, 11 - 14 psi) 59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi) (Limit)

See LC-11, “System Check”.

ON*2

5

쐌 Coolant leaks

쐌 Visual

No leaks

See LC-11, “System Check”.

ON*2

6

쐌 Thermostat

쐌 Touch the upper and lower radiator hoses

Both hoses should be hot

See LC-13, “Thermostat” and LC-14, “Radiator”.

OFF

7

쐌 Combustion gas leak

쐌 Color checker chemical tester 4 Gas analyzer

Negative

—

ON*3

8

쐌 Coolant temperature gauge

쐌 Visual

Gauge less than 3/4 when driving

—

쐌 Coolant overflow to reservoir tank

쐌 Visual

No overflow during driving and idling

See MA-17, “Changing Engine Coolant”.

Blocked Blocked Blocked Blocked

radiator condenser radiator grille bumper

—

OFF*4

9

쐌 Coolant return from 쐌 Visual reservoir tank to radiator

Should be initial level in reservoir tank

See MA-16, “ENGINE MAINTENANCE”.

OFF

10

쐌 Cylinder head

0.1 mm (0.004 in) Maximum distortion (warping)

See EM-31, “Inspection”.

11

쐌 Cylinder block and pis- 쐌 Visual tons

No scuffing on cylinder walls or piston

See EM-45, “Inspection”.

쐌 Straight gauge feeler gauge

*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 LC-17, “OVERHEATING CAUSE ANALYSIS”.

EC-280

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE KA24DE On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0202

When a misfire occurs, 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 (OBD)

ECM function

Engine speed

MA

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 MIL 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 MIL will turn off. If another misfire condition occurs that can damage the TWC on a second trip, the MIL will blink. When the misfire condition decreases to a level that will not damage the TWC, the MIL will remain on. If another misfire condition occurs that can damage the TWC, the MIL will begin to blink again. 2. Two Trip Detection Logic (Exhaust quality deterioration) For misfire conditions that will not damage the TWC (but will affect vehicle emissions), the MIL 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

쐌 Multiple cylinders misfire.

P0301

쐌 No. 1 cylinder misfires.

P0302

쐌 No. 2 cylinder misfires.

P0303

쐌 No. 3 cylinder misfires.

P0304

쐌 No. 4 cylinder misfires.

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

Improper spark plug Insufficient compression Incorrect fuel pressure EGR valve The injector circuit is open or shorted Injectors Intake air leak The ignition secondary circuit is open or shorted Lack of fuel Flywheel Heated oxygen sensor 1 Incorrect distributor rotor NGEC0203

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 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 warm it up to normal operating temperature. 3) Turn ignition switch OFF and wait at least 5 seconds. 4) Start engine again and drive at 1,500 to 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-282. With GST Follow the procedure “With CONSULT-II”.

EC-281

EM LC

FE CL MT

Check Items (Possible Cause)

DTC Confirmation Procedure

SEF174Y

GI

AT TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE KA24DE Diagnostic Procedure

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

䊳

GO TO 2.

NG

䊳

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

䊳

GO TO 3.

NG

䊳

Repair or replace it.

3

CHECK EGR FUNCTION

Perform DTC Confirmation Procedure for DTC P1402 EGR FUNCTION (OPEN). Refer to EC-503. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair EGR system.

EC-282

NGEC0204

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE KA24DE Diagnostic Procedure (Cont’d)

4

PERFORM POWER BALANCE TEST

With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode.

GI MA EM LC

SEF190Y

2. Is there any cylinder which does not produce a momentary engine speed drop?

FE

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?

CL MT AT TF SEF319V

PD

Yes or No Yes

䊳

GO TO 5.

No

䊳

GO TO 8.

5

AX SU

CHECK INJECTOR

Does each injector make an operating sound at idle?

BR ST RS BT MEC703B

Yes or No Yes

䊳

GO TO 6.

No

䊳

Check injector(s) and circuit(s). Refer to EC-571.

HA SC EL

EC-283

IDX

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE KA24DE Diagnostic Procedure (Cont’d)

6 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.

SEF282G

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

CHECK IGNITION WIRES

1. Inspect wires for cracks, damage, burned terminals and for improper fit. 2. Measure the resistance of wires to their distributor cap terminal. Move each wire while testing to check for intermittent breaks.

SEF174P

Resistance: 13.6 - 18.4 kΩ/m (4.15 - 5.61 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. OK or NG OK

䊳

Check distributor rotor head for incorrect parts. Check ignition coil, power transistor and their circuits. Refer to EC-562.

NG

䊳

Replace.

EC-284

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE KA24DE Diagnostic Procedure (Cont’d)

8

CHECK SPARK PLUGS

Remove the spark plugs and check for fouling, etc.

GI MA EM LC SEF156I

OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to “ENGINE MAINTENANCE”, MA-16.

FE CL

9

CHECK COMPRESSION PRESSURE

MT

Refer to EM-15. 쐌 Check compression pressure. Standard: 1,226 kPa (12.5 kg/cm2, 178 psi)/300 rpm Minimum: 1,030 kPa (10.5 kg/cm2, 149 psi)/300 rpm Difference between each cylinder: 98 kPa (1.0 kg/cm2, 14 psi)/300 rpm

AT TF OK or NG

OK

䊳

GO TO 10.

NG

䊳

Check pistons, piston rings, valves, valve seats and cylinder head gaskets.

10

PD AX

CHECK FUEL PRESSURE

SU

1. Install any parts removed. 2. Release fuel pressure to zero. Refer to EC-57. 3. Install fuel pressure gauge and check fuel pressure.

BR ST RS BT AEC064B

At idle: Approx. 235 kPa (2.4 kg/cm2, 34 psi) OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 11.

HA SC EL

EC-285

IDX

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE KA24DE Diagnostic Procedure (Cont’d)

11

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuel pump and circuit refer to EC-580. 쐌 Fuel pressure regulator refer to EC-58. 쐌 Fuel lines refer to “Checking Fuel Lines”, MA-19. 쐌 Fuel filter for clogging 䊳

12

Repair or replace.

CHECK IGNITION TIMING

1. Check the following items. Refer to “Basic Inspection”, EC-112.

MTBL0328

OK or NG OK (With CONSULT-II)

䊳

GO TO 13.

OK (Without CONSULTII)

䊳

GO TO 14.

NG

䊳

Adjust ignition timing.

EC-286

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE KA24DE Diagnostic Procedure (Cont’d)

13 1. 2. 3. 4. 5.

CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode, and the trigger point is adjusted to 100%. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)” in item selection. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “START” on CONSULT-II screen.

GI MA EM LC

FE SEF646Y

6. Check the following. 쐌 “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:

CL MT AT TF PD

SEF217YA

쐌 “HO2S1 (B1)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)” voltage never exceeds 1.0V.

AX SU BR ST RS SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BT HA

OK or NG

SC

OK

䊳

GO TO 15.

NG

䊳

Replace heated oxygen sensor 1.

EL

EC-287

IDX

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE KA24DE Diagnostic Procedure (Cont’d)

14

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (Heated oxygen sensor 1 signal) and engine ground.

AEC873A

3. Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than five times within 10 seconds. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 쐌 The maximum voltage is over 0.6V at least one time. 쐌 The minimum voltage is below 0.3V at least one time. 쐌 The voltage never exceeds 1.0V. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 15.

NG

䊳

Replace heated oxygen sensor 1.

15

CHECK MASS AIR FLOW SENSOR

With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 0.9 - 5.8 g·m/sec at 2,500 rpm: 7.5 - 13.2 g·m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 0.9 - 5.8 g·m/sec at 2,500 rpm: 7.5 - 13.2 g·m/sec OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 16.

16

CHECK CONNECTORS

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-168. OK or NG NG

䊳

Repair or replace it.

EC-288

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE KA24DE Diagnostic Procedure (Cont’d)

17

CHECK SYMPTOM MATRIX CHART

Check items on the rough idle symptom in “Symptom Matrix Chart”, EC-128.

GI

OK or NG OK

䊳

GO TO 18.

NG

䊳

Repair or replace.

18

MA EM

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-86. 䊳

19

LC

GO TO 19.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

FE

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-289

IDX

DTC P0327, P0328 KS

KA24DE

Component Description

Component Description

NGEC0206

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 MIL will not light for knock sensor malfunction. The knock sensor has one trip detection logic.

SEF598K

ECM Terminals and Reference Value

NGEC0207

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. 64

WIRE COLOR W

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Idle speed

Knock sensor

Approximately 2.4V

On Board Diagnosis Logic DTC No. P0327 P0328

Malfunction is detected when ...

NGEC0208

Check Items (Possible Cause)

쐌 An excessively low (P0327) or high (P0328) voltage from 쐌 Harness or connectors the knock sensor is sent to ECM. (The knock sensor circuit is open or shorted.) 쐌 Knock sensor

DTC Confirmation Procedure

SEF058Y

NGEC0209

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. 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-292. With GST Follow the procedure “With CONSULT-II”.

EC-290

DTC P0327, P0328 KS

KA24DE Wiring Diagram

Wiring Diagram

NGEC0210

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC777

EC-291

EL IDX

DTC P0327, P0328 KS

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0211

RETIGHTEN GROUND SCREWS

Loosen and retighten engine ground screws.

SEF325V

䊳

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT-1

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 64 and ground.

SEF173V

Resistance: Approximately 500 - 620 kΩ [at 25°C (77°F)] It is necessary to use an ohmmeter which can measure more than 10 MΩ. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the harness for open or short between knock sensor and ECM. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-292

DTC P0327, P0328 KS

KA24DE Diagnostic Procedure (Cont’d)

4

CHECK KNOCK SENSOR

Use an ohmmeter which can measure more than 10 MΩ. 1. Disconnect knock sensor harness connector. 2. Check resistance between terminal 1 and ground.

GI MA EM LC

SEF174V

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. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace knock sensor.

5

CHECK SHIELD CIRCUIT

AT

OK or NG 䊳

GO TO 7.

NG

䊳

GO TO 6.

6

CL MT

1. Turn ignition switch OFF. 2. Remove joint connector-2. 3. Check the following. Refer to the wiring diagram. 쐌 Continuity between joint connector-2 terminal 1 and ground 쐌 Joint connector-2 (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect harness connectors.

OK

FE

TF PD AX SU

DETECT MALFUNCTIONING PART

BR

Check the joint connector-2. (Refer to “HARNESS LAYOUT”, EL-250.) 䊳

7

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

ST RS

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

BT HA SC EL

EC-293

IDX

DTC P0335 CKP SENSOR (OBD)

KA24DE

Component Description

Component Description

SEF956N

NGEC0213

The crankshaft position sensor (OBD) is located on the transaxle 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 directly used to control the engine system. It is used only for the on board diagnosis.

SEF335V

ECM Terminals and Reference Value

NGEC0214

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 (AC Voltage)

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

47

L

Crankshaft position sensor (OBD)

[Engine is running] 쐌 Engine speed is 2,000 rpm

On Board Diagnosis Logic DTC No. P0335

Malfunction is detected when ...

NGEC0215

Check Items (Possible Cause)

쐌 The proper pulse signal from the crankshaft position sen- 쐌 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.) 쐌 Crankshaft position sensor (OBD) 쐌 Dead battery

EC-294

DTC P0335 CKP SENSOR (OBD)

KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

SEF058Y

NGEC0216

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 15 seconds at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-297. With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-295

IDX

DTC P0335 CKP SENSOR (OBD)

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0217

WEC778

EC-296

DTC P0335 CKP SENSOR (OBD)

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0218

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

SEF325V

FE 䊳

GO TO 2.

CL 2

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.

MT AT TF PD SEF335V

2. Check continuity between ECM terminal 47 and terminal 2.

AX SU BR ST

SEF175V

Continuity should exist. 3. Also check harness for short to ground and short to power.

RS BT

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

HA SC EL

EC-297

IDX

DTC P0335 CKP SENSOR (OBD)

KA24DE

Diagnostic Procedure (Cont’d)

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E202, E32 쐌 Harness connectors E41, F25 쐌 Harness for open or short between crankshaft position sensor (OBD) and ECM 䊳

4

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Reconnect ECM harness connector. 2. Check harness continuity between crankshaft position sensor (OBD) terminal 1 and engine ground. Refer to the wiring diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E202, E32 쐌 Harness connectors E41, F25 쐌 Harness for open or short between crankshaft position sensor (OBD) and ECM 䊳

6

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK SHIELD CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect harness connector E202, E32. 3. Check harness continuity between harness connector E32 terminal 2 and ground.

SEF177V

Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect harness connectors. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

EC-298

DTC P0335 CKP SENSOR (OBD)

KA24DE Diagnostic Procedure (Cont’d)

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E41, F25 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) 쐌 Harness for open or short between harness connector E32 and engine ground 䊳

GI MA

Repair open circuit or short to power in harness or connectors.

EM 8

CHECK 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.

LC

FE CL MT SEF960N

5. Check resistance as shown in the figure.

AT TF PD AX SU

SEF231W

Resistance: Approximately 512 - 632Ω [at 20°C (68°F)] OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace crankshaft position sensor (OBD).

9

CHECK INTERMITTENT INCIDENT

BR ST RS

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

BT HA SC EL

EC-299

IDX

DTC P0340 CMP SENSOR

KA24DE

Component Description

Component Description

SEF928V

NGEC0220

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

ECM Terminals and Reference Value

NGEC0221

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

LG/R

ITEM

ECM relay (Self shutoff)

CONDITION

DATA (DC Voltage)

[Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

0 - 1V

[Ignition switch OFF] 쐌 More than a few seconds after turning ignition switch OFF

BATTERY VOLTAGE (11 - 14V) 0.2 - 0.5V

[Engine is running] (Warm-up condition) 쐌 Idle speed

44 48

PU PU

Camshaft position sensor (Reference signal)

0 - 0.5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

EC-300

DTC P0340 CMP SENSOR

KA24DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

GI

Approximately 2.6V

MA [Engine is running] 쐌 Warm-up condition 쐌 Idle speed

49

EM LC

Camshaft position sensor (Position signal)

LG

Approximately 2.5 - 2.6V

[Engine is running] 쐌 Engine speed is 2,000 rpm

FE CL

67

B/P

72

B/P

117

B/P

Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

MT

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

AT

On Board Diagnosis Logic DTC No. P0340

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.

NGEC0222

TF

Check Items (Possible Cause) 쐌 Harness or connectors (The camshaft position sensor circuit is open or shorted.) 쐌 Camshaft position sensor 쐌 Starter motor (Refer to SC-10.) 쐌 Starting system circuit (Refer to SC-13.) 쐌 Dead (Weak) battery

PD AX SU BR ST RS BT HA SC EL

EC-301

IDX

DTC P0340 CMP SENSOR

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC0223

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 5 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

NGEC0223S01

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”, EC-304. With GST Follow the procedure “With CONSULT-II”. SEF058Y

PROCEDURE FOR MALFUNCTION B AND C

NGEC0223S02

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”, EC-304. With GST Follow the procedure “With CONSULT-II”. SEF058Y

EC-302

DTC P0340 CMP SENSOR

KA24DE Wiring Diagram

Wiring Diagram

NGEC0224

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC973

EC-303

EL IDX

DTC P0340 CMP SENSOR

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0225

CHECK STARTING SYSTEM

Does the engine turn over? (Does the starter motor operate?) Yes or No Yes

䊳

GO TO 2.

No

䊳

Check starting system. (Refer to SC-10.)

2

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

SEF325V

䊳

GO TO 3.

EC-304

DTC P0340 CMP SENSOR

KA24DE Diagnostic Procedure (Cont’d)

3

CHECK POWER SUPPLY

1. Disconnect camshaft position sensor harness connector.

GI MA EM LC SEF128S

2. Turn ignition switch ON. 3. Check voltage between terminal 5 and ground with CONSULT-II or tester.

FE CL MT AT SEF040S

Voltage: Battery voltage

TF

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

PD AX

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between camshaft position sensor and ECM relay 쐌 Harness for open or short between camshaft position sensor and ECM 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

SU BR ST RS BT HA SC EL

EC-305

IDX

DTC P0340 CMP SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

5

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between sensor terminal 4 and ECM terminal 49, sensor terminal 3 and ECM terminals 44, 48.

SEF178V

Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 6.

NG

䊳

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 distributor (camshaft position sensor) terminal 6 and engine ground. Refer to the wiring diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to power in harness or connectors.

EC-306

DTC P0340 CMP SENSOR

KA24DE Diagnostic Procedure (Cont’d)

7

CHECK CAMSHAFT POSITION SENSOR

1. Reconnect all harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 49 and engine ground, ECM terminals 44, 48 and engine ground.

GI MA EM LC

FE CL MT AT TF PD SEC751C

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace camshaft position sensor.

8

CHECK SHIELD CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect joint connector-2. 3. Check the following. 쐌 Continuity between joint connector-2 terminal 1 and ground 쐌 Joint connector-2 (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-2.

AX SU BR ST RS BT

OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair open circuit, short to power in harness or connectors.

9

HA SC

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

EL

INSPECTION END

EC-307

IDX

DTC P0400 EGR FUNCTION

KA24DE

Description

Description

NGEC0227

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft position sensor

Engine speed

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Intake air temperature sensor

Intake air temperature

Ignition switch

Start signal

Throttle position sensor

Throttle position

Vehicle speed sensor

Vehicle speed

ECM function

NGEC0227S01

Actuator

EGR control EGRC-solenoid valve

This system cuts and controls vacuum applied to the EGR valve to suit engine operating conditions. This cut-and-control operation is accomplished through the ECM and the EGRC-solenoid valve. When the ECM detects any of the following conditions, current flows through the solenoid valve is cut. This causes the vacuum to be discharged into the atmosphere. The EGR valve remains closed. 쐌 Low engine coolant temperature 쐌 Engine starting 쐌 High-speed engine operation 쐌 Engine idling 쐌 Excessively high engine coolant temperature 쐌 Mass air flow sensor malfunction 쐌 Low intake air temperature

SEF641Q

COMPONENT DESCRIPTION Exhaust Gas Recirculation (EGR) Valve

NGEC0227S02 NGEC0227S0201

The EGR valve controls the amount of exhaust gas routed to the intake manifold. Vacuum is applied to the EGR valve in response to throttle valve opening. The vacuum controls the movement of a taper valve connected to the vacuum diaphragm in the EGR valve.

SEF783K

EC-308

DTC P0400 EGR FUNCTION

KA24DE Description (Cont’d)

EGRC-Solenoid Valve

NGEC0227S0202

The EGRC-solenoid valve responds to signals from the ECM. When the ECM sends an OFF signal, the vacuum signal passes through the solenoid valve. The signal then reaches the EGR valve. When the ECM sends an ON signal, a plunger will then move to cut the vacuum signal from the intake manifold collector to the EGR valve.

GI MA EM LC

SEF240PD

On Board Diagnosis Logic

NGEC0228

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.

FE CL MT

SEF073P

DTC No. P0400

Malfunction is detected when ... 쐌 No EGR flow is detected under conditions that call for EGR.

Check Items (Possible Cause) 쐌 쐌 쐌 쐌 쐌 쐌 쐌

EGR valve stuck closed EGRC-BPT valve Vacuum hose EGRC-solenoid valve EGR passage EGR temperature sensor Exhaust gas leaks

AT TF PD AX SU BR ST RS BT HA SC EL

EC-309

IDX

DTC P0400 EGR FUNCTION

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF191Y

SEF192Y

SEF235Y

NGEC0229

CAUTION: Always drive vehicle at a safe speed. NOTE: 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. 쐌 P0400 will not be displayed at “SELF-DIAG RESULTS” mode with CONSULT-II even though DTC work support test result is “NG”. TESTING CONDITION: For best results, perform the test at a temperature above 5°C (41°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 9. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Check the output voltage of “THRTL POS SEN” (at closed throttle position) and note it. 8) 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 30 seconds or more.) ENG SPEED

2,000 - 2,800 rpm

Vehicle speed

10 km/h (6 MPH) or more

B/FUEL SCHDL

7 - 10 msec

THRTL POS SEN

(X + 0.23) − (X + 0.74) V X = Voltage value measured at step 7

Selector lever

Suitable position

9)

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-313.

EC-310

DTC P0400 EGR FUNCTION

KA24DE Overall Function Check

Overall Function Check

SEF182V

SEF336V

NGEC0230

Use this procedure to check the overall EGR function. 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 EGR valve lifting when revving engine from 2,000 rpm to 4,000 rpm quickly under no load using the following methods. 쐌 Disconnect EGRC-solenoid valve harness connector. (The DTC for EGRC-solenoid valve will be displayed, however, ignore it.) EGR valve should lift up and down without sticking. If NG, go to “Diagnostic Procedure”, EC-313. 3) Check voltage between ECM terminal 63 (EGR temperature sensor signal) and ground at idle speed. Less than 4.5V should exist. If NG, go to next step. 4) Turn ignition switch OFF. 5) Check harness continuity between EGR temperature sensor harness connector terminal 2 and ECM terminal 43 (ECM ground). Continuity should exist. 6) Check “EGR TEMPERATURE SENSOR”. Refer to “CHECK EGR TEMPERATURE SENSOR” in “Diagnostic Procedure”.

GI MA EM LC

FE CL MT AT TF PD AX

SEF183V

SU BR ST RS SEF642Q

BT HA SC EL

EC-311

IDX

DTC P0400 EGR FUNCTION

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0231

LEC114A

EC-312

DTC P0400 EGR FUNCTION

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0232

CHECK EXHAUST SYSTEM

GI

1. Start engine. 2. Check exhaust pipes and muffler for leaks.

MA EM LC

SEF099P

FE

OK or NG OK (With CONSULT-II)

䊳

GO TO 2.

OK (Without CONSULTII)

䊳

GO TO 3.

NG

䊳

Repair or replace exhaust system.

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-313

IDX

DTC P0400 EGR FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

2

CHECK VACUUM SOURCE TO EGR VALVE

With CONSULT-II 1. Warm engine up to normal operating temperature. 2. Disconnect vacuum hose to EGR valve. 3. Check for vacuum existence at idle.

SEF337V

Vacuum should not exist at idle. 4. Select “EGRC SOLENOID VALVE” in “ACTIVE TEST” mode with CONSULT-II and turn the solenoid valve OFF. 5. Check for vacuum existence when revving engine from 2,000 rpm up to 4,000 rpm.

SEF716Z

Vacuum should exist when revving engine. OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 5.

EC-314

DTC P0400 EGR FUNCTION

KA24DE Diagnostic Procedure (Cont’d)

3

CHECK VACUUM SOURCE TO EGR VALVE

Without CONSULT-II 1. Warm engine up to normal operating temperature. 2. Disconnect vacuum hose to EGR valve. 3. Check for vacuum existence at idle.

GI MA EM LC

SEF337V

Vacuum should not exist at idle. 4. Disconnect EGRC-solenoid valve harness connector. (The 1st trip DTC for EGRC-solenoid valve will be displayed, but ignore it.) 5. Check for vacuum existence when revving engine from 2,000 rpm up to 4,000 rpm. Vacuum should exist when revving engine. 䊳

GO TO 4.

NG

䊳

GO TO 5.

4

CL MT

OK or NG OK

FE

AT

CHECK EGR VALVE

TF

쐌 Apply vacuum to EGR vacuum port with a hand vacuum pump.

PD AX SU BR MEF137D

EGR valve spring should lift. 쐌 Check for sticking.

ST OK or NG

OK

䊳

GO TO 11.

NG

䊳

Repair or replace EGR valve.

RS BT HA SC EL

EC-315

IDX

DTC P0400 EGR FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

5

CHECK VACUUM HOSE

1. Turn ignition switch OFF. 2. Check vacuum hose for clogging, cracks or improper connection.

SEF109L

OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

Repair or replace vacuum hose.

6

CHECK EGRC-SOLENOID VALVE OPERATION

With CONSULT-II 1. Turn ignition switch ON. 2. Turn EGRC-solenoid valve “ON” and “OFF” in “ACTIVE TEST” mode with CONSULT-II and check operating sound.

SEF716Z

Clicking noise should be heard. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

7

CHECK EGRC-SOLENOID VALVE OPERATION

Without CONSULT-II Check operating sound of the solenoid valve when disconnecting and reconnecting EGRC-solenoid valve harness connector. (The DTC or the 1st trip DTC for the EGRC-solenoid valve will be displayed, however, ignore it.) Clicking noise should be heard. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

EC-316

DTC P0400 EGR FUNCTION

KA24DE Diagnostic Procedure (Cont’d)

8

CHECK EGRC-SOLENOID VALVE CIRCUIT

1. Turn ignition switch “OFF”. 2. Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M59, F27 쐌 10A fuse 쐌 Harness for open or short between fuse block and EGRC-solenoid valve 쐌 Harness for open or short between ECM and EGRC-solenoid valve

GI MA EM

OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

9

LC

CHECK EGRC-SOLENOID VALVE

With CONSULT-II Check air passage continuity. Perform “EGRC SOLENOID VALVE” in “ACTIVE TEST” mode.

FE CL MT AT TF SEC752C

Without CONSULT-II Check air passage continuity shown in the figure.

PD AX SU BR ST AEC919

RS BT MTBL0664

HA

OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EGRC-solenoid valve.

SC EL

EC-317

IDX

DTC P0400 EGR FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

10

CHECK EGRC-BPT VALVE

1. Plug one of two ports of EGRC-BPT valve. 2. Vacuum from the other port and check for leakage while applying a pressure above 0.981 kPa (100 mmH2O, 3.94 inH2O) from under EGRC-BPT valve.

SEF083P

3. If a leakage is noted, replace the valve. OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EGRC-BPT valve.

EC-318

DTC P0400 EGR FUNCTION

KA24DE Diagnostic Procedure (Cont’d)

11

CHECK EGR TEMPERATURE SENSOR

Check resistance change and resistance value.

GI MA EM LC SEF643Q



FE CL MTBL0549

MT AT TF PD AX SU BR ST SEF068XB

OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace EGR temperature sensor.

12

RS BT HA

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

SC

INSPECTION END

EL

EC-319

IDX

DTC P0402 EGRC-BPT VALVE FUNCTION

KA24DE

Description

Description

NGEC0234

SEF453PD

SYSTEM DESCRIPTION

NGEC0234S01

The EGRC-BPT valve monitors exhaust pressure to activate the diaphragm, controlling throttle body vacuum applied to the EGR valve. In other words, recirculated exhaust gas is controlled in response to positioning of the EGR valve or to engine operation.

On Board Diagnosis Logic

NGEC0235

If too much EGR flow exists due to an EGRC-BPT valve malfunction, off idle engine roughness will increase. If the roughness is large, then the vacuum to the EGR valve is interrupted through the EGRC-solenoid valve. If the engine roughness is reduced at that time, the EGRC-BPT valve malfunction is indicated. DTC No. P0402

Malfunction is detected when ... 쐌 The EGRC-BPT valve does not operate properly.

EC-320

Check Items (Possible Cause) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

EGRC-BPT valve EGR valve Loose or disconnected rubber tube Blocked rubber tube Camshaft position sensor Blocked exhaust system Orifice Mass air flow sensor EGRC-solenoid valve

DTC P0402 EGRC-BPT VALVE FUNCTION

KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

SEF930VA

SEF718Z

SEF719Z

SEC753C

NGEC0236

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above 5°C (41°F). 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Install vacuum gauge between EGRC-BPT valve and EGR valve as shown in the illustration. 2) Start engine and warm it up to normal operating temperature. 3) Stop engine and wait at least 5 seconds. 4) Turn ignition switch ON and select “EGRC-BPT VLV P0402” of “EGR SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. 5) Start engine and let it idle. 6) Touch “START”. 7) Check the output voltage of “THRTL POS SEN” (at closed throttle position) and note it. 8) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen and the bar chart may increase. Maintain the conditions many times until “COMPLETED” appears. Selector lever

Suitable position

ENG SPEED

1,400 - 2.000 rpm

Vehicle speed

30 - 100 km/h (19 - 62 MPH)

B/FUEL SCHDL

5 - 7.5 msec

THRTL POS SEN

X – (X + 0.88) V X = Voltage value measured at step 7

NOTE: 쐌 The bar chart on CONSULT-II screen indicates the status of this test. However, the test may be finished before the bar chart becomes full scale. 쐌 If the bar chart indication does not continue to progress, completely release accelerator pedal once and try to meet the conditions again. 쐌 If “TESTING” does not appear on CONSULT-II screen, retry from step 2. 9) If CONSULT-II instructs to carry out “Overall Function Check”, go to next step. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-323. 10) Open engine hood. 11) Raise engine speed to 2,400 to 3,200 rpm under no-load and hold it. Then touch “NEXT” on CONSULT-II screen.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

SEF384X

EC-321

IDX

DTC P0402 EGRC-BPT VALVE FUNCTION

KA24DE

DTC Confirmation Procedure (Cont’d)

PEF963V

12) Check vacuum gauge while keeping engine speed at 2,400 to 3,200 rpm. Vacuum should be 0 to −20 kPa (0 to −150 mmHg, 0 to −5.91 inHg). If NG, go to “Diagnostic Procedure”, EC-323. If OK, touch “YES” on the CONSULT-II screen. 13) Check the EGR valve lifting when revving from 2,000 rpm to 4,000 rpm quickly under no load. EGR valve should lift up, and go down without sticking when the engine is returned to idle. If NG, check EGR valve. If OK, touch “YES” or the CONSULT-II screen. 14) Check the rubber tube between intake manifold collector, EGRC-solenoid valve, EGR valve and EGRC-BPT valve for cracks, blockages or twisting. If NG, repair or replace. If OK, touch “YES” on the CONSULT-II screen.

Overall Function Check

SEF930V

NGEC0237

Use this procedure to check the overall function of the EGRC-BPT valve. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Install vacuum gauge between EGRC-BPT valve and EGR valve as shown in the illustration. 2) Lift up vehicle. 3) Start engine and shift to 1st gear position. 4) Check vacuum gauge while keeping engine speed at 2,400 to 3,200 rpm. Vacuum should be 0 to −20 kPa (0 to −150 mmHg, 0 to −5.91 inHg). If NG, go to “Diagnostic Procedure”, EC-323. If OK, go to next step. 5) Check the EGR valve lifting when revving from 2,000 rpm to 4,000 rpm quickly under no load. EGR valve should lift up, and go down without sticking when the engine is returned to idle. 6) Check rubber tube between intake manifold collector, EGRCsolenoid valve, EGR valve and EGRC-BPT valve for misconnection, cracks or blockages. 7) If NG, go to “Diagnostic Procedure”, EC-323.

EC-322

DTC P0402 EGRC-BPT VALVE FUNCTION

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

=NGEC0238

CHECK HOSE

GI

Check vacuum hose for clogging and improper connection. OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair or replace vacuum hose.

2

MA EM

CHECK EXHAUST SYSTEM

LC

Check exhaust system for collapse. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace exhaust system.

3

FE

CHECK ORIFICE

CL

Check if orifice is installed in vacuum hose between EGRC-BPT valve and EGRC-solenoid valve. OK or NG

MT

OK

䊳

GO TO 4.

NG

䊳

Replace vacuum hose.

AT 4

CHECK EGRC-BPT VALVE

1. Plug one of two ports of EGRC-BPT valve. 2. Vacuum from the other port and check leakage without applying any pressure from under EGR-BPT valve. Leakage should exist.

TF PD AX SU BR SEF172P

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace EGRC-BPT valve.

ST RS BT HA SC EL

EC-323

IDX

DTC P0402 EGRC-BPT VALVE FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

5

CHECK CAMSHAFT POSITION SENSOR

1. Start engine and warm it up to normal operating temperature. 2. Check voltage between ECM terminals 49 and engine ground ECM terminals 44, 48 and engine ground.

SEC751C

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace camshaft position sensor.

EC-324

DTC P0402 EGRC-BPT VALVE FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

6

CHECK MASS AIR FLOW SENSOR

1. Turn ignition switch ON. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 54 (Mass air flow sensor signal) and ground.

GI MA EM LC

SEF326V

FE CL MT MTBL0326

4. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Repeat above check. 5. If NG, remove mass air flow sensor from air duct. Check hot wire for damage or dust.

AT TF PD AX SU

SEF893J

BR

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace mass air flow sensor.

ST RS BT HA SC EL

EC-325

IDX

DTC P0402 EGRC-BPT VALVE FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

7

CHECK EGRC-SOLENOID VALVE

With CONSULT-II Check air passage continuity. Perform “EGRC SOLENOID VALVE” in “ACTIVE TEST” mode.

SEC752C

Without CONSULT-II Check air passage continuity shown in the figure.

AEC919

MTBL0664

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace EGRC-solenoid valve.

EC-326

DTC P0402 EGRC-BPT VALVE FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

8

CHECK EGR VALVE

쐌 Apply vacuum to EGR vacuum port with a hand vacuum pump.

GI MA EM LC MEF137D

EGR valve spring should lift. 쐌 Check for sticking. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace EGR valve.

9

FE CL

CHECK INTERMITTENT INCIDENT

MT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

AT TF PD AX SU BR ST RS BT HA SC EL

EC-327

IDX

DTC P0405, P0406 EGRT SENSOR

KA24DE

Component Description

Component Description

NGEC0342

The EGR temperature sensor detects temperature changes in the EGR passageway. When the EGR 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 63 (EGR temperature sensor) and ground. When EGR system is operating. Voltage: 0 - 1.5V

SEF068XB

On Board Diagnosis Logic DTC No.

Malfunction is detected when ...

NGEC0343

Check Items (Possible Cause)

P0405

A)

An excessively low voltage from the EGR tempera- 쐌 Harness or connectors ture sensor is sent to ECM even when engine cool(The EGR temperature sensor circuit is shorted.) ant temperature is low. 쐌 EGR temperature sensor 쐌 Malfunction of EGR function, EGRC-BPT valve or EGRC-solenoid valve

P0406

B)

An excessively high voltage from the EGR temperature sensor is sent to ECM even when engine coolant temperature is high.

EC-328

쐌 Harness or connectors (The EGR temperature sensor circuit is open.) 쐌 EGR temperature sensor 쐌 Malfunction of EGR function, EGRC-BPT valve or EGRC-solenoid valve

DTC P0405, P0406 EGRT SENSOR

KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC0344

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 5 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A SEF174Y

1) 2) 3)

4) 5)

쐌

SEF201Y

NGEC0344S02

CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: Always perform the test at a temperature above 5°C (41°F). With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Run engine at idle for at least 2 minutes. 3) Confirm that EGR valve is not lifting. If the result is NG, perform trouble diagnosis for DTC P1402. Refer to EC-503. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Read “EGR TEMP SEN” at about 1,500 rpm while holding the EGR valve in full open position by hand. Voltage should decrease to less than 1.0V. If the result is NG, go to “Diagnostic Procedure”, EC-332. If the result is OK, go to following step. 6) Turn ignition switch OFF and wait at least 5 seconds. 7) Turn ignition switch ON. 8) Check the output voltage of “THRTL POS SEN” (at closed throttle position) and note it. 9) Start engine. 10) Maintain the following conditions for at least 5 consecutive seconds. ENG SPEED

2,000 - 2,800 rpm

VHCL SPEED SE

10 km/h (6 MPH) or more

B/FUEL SCHDL

7 - 10.5 msec

THRTL POS SEN

(X + 0.23) − (X + 0.74) V X = Voltage value measured at step 7

Selector lever

Suitable position

EC-329

MA EM

NGEC0344S01

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. 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. Start engine and let it idle for at least 8 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-332. With GST Follow the procedure “With CONSULT-II”.

PROCEDURE FOR MALFUNCTION B

GI

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P0405, P0406 EGRT SENSOR

KA24DE

DTC Confirmation Procedure (Cont’d)

11) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-332.

Overall Function Check

NGEC0345

Use this procedure to check the overall function of the EGR temperature sensor. During this check, a 1st trip DTC might not be confirmed.

PROCEDURE FOR MALFUNCTION B 1) 2) 3) SEF360Q

4)

5)

NGEC0345S01

Without CONSULT-II Start engine and warm it up to normal operating temperature. Run engine at idle for at least 2 minutes. Confirm that EGR valve is not lifting. If NG, perform trouble diagnosis for DTC P1402. Refer to EC-504. Check voltage between ECM terminal 63 (EGR temperature sensor signal) and ground at about 1,500 rpm with EGR valve lifted up to the full position by hand. Voltage should decrease to less than 1.0V. If NG, go to “Diagnostic Procedure”, EC-332. If OK, perform trouble diagnoses for DTC P0400 and P1400. Refer to EC-308, 496.

SEF362Q

EC-330

DTC P0405, P0406 EGRT SENSOR

KA24DE Wiring Diagram

Wiring Diagram

NGEC0346

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC AEC006B

EC-331

EL IDX

DTC P0405, P0406 EGRT SENSOR

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0347

CHECK POWER SUPPLY

1. Turn ignition switch OFF. 2. Disconnect EGR temperature sensor harness connector.

SEF345V

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

SEF263W

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair harness or connectors.

2

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Check harness continuity between EGR temperature sensor terminal 2 and engine ground. Refer to the wiring diagram.

SEF264W

Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the harness for open or short between EGR temperature sensor and ECM. 䊳

Repair open circuit or short to ground or short to power in harness or connector.

EC-332

DTC P0405, P0406 EGRT SENSOR

KA24DE Diagnostic Procedure (Cont’d)

4

CHECK EGR TEMPERATURE SENSOR

Check resistance change and resistance value.

GI MA EM LC SEF643Q



FE CL MTBL0549

MT AT TF PD AX SU BR ST SEF068XB

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace EGR temperature sensor.

5

RS BT HA

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

SC

INSPECTION END

EL

EC-333

IDX

DTC P0420 THREE WAY CATALYST FUNCTION

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1042

The ECM monitors the switching frequency ratio of heated oxygen sensor 1 and 2. A three way catalyst with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2. As oxygen storage capacity decreases, the heated oxygen sensor 2 switching frequency will increase. When the frequency ratio of heated oxygen sensors 1 and 2 approaches a specified limit value, the three way catalyst malfunction is diagnosed. SEF484YC

DTC No. P0420

Malfunction is detected when ... 쐌 Three way catalyst does not operate properly. 쐌 Three way catalyst does not have enough oxygen storage capacity.

Check Items (Possible Cause) 쐌 쐌 쐌 쐌 쐌 쐌 쐌

Three way catalyst Exhaust tube Intake air leaks Injectors Injector leaks Spark plug Improper ignition timing

DTC Confirmation Procedure

SEC754C

SEC755C

NGEC1043

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. TESTING CONDITION: 쐌 Open engine hood before conducting following procedure. 쐌 Do not hold engine speed more than specified minutes below. With CONSULT-II 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 2,500 to 3,500 rpm and hold it for 3 consecutive minutes then release then accelerator pedal completely. If “INCMP” of “CATALYST” changes to “CMPLT”, go to step 7. 5) Wait 5 seconds at idle. 6) Rev engine up to 2,000 to 3,000 rpm and hold it until “INCMP” of “CATALYST” changes to “CMPLT”. (It will take maximum of approximately 5 minute.) 7) Select “SELF-DIAG RESULTS” mode with CONSULT-II. If the 1st trip DTC is detected, go to “DIAGNOSTIC PROCEDURE”, EC-283. If not “COMPLT” stop engine and cool down “COOLANT TEMP/SE” to less than 70°C (158°F) and then retest from step 1).

SEF560X

EC-334

DTC P0420 THREE WAY CATALYST FUNCTION

KA24DE Overall Function Check

Overall Function Check

AEC876A

NGEC0242

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 50 (Heated oxygen sensor 1 signal), 56 (Heated oxygen sensor 2 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 56 and engine ground is much less than that of ECM terminal 50 and engine ground. Switching frequency ratio = A/B A: Heated oxygen sensor 2 voltage switching frequency B: Heated oxygen sensor 1 voltage switching frequency This ratio should be less than 0.75. If the ratio is greater than above, it means three way catalyst does not operate properly. NOTE: If the voltage at terminal 50 does not switch periodically more than 5 times within 10 seconds at step 4, perform trouble diagnosis for DTC P0133 first. (See EC-219.)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-335

IDX

DTC P0420 THREE WAY CATALYST FUNCTION

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

=NGEC0243

CHECK EXHAUST SYSTEM

Visually check exhaust tubes and muffler for dent. OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair or replace.

2

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

䊳

GO TO 3.

NG

䊳

Repair or replace.

3

CHECK INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace.

4

CHECK IGNITION TIMING

1. Check the following items. Refer to “Basic Inspection”, EC-112.

MTBL0328

OK or NG OK

䊳

GO TO 5.

NG

䊳

Adjust ignition timing.

EC-336

DTC P0420 THREE WAY CATALYST FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

5

CHECK INJECTORS

1. Refer to Wiring Diagram for Injectors, EC-572. 2. Stop engine and then turn ignition switch ON. 3. Check voltage between ECM terminals 102, 104, 109, 111 and ground with CONSULT-II or tester.

GI MA EM LC

SEC756C

FE

Battery voltage should exist. OK or NG OK

䊳

GO TO 6.

NG

䊳

Perform “Diagnostic Procedure” INJECTOR, EC-573.

CL MT

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.

AT TF PD AX SU SEF282G

BR

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

ST RS BT HA SC EL

EC-337

IDX

DTC P0420 THREE WAY CATALYST FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

7

CHECK IGNITION WIRES

1. Inspect wires for cracks, damage, burned terminals and for improper fit. 2. Measure the resistance of wires to their distributor cap terminal. Move each wire while testing to check for intermittent breaks.

SEF174P

Resistance: 13.6 - 18.4 kΩ/m (4.15 - 5.61 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. OK or NG OK

䊳

Check ignition coil, power transistor and their circuits. Refer to EC-562.

NG

䊳

Replace.

8

CHECK INJECTOR

1. Turn ignition switch OFF. 2. Remove injector assembly. Refer to EC-58. 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.)

䊳

GO TO 9.

NG (Drips.)

䊳

Replace the injector(s) from which fuel is dripping.

9

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. Trouble is fixed.

䊳

INSPECTION END

Trouble is not fixed.

䊳

Replace three way catalyst.

EC-338

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE System Description

System Description

NGEC0373

NOTE: If DTC P0441 is displayed with DTC P0510, perform trouble diagnosis for “DTC P0510” first. (See EC-440.)

GI MA EM LC

FE CL MT SEF865Z

In this evaporative emission (EVAP) control system, purge flow occurs during non-closed throttle conditions. Purge volume is related to air intake volume. Under normal purge conditions (non-closed throttle), the EVAP canister purge volume control solenoid valve is open. Purge flow exposes the EVAP control system pressure sensor to intake manifold vacuum.

On Board Diagnosis Logic

NGEC0374

Under normal conditions (non-closed throttle), sensor output voltage indicates if pressure drop and purge flow are adequate. If not, a fault is determined. DTC No. P0441

Malfunction is detected when ...

Check Items (Possible Cause)

쐌 EVAP control system does not operate properly. 쐌 EVAP canister purge volume control solenoid 쐌 EVAP control system has a leak between intake manifold valve stuck closed and EVAP control system pressure sensor. 쐌 EVAP control system pressure sensor and the circuit 쐌 Loose, disconnected or improper connection of rubber tube 쐌 Blocked rubber tube 쐌 Cracked EVAP canister 쐌 Closed throttle position switch 쐌 Blocked purge port 쐌 EVAP canister vent control valve

AT TF PD AX SU BR ST RS BT HA SC EL

EC-339

IDX

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEC757C

SEC758C

SEC759C

Selector lever

Suitable position

Vehicle speed

32 - 120 km/h (20 - 75 MPH)

ENG SPEED

500 - 3,750 rpm

Engine coolant temperature

More than 70°C (158°F)

7)

If “TESTING” is not changed for a long time, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”.

Overall Function Check

SEC820C

NGEC0375

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 For best results perform test at a temperature of 5°C (41°F) or more. 쐌 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) Turn ignition switch OFF and wait at least 5 seconds. 3) Start engine and let it idle for at least 60 seconds. 4) Select “PURG FLOW P0441” of “EVAP SYSTEM” in “DTC CONFIRMATION” mode with CONSULT-II. 5) Touch “START”. If “COMPLETED” is displayed, go to step 7. 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 at least 30 seconds.)

NGEC0376

Use this procedure to check the overall monitoring function of the EVAP control system purge flow monitoring. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Lift up drive wheels. 2) Start engine and warm it up to normal operating temperature. 3) Turn ignition switch OFF, wait at least 5 seconds. 4) Start engine and wait at least 60 seconds. 5) Set voltmeter probes to ECM terminals 62 (EVAP control system pressure sensor signal) and ground.

EC-340

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE

Overall Function Check (Cont’d)

6) 7)

Check EVAP control system pressure sensor value at idle speed and note it. Establish and maintain the following conditions for at least 1 minute. Air conditioner switch: ON Steering wheel: Fully turned Headlamp switch: ON Rear window defogger switch: ON Engine speed: Approx. 3,000 rpm Gear position: Any position other than “Neutral” or “Reverse” Verify that EVAP control system pressure sensor value stays 0.1V less than the value at idle speed (measured at step 6) for at least 1 second.

GI MA EM LC

FE CL MT

Diagnostic Procedure 1

CHECK EVAP CANISTER

1. Turn ignition switch OFF. 2. Check EVAP canister for cracks.

NGEC0377

AT TF

OK or NG

PD

OK (With CONSULT-II)

䊳

GO TO 2.

OK (Without CONSULTII)

䊳

GO TO 3.

NG

䊳

Replace EVAP canister.

AX SU BR ST RS BT HA SC EL

EC-341

IDX

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE

Diagnostic Procedure (Cont’d)

2

CHECK PURGE FLOW

With CONSULT-II 1. Disconnect vacuum hose connected to EVAP canister purge volume control solenoid valve at EVAP service port and install vacuum gauge.

SEF339V

2. Start engine and let it idle. 3. Select “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II.

SEF801Y

4. Rev engine up to 2,000 rpm. 5. Touch “Qd” and “Qu” on CONSULT-II screen to adjust “PURG VOL CONT/V” opening. 100.0%: Vacuum should exist. 0.0%: Vacuum should not exist. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 4.

EC-342

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE

Diagnostic Procedure (Cont’d)

3

CHECK PURGE FLOW

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Stop engine. 3. Disconnect vacuum hose connected to EVAP canister purge volume control solenoid valve at EVAP service port and install vacuum gauge.

GI MA EM LC

SEF339V

4. Start engine and let it idle for at least 60 seconds. 5. Check vacuum gauge indication when revving engine up to 2,000 rpm. Vacuum should exist. 6. Release the accelerator pedal fully and let idle. Vacuum should not exist. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 4.

4

FE CL MT AT TF

CHECK EVAP PURGE LINE

Check EVAP purge line for improper connection or disconnection. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43.

PD

OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair it.

AX SU BR ST RS BT HA SC EL

EC-343

IDX

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE

Diagnostic Procedure (Cont’d)

5

CHECK EVAP PURGE HOSE AND PURGE PORT

1. Disconnect purge hoses connected to EVAP service port A and EVAP canister purge volume control solenoid valve B.

SEF367U

2. Blow air into each hose and EVAP purge port C. 3. Check that air flows freely.

SEF368U

OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

Repair or clean hoses and/or purge port.

6

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

SEF801Y

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

EC-344

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE

Diagnostic Procedure (Cont’d)

7

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

GI MA EM LC SEF334X

FE

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

CL MT AT

SEF335X

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

8

TF PD AX

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

1. Turn ignition switch OFF. 2. Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair it.

SU BR ST RS BT HA SC EL

EC-345

IDX

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE

Diagnostic Procedure (Cont’d)

9

CHECK CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

SEF341V

2. Check connectors for water. Water should not exist. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

10

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR AND CIRCUIT

Refer to “DTC Confirmation Procedure” for DTC P0452, P0453, EC-382. OK or NG OK (With CONSULT-II)

䊳

GO TO 11.

OK (Without CONSULTII)

䊳

GO TO 12.

NG

䊳

Replace EVAP control system pressure sensor.

11

CHECK EVAP CANISTER VENT CONTROL VALVE-I

1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted.

SEF337X

OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace EVAP canister vent control valve.

EC-346

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE

Diagnostic Procedure (Cont’d)

12 1. 2. 3. 4.

CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II Reconnect harness connectors disconnected. Turn ignition switch “ON”. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time.

GI MA EM LC

SEF803Y

Without CONSULT-II Check air passage continuity and operation delay time under the following conditions.

FE CL MT AT TF

SEF339X

PD

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 14.

NG

䊳

GO TO 13.

13

AX SU

CHECK EVAP CANISTER VENT CONTROL VALVE-III

1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 12 again. OK or NG OK (With CONSULT-II)

䊳

GO TO 14.

OK (Without CONSULTII)

䊳

GO TO 15.

NG

䊳

Replace EVAP canister vent control valve.

BR ST RS BT HA SC EL

EC-347

IDX

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE

Diagnostic Procedure (Cont’d)

14 1. 2. 3. 4. 5. 6.

CHECK THROTTLE POSITION SWITCH With CONSULT-II Install all removed parts. Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF”. Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Check indication of “CLSD THL/P SW” under the following conditions. Measurement must be made with throttle position switch installed in vehicle.

MTBL0355

OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 16.

15

CHECK THROTTLE POSITION SWITCH

1. 2. 3. 4. 5.

Install all removed parts. Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF”. Disconnect closed throttle position switch harness connector. Check continuity between closed throttle position switch terminals 5 and 6 under the following conditions. Resistance measurement must be made with throttle position switch installed in vehicle.

SEC779C

OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 16.

EC-348

DTC P0441 EVAP CONTROL SYSTEM PURGE FLOW MONITORING

KA24DE

Diagnostic Procedure (Cont’d)

16

ADJUST THROTTLE POSITION SWITCH

Check the following items. Refer to “Basic Inspection”, EC-112 .

GI MA EM MTBL0328

LC

Is it possible to adjust closed throttle position switch? Yes or No Yes

䊳

GO TO 17.

No

䊳

Replace throttle position switch.

17

CHECK EVAP PURGE LINE

Inspect EVAP purge line (pipe and rubber tube). Check for evidence of leaks. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43. OK or NG OK

䊳

GO TO 18.

NG

䊳

Replace it.

18

FE CL MT AT

CLEAN EVAP PURGE LINE

TF

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

19

GO TO 19.

PD

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

AX SU BR ST RS BT HA SC EL

EC-349

IDX

DTC P0442 EVAP CONTROL SYSTEM

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0244

NOTE: If DTC P0442 is displayed with DTC P1448, perform trouble diagnosis for DTC P1448 first. (See EC-529.) This diagnosis detects leaks in the EVAP purge line using engine intake manifold vacuum. If pressure does not increase, the ECM will check for leaks in the line between the fuel tank and EVAP canister purge volume control solenoid valve under the following “Vacuum test” conditions. The vacuum cut valve bypass valve is opened to clear the line between the fuel tank and the EVAP canister purge volume control solenoid valve. The EVAP canister vent control valve will then be closed to shut the EVAP purge line off. The EVAP canister purge volume control solenoid valve is opened to depressurize the EVAP purge line using intake manifold vacuum. After this occurs, the EVAP canister purge volume control solenoid valve will be closed.

SEF865Z

DTC No. P0442

Malfunction is detected when ... 쐌 EVAP control system has a leak. 쐌 EVAP control system does not operate properly.

Check Items (Possible Cause) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

EC-350

Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Fuel filler cap remains open or fails to close. Foreign matter caught in fuel filler cap. Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. Foreign matter caught in EVAP canister vent control valve. EVAP canister or fuel tank leaks EVAP purge line (pipe and rubber tube) leaks EVAP purge line rubber tube bent. Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit EVAP canister purge volume control solenoid valve and the circuit Absolute pressure sensor Fuel tank temperature sensor O-ring of EVAP canister vent control valve is missing or damaged. Water separator EVAP canister is saturated with water. EVAP control system pressure sensor Fuel level sensor and the circuit Refueling control valve ORVR system leaks

DTC P0442 EVAP CONTROL SYSTEM

KA24DE

On Board Diagnosis Logic (Cont’d)

CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

GI MA EM LC

DTC Confirmation Procedure

SEC760C

SEC761C

NGEC0245

NOTE: 쐌 If DTC P0442 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. Refer to EC-529. 쐌 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 TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is between 1/4 to 3/4 full and vehicle is placed on flat level surface. 쐌 Always perform test at a temperature of 0 to 30°C (32 to 86°F). 쐌 It is better that the fuel level is low. 1) Turn ignition switch ON. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 4) Check that the following conditions are met. COOLAN TEMP/S

0 - 70°C (32 - 158°F)

INT/A TEMP SE

0 - 60°C (32 - 140°F)

FE CL MT AT TF PD AX SU

5)

SEC762C

SEC763C

Select “EVAP SML LEAK P0442/P1442” of “EVAP SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. NOTE: 쐌 If the engine cannot be maintained within the range on CONSULT-II screen, go to “Basic Inspection”, EC-112. 6) Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-353. NOTE: Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. With GST 1) Start engine. 2) Drive vehicle according to “Driving pattern”, EC-81. NOTE: Be sure to read the explanation of “Driving pattern” on EC-81 before driving vehicle. 3) Stop vehicle. 4) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is not set yet, go to the following step.

EC-351

BR ST RS BT HA SC EL IDX

DTC P0442 EVAP CONTROL SYSTEM

KA24DE

DTC Confirmation Procedure (Cont’d)

쐌 5) 6)

If SRT of EVAP system is set, the result will be OK. Turn ignition switch OFF and wait at least 5 seconds. Start engine. It is not necessary to cool engine down before driving. 7) Drive vehicle again according to the “Driving pattern”, EC-81. 8) Stop vehicle. 9) Select “MODE 3” with GST. 쐌 If P0441 is displayed on the screen, go to “Diagnostic Procedure”, EC-341. 쐌 If P0442 is displayed on the screen, go to “Diagnostic Procedure”, EC-353. 쐌 If P0441 and P0442 are not displayed on the screen, go to the following step. 10) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is set, the result will be OK. 쐌 If SRT of EVAP system is not set, go to step 5.

EC-352

DTC P0442 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

=NGEC0246

CHECK FUEL FILLER CAP DESIGN

GI

1. Turn ignition switch OFF. 2. Check for genuine NISSAN fuel filler cap design.

MA EM LC SEF915U

OK or NG

FE

OK

䊳

GO TO 2.

NG

䊳

Replace with genuine NISSAN fuel filler cap.

CL 2

CHECK FUEL FILLER CAP INSTALLATION

Check that the cap is tightened properly rotating the cap clockwise.

MT

OK or NG OK

䊳

GO TO 3.

NG

䊳

쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard.

3

AT TF

CHECK FUEL FILLER CAP FUNCTION

Check for air releasing sound while opening the fuel filler cap.

PD

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

AX SU BR ST RS BT HA SC EL

EC-353

IDX

DTC P0442 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)

1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum.

SEF427N

SEF943S

Pressure: 16.0 - 20.0 kPa (0.163 - 0.204 kg/cm2, 2.32 - 2.90 psi) Vacuum: −6.0 to −3.5 kPa (−0.061 to −0.036 kg/cm2, −0.87 to −0.51 psi) CAUTION: Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace fuel filler cap with a genuine one.

EC-354

DTC P0442 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure (Cont’d)

5

INSTALL PRESSURE PUMP

1. Install the EVAP service port adapter and the pressure pump securely to EVAP service port.

GI MA EM LC SEF339V

FE CL MT SEF462UE

AT

NOTE: 쐌 Improper installation of service port may cause leaking.

TF Models with CONSULT-II

䊳

GO TO 6.

Models without CONSULT-II

䊳

GO TO 7.

PD AX SU BR ST RS BT HA SC EL

EC-355

IDX

DTC P0442 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

6

CHECK FOR EVAP LEAK

With CONSULT-II 1. Turn ignition switch ON. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II.

PEF658U

3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system.

PEF917U

4. Using EVAP leak detector, locate the leak portion. For the leak detector, refer to instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43.

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

EC-356

DTC P0442 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure (Cont’d)

7

CHECK FOR EVAP LEAK

Without CONSULT-II 1. Turn ignition switch OFF. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.)

GI MA EM LC

SEF503V

3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12 volts until the end of test.) Shown in the above figure. 4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg). NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the leak. For the leak detector, refer to instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43.

FE CL MT AT TF PD AX

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

SU BR ST RS BT HA SC EL

EC-357

IDX

DTC P0442 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace water separator.

9

CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT

Refer to “DTC Confirmation Procedure”, EC-374. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair or replace EVAP canister vent control valve and O-ring or harness/connectors.

10

CHECK IF EVAP CANISTER IS SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

SEF596U

Yes or No Yes

䊳

GO TO 11.

No (With CONSULT-II)

䊳

GO TO 13.

No (Without CONSULTII)

䊳

GO TO 14.

EC-358

DTC P0442 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure (Cont’d)

11

CHECK EVAP CANISTER

Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb).

GI

OK or NG OK (With CONSULT-II)

䊳

GO TO 13.

OK (Without CONSULTII)

䊳

GO TO 14.

NG

䊳

GO TO 12.

MA EM LC

12

DETECT MALFUNCTIONING PART

Check the following. 1. Visually check the EVAP canister for damage. 2. Check hose connection between EVAP canister and water separator for clogging and poor connection. 䊳

13 1. 2. 3. 4. 5.

FE

Repair hose or replace EVAP canister.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

CL

With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100.0%. Check vacuum hose for vacuum.

MT AT TF PD AX SEF595Y

SU

OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 15.

BR ST

14 1. 2. 3. 4. 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 60 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist.

RS BT HA

OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 15.

SC EL

EC-359

IDX

DTC P0442 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

15

CHECK VACUUM HOSE

Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-33. OK or NG OK (With CONSULT-II)

䊳

GO TO 16.

OK (Without CONSULTII)

䊳

GO TO 17.

NG

䊳

Repair or reconnect the hose.

16

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

SEF801Y

OK or NG OK

䊳

GO TO 18.

NG

䊳

GO TO 17.

EC-360

DTC P0442 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure (Cont’d)

17

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

GI MA EM LC SEF334X

FE

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

CL MT AT

SEF335X

OK or NG OK

䊳

GO TO 18.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

TF PD AX SU BR ST RS BT HA SC EL

EC-361

IDX

DTC P0442 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

18

CHECK FUEL TANK TEMPERATURE SENSOR

Check resistance by heating with hot water or heat gun as shown in the figure.

AFE095

SEF710Z

MTBL0291

OK or NG OK

䊳

GO TO 19.

NG

䊳

Replace fuel tank temperature sensor.

EC-362

DTC P0442 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure (Cont’d)

19

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

1. Remove EVAP control system pressure sensor with its harness connector connected.

GI MA EM LC SEF341V

2. Remove hose from EVAP control system pressure sensor. 3. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. 4. Check output voltage between ECM terminal 62 and engine ground.

FE CL MT AT SEF198V

TF PD

MTBL0295

CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −20 kPa (−150 mmHg, −5.91 inHg) or over 20 kPa (150 mmHg, 5.91 inHg) of pressure.

AX SU BR ST RS

SEF799W

쐌 Never apply force to the air hole protector of the sensor, if equipped. 쐌 Discard any EVAP control system pressure sensor which has been dropped from height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

BT HA

OK or NG OK

䊳

GO TO 20.

NG

䊳

Replace EVAP control system pressure sensor.

SC EL

EC-363

IDX

DTC P0442 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

20

CHECK EVAP PURGE LINE

Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43. OK or NG OK

䊳

GO TO 21.

NG

䊳

Repair or reconnect the hose.

21

CLEAN EVAP PURGE LINE

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

22

GO TO 22.

CHECK REFUELING EVAP VAPOR LINE

Check refueling EVAP vapor line between EVAP canister and fuel tank for clogging, kink, looseness and improper connection. For location, refer to “ON BOARD REFUELING VAPOR RECOVERY (ORVR)”, EC-45. OK or NG OK

䊳

GO TO 23.

NG

䊳

Repair or replace hoses and tubes.

23

CHECK SIGNAL LINE AND RECIRCULATION LINE

Check signal line and recirculation line between filler neck tube and fuel tank for clogging, kink, cracks, looseness and improper connection. OK or NG OK

䊳

GO TO 24.

NG

䊳

Repair or replace hoses, tubes or filler neck tube.

EC-364

DTC P0442 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure (Cont’d)

24

CHECK REFUELING CONTROL VALVE

1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3–way connector. Check that there is no leakage.

GI MA EM LC

FE CL MT AT SEF707Z

OK or NG OK

䊳

GO TO 25.

NG

䊳

Replace refueling control valve with fuel tank.

25

TF PD AX

CHECK FUEL LEVEL SENSOR

1. Remove fuel level sensor assembly. Refer to FE-4. 2. Refer to “FUEL LEVEL SENSOR UNIT CHECK”, EL-89

SU

OK or NG OK

䊳

GO TO 26.

NG

䊳

Replace fuel level sensor.

26

BR ST

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

RS

INSPECTION END

BT HA SC EL

EC-365

IDX

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Description

Description

NGEC0248

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

Throttle position switch

Closed throttle position

Heated oxygen sensor 1

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Fuel tank temperature sensor

Fuel temperature in fuel tank

Vehicle speed sensor

Vehicle speed

NGEC0248S01

ECM function

Actuator

EVAP canEVAP canister purge volume ister purge control solenoid valve flow control

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

NGEC0248S02

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

NGEC0249

Specification data are reference values. MONITOR ITEM

PURG VOL C/V

CONDITION 쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch “OFF” Shift lever: “N” No-load

SPECIFICATION

Idle (Vehicle stopped)

0%

2,000 rpm

—

EC-366

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE ECM Terminals and Reference Value

ECM Terminals and Reference Value

NGEC0250

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.

4

LG/R

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch ECM relay (Self-shutOFF off) [Ignition switch OFF] 쐌 A few seconds passed after turning ignition switch OFF

GI MA EM LC

0 - 1V

BATTERY VOLTAGE (11 - 14V)

FE

BATTERY VOLTAGE (11 - 14V)

CL [Engine is running] 쐌 Idle speed

5

R/Y

MT AT

EVAP canister purge volume control solenoid valve

BATTERY VOLTAGE (11 - 14V)

TF

[Engine is running] 쐌 Engine speed is 2,000 rpm (More than 200 seconds after starting engine)

PD AX

67

B/P

72

B/P

Power supply for ECM

117

B/P

Current return

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

SU

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

BR

On Board Diagnosis Logic DTC No. P0444 P0445

Malfunction is detected when ... An excessively low (P0444) or high (P0445) voltage signal is sent to ECM through the valve.

NGEC0251

ST

Check Items (Possible Cause) 쐌 Harness or connectors (The valve circuit is open or shorted.) 쐌 EVAP canister purge volume control solenoid valve

RS BT HA SC EL

EC-367

IDX

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

SEF058Y

=NGEC0252

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. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle. 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 30 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-370. With GST Follow the procedure “With CONSULT-II”.

EC-368

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Wiring Diagram

Wiring Diagram

NGEC0253

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC974

EC-369

EL IDX

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0254

CHECK POWER SUPPLY

1. Turn ignition switch OFF. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector.

SEF339V

3. Turn ignition switch ON. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF192V

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM relay 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM 䊳

Repair harness or connectors.

EC-370

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE 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 5 and terminal 1.

GI MA EM LC

SEF193V

FE

Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK (With CONSULT-II)

䊳

GO TO 5.

OK (Without CONSULTII)

䊳

GO TO 6.

NG

䊳

GO TO 4.

CL MT AT

4

DETECT MALFUNCTIONING PART

TF

Check the harness for open or short between EVAP canister purge volume control solenoid valve and ECM. 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

PD 5

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

AX SU BR ST RS

SEF801Y

BT

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

HA SC EL

EC-371

IDX

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Diagnostic Procedure (Cont’d)

6

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

SEF334X

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

SEF335X

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

7

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-372

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Component Description

Component Description

SEF378Q

NGEC0256

The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid (the EVAP canister vent control valve) responds to signals from the ECM. When the ECM sends an ON signal, the coil in the solenoid valve is energized. A plunger will then move to seal the canister vent. The ability to seal the vent is necessary for the on board diagnosis of other evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis.

GI MA EM LC

FE CL MT

SEF143S

CONSULT-II Reference Value in Data Monitor Mode

AT

CONDITION

TF

NGEC0257

Specification data are reference values. MONITOR ITEM

SPECIFICATION

쐌 Ignition switch: ON

VENT CONT/V

OFF

ECM Terminals and Reference Value

PD NGEC0258

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. 108

WIRE COLOR R/G

ITEM EVAP canister vent control valve

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

[Ignition switch ON]

On Board Diagnosis Logic DTC No. P0447

Malfunction is detected when ...

AX SU BR ST

NGEC0259

Check Items (Possible Cause)

쐌 An excessively low voltage signal is sent to ECM through 쐌 Harness or connectors EVAP canister vent control valve. (EVAP canister vent control valve circuit is open.) 쐌 EVAP canister vent control valve

RS BT HA SC EL

EC-373

IDX

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF058Y

NGEC0260

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. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle. With CONSULT-II 1) Turn ignition switch ON. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and wait at least 5 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-376. With GST Follow the procedure “With CONSULT-II”.

EC-374

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

KA24DE Wiring Diagram

Wiring Diagram

NGEC0261

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC AEC997A

EC-375

EL IDX

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0262

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

CHECK EVAP CANISTER VENT CONTROL VALVE CIRCUIT

1. Turn ignition switch ON. 2. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

SEF802Y

3. Make sure that ratcheting sound is heard from the vent control valve. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 3.

EC-376

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure (Cont’d)

3

CHECK POWER SUPPLY

1. Turn ignition switch OFF. 2. Disconnect EVAP canister vent control valve harness connector.

GI MA EM LC

SEF143S

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

FE CL MT AT SEF240W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

PD AX

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M67, B101 쐌 Harness connectors B113, C3 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between EVAP canister vent control valve and 10A fuse 䊳

TF

Repair harness or connectors.

SU BR ST RS BT HA SC EL

EC-377

IDX

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure (Cont’d)

5

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 108 and terminal 2.

SEF241W

Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 6.

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors B101, M67 쐌 Harness connectors M81, F36 쐌 Harness connectors B113, C3 쐌 Harness for open or short between EVAP canister vent control valve and ECM 䊳

7

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK EVAP CANISTER VENT CONTROL VALVE-I

1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted.

SEF337X

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace EVAP canister vent control valve.

EC-378

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II Reconnect harness connectors disconnected. Turn ignition switch “ON”. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time.

GI MA EM LC

SEF803Y

FE CL

Without CONSULT-II Check air passage continuity and operation delay time under the following conditions.

MT AT TF PD SEF339X

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 10.

NG

䊳

GO TO 9.

9

SU

CHECK EVAP CANISTER VENT CONTROL VALVE-III

1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 8 again. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP canister vent control valve.

10

AX

BR ST RS BT

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

HA

INSPECTION END

SC EL

EC-379

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

Component Description

Component Description

NGEC0264

The EVAP control system pressure sensor detects pressure in the purge line. The sensor output voltage to the ECM increases as pressure increases. The EVAP control system pressure sensor is not used to control the engine system. It is used only for on board diagnosis.

SEF340V

SEF954S

CONSULT-II Reference Value in Data Monitor Mode

NGEC0265

Specification data are reference values. MONITOR ITEM EVAP SYS PRES

CONDITION

SPECIFICATION

쐌 Ignition switch: ON

Approx. 3.4V

ECM Terminals and Reference Value

NGEC0266

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)

42

BR

Sensors’ power supply

[Ignition switch ON]

Approximately 5V

43

B/W

Sensors’ ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

62

Y

EVAP control system pressure sensor

[Ignition switch ON]

Approximately 3.4V

EC-380

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic DTC No. P0452 P0453

NGEC0267

Malfunction is detected when ...

Check Items (Possible Cause)

쐌 An excessively low (P0452) or high (P0453) voltage signal from EVAP control system pressure sensor is sent to ECM.

쐌 Harness or connectors (The EVAP control system pressure sensor circuit is open or shorted.) 쐌 Rubber hose to EVAP control system pressure is clogged, vent, kinked, disconnected or improper connection. 쐌 EVAP control system pressure sensor 쐌 EVAP canister vent control valve 쐌 EVAP canister purge volume control solenoid valve 쐌 EVAP canister 쐌 Rubber hose from EVAP canister vent control valve to water separator

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-381

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF194Y

=NGEC0268

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. TESTING CONDITION: 쐌 Always perform test at a temperature above 5°C (41°F). 쐌 Before performing the following procedure, confirm battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that “FUEL T/TMP SE” is more than 0°C (32°F). 6) Start engine and wait at least 20 seconds. 7) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-384.

1) 2) 3) 4) 5) 6)

With GST Start engine and warm it up to normal operating temperature. Check that voltage between ECM terminal 60 (Fuel tank temperature sensor signal) and ground is less than 4.2V. Turn ignition switch OFF and wait at least 5 seconds. Start engine and wait at least 20 seconds. Select “MODE 7” with GST. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-384.

SEF196V

EC-382

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE Wiring Diagram

Wiring Diagram

NGEC0269

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC975

EC-383

EL IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0270

CHECK RUBBER TUBE CONNECTED TO THE SENSOR

Check rubber tube connected to the sensor for clogging, vent, kink, disconnection or improper connection. OK or NG OK

䊳

GO TO 2.

NG

䊳

Reconnect, repair or replace.

2

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

SEF325V

䊳

3

GO TO 3.

CHECK HARNESS CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

SEF341V

2. Check sensor harness connector for water. Water should not exist. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace harness connector.

EC-384

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK POWER SUPPLY

1. Turn ignition switch ON. 2. Check voltage between terminal 3 and engine ground with CONSULT-II or tester.

GI MA EM LC

SEF410Q

Voltage: Approximately 5V

FE

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

CL MT

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C3, B113 쐌 Harness connectors B101, M67 쐌 Harness connectors M59, F27 쐌 Harness for open or short between EVAP control system pressure sensor and ECM 䊳

6

AT TF

Repair harness or connectors.

PD

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Check harness continuity between EVAP control system pressure sensor terminal 1 and engine ground.

AX SU BR ST SEF411Q

Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

RS BT HA SC EL

EC-385

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C3, B113 쐌 Harness connectors B101, M67 쐌 Harness connectors M81, F36 쐌 Harness for open or short between EVAP control system pressure sensor and ECM 䊳

8

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 62 and terminal 2.

SEF412Q

Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK (With CONSULT-II)

䊳

GO TO 10.

OK (Without CONSULTII)

䊳

GO TO 11.

NG

䊳

GO TO 9.

9

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C3, B113 쐌 Harness connectors B101, M67 쐌 Harness connectors M59, F27 쐌 Harness for open or short between EVAP control system pressure sensor and ECM 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-386

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

10

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

GI MA EM LC

SEF801Y

FE

OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 11.

11

CL MT

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

AT TF PD AX SEF334X

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

SU BR ST RS BT

SEF335X

HA

OK or NG

SC

OK

䊳

GO TO 12.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EL

EC-387

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

12

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

1. Turn ignition switch “OFF”. 2. Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK

䊳

GO TO 13.

NG

䊳

Repair it.

13

CHECK EVAP CANISTER VENT CONTROL VALVE-I

1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted.

SEF337X

OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace EVAP canister vent control valve.

EC-388

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

14 1. 2. 3. 4.

CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II Reconnect harness connectors disconnected. Turn ignition switch “ON”. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time.

GI MA EM LC

SEF803Y

FE CL

Without CONSULT-II Check air passage continuity and operation delay time under the following conditions.

MT AT TF PD SEF339X

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 16.

NG

䊳

GO TO 15.

15

AX SU

CHECK EVAP CANISTER VENT CONTROL VALVE-III

1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 13 again. OK or NG OK

䊳

GO TO 16.

NG

䊳

Replace EVAP canister vent control valve.

BR ST RS BT HA SC EL

EC-389

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

16

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

1. Remove EVAP control system pressure sensor with its harness connector connected.

SEF341V

2. Remove hose from EVAP control system pressure sensor. 3. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. 4. Check output voltage between ECM terminal 62 and engine ground.

SEF198V

MTBL0295

CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −20 kPa (−150 mmHg, −5.91 inHg) or over 20 kPa (150 mmHg, 5.91 inHg) of pressure.

SEF799W

쐌 Never apply force to the air hole protector of the sensor, if equipped. 쐌 Discard any EVAP control system pressure 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. OK or NG OK

䊳

GO TO 17.

NG

䊳

Replace EVAP control system pressure sensor.

EC-390

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

17

CHECK RUBBER TUBE FOR CLOGGING

Check obstructed water separator and rubber tube to EVAP canister vent control valve and clean the rubber tube using air blower. Check water separator. 1. Check visually for insect nests in the water separator air inlet. 2. Check visually for cracks or flaws in the appearance. 3. Check visually for cracks or flaws in the hose. 4. Check that A and C are not clogged by blowing air into B with A, and then C plugged.

GI MA EM LC

FE SEF829T

CL

5. In case of NG in items 2 - 4, replace the parts. 쐌 Do not disassemble water separator.

MT

OK or NG OK

䊳

GO TO 18.

NG

䊳

Clean, repair or replace rubber tube and/or water separator.

18

AT TF

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

PD AX SU BR SEF596U

ST

Yes or No Yes

䊳

GO TO 19.

No

䊳

GO TO 21.

19

RS BT

CHECK EVAP CANISTER

Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb).

HA

OK or NG OK

䊳

GO TO 21.

NG

䊳

GO TO 20.

SC EL

EC-391

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

20

DETECT MALFUNCTIONING PART

Check the following. 1. Visually check the EVAP canister for damage. 2. Check hose connection between EVAP canister and water separator for clogging and poor connection. 䊳

21 1. 2. 3. 4.

Repair hose or replace EVAP canister or water separator.

CHECK SHIELD CIRCUIT Turn ignition switch OFF. Reconnect disconnected harness connectors. Disconnect harness connectors B113. Check harness continuity between harness connector B113 terminal 6 and ground.

SEF699Z

Continuity should exist. 5. Also check harness for short to power. 6. Then reconnect harness connectors. OK or NG OK

䊳

GO TO 23.

NG

䊳

GO TO 22.

22

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M59, F27 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) 쐌 Harness for open or short between harness connector M67 and engine ground 䊳

23

Repair open circuit, short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-392

DTC P0455 EVAP CONTROL SYSTEM

KA24DE On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0951

NOTE: If DTC P0455 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-529.) This diagnosis detects a very large leak (fuel filler cap fell off etc.) in the EVAP system between the fuel tank and the EVAP canister purge volume control solenoid valve.

GI MA EM LC

FE CL MT AT SEF865Z

TF Malfunction is detected when EVAP control system has a very large leak, such as fuel filler cap fell off, EVAP control system does not operate properly. CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

AX SU BR

NGEC0951S01

Fuel filler cap remains open or fails to close. Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Foreign matter caught in fuel filler cap. Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. Foreign matter caught in EVAP canister vent control valve. EVAP canister or fuel tank leaks EVAP purge line (pipe and rubber tube) leaks EVAP purge line rubber tube bent. Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit EVAP canister purge volume control solenoid valve and the circuit Absolute pressure sensor

EC-393

PD

ST RS BT HA SC EL IDX

DTC P0455 EVAP CONTROL SYSTEM

KA24DE

On Board Diagnosis Logic (Cont’d)

쐌 쐌 쐌

Fuel tank temperature sensor O-ring of EVAP canister vent control valve is missing or damaged. EVAP control system pressure sensor

DTC Confirmation Procedure

SEC760C

SEC761C

SEC762C

NGEC0952

CAUTION: Never remove fuel filter cap during the DTC confirmation procedure. NOTE: 쐌 If DTC P0455 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-529.) 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. 쐌 Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is between 1/4 to 3/4 full and vehicle is placed on flat level surface. 쐌 Open engine hood before conducting the following procedure. 쐌 It is better that the fuel level is low. With CONSULT-II 1) Tighten fuel filter cap securely until ratcheting sound is heard. 2) Turn ignition switch ON. 3) Turn ignition switch OFF and wait at least 5 seconds. 4) Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that the following conditions are met. COOLAN TEMP/S: 0 - 70°C (32 - 158°F) INT/A TEMP SE: 0 - 60°C (32 - 140°F) 6) Select “EVAP SML LEAK P0442/P1442” of “EVAP SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-112. 7) Make sure that “OK” is displayed. If “NG” is displayed, select “SELF-DIAG RESULTS” mode with CONSULT-II and make sure that “EVAP GROSS LEAK [P0455]” is displayed. If it is displayed, refer to “Diagnostic Procedure”, EC-395. If P0442 is displayed, perform “Diagnostic Procedure” for DTC P0442.

SEC763C

EC-394

DTC P0455 EVAP CONTROL SYSTEM

KA24DE

DTC Confirmation Procedure (Cont’d)

With GST NOTE: 쐌 Be sure to read the explanation of “Driving Pattern” on EC-81 before driving vehicle. 쐌 It is better that the fuel level is low. 1) Start engine. 2) Drive vehicle according to “Driving Pattern”, EC-81. 3) Stop vehicle. 4) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is not set yet, go to the following step. 쐌 If SRT of EVAP system is set, the result will be OK. 5) Turn ignition switch “OFF” and wait at least 5 seconds. 6) Start engine. It is not necessary to cool engine down before driving. 7) Drive vehicle again according to the “Driving Pattern”, EC-81. 8) Stop vehicle. 9) Select “MODE 3” with GST. 쐌 If P0455 is displayed on the screen, go to “Diagnostic Procedure”, EC-395. 쐌 If P0442 is displayed on the screen, go to “Diagnostic Procedure”, EC-353. 쐌 If P0441 is displayed on the screen, go to “Diagnostic Procedure”, EC-341. 쐌 If P0441, P0442 and P0445 are not displayed on the screen, go to the following step. 10) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is set, the result will be OK. 쐌 If SRT of EVAP system is not set, go to step 6.

GI MA EM LC

FE CL MT AT TF PD AX

Diagnostic Procedure 1

NGEC0953

SU

CHECK FUEL FILLER CAP DESIGN

1. Turn ignition switch OFF. 2. Check for genuine NISSAN fuel filler cap design.

BR ST RS BT SEF915U

OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace with genuine NISSAN fuel filler cap.

HA SC EL

EC-395

IDX

DTC P0455 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

2

CHECK FUEL FILLER CAP INSTALLATION

Check that the cap is tightened properly by rotating the cap clockwise. OK or NG OK

䊳

GO TO 3.

NG

䊳

쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard.

3

CHECK FUEL FILLER CAP FUNCTION

Check for air releasing sound while opening the fuel filler cap. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 4.

4

CHECK FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)

1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum.

SEF427N

SEF943S

Pressure: 16.0 - 20.0 kPa (0.163 - 0.204 kg/cm2, 2.32 - 2.90 psi) Vacuum: −6.0 to −3.5 kPa (−0.061 to −0.036 kg/cm2, −0.87 to −0.51 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace fuel filler cap with a genuine one.

EC-396

DTC P0455 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure (Cont’d)

5

CHECK EVAP PURGE LINE

Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection or disconnection. Refer to “Evaporative Emission System”, EC-40.

MA

OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair or reconnect the hose.

6

GI

EM

CLEAN EVAP PURGE LINE

LC

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

7

GO TO 7.

CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT

FE

Refer to “DTC Confirmation Procedure”, EC-374. OK or NG

CL

OK

䊳

GO TO 8.

NG

䊳

Repair or replace EVAP canister vent control valve and O-ring or harness/connector.

8

MT

INSTALL THE PRESSURE PUMP

AT

To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely.

TF PD AX SEF339V

SU BR ST RS

SEF916U

BT

NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. Models with CONSULT-II

䊳

GO TO 9.

Models without CONSULT-II

䊳

GO TO 10.

HA SC EL

EC-397

IDX

DTC P0455 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

9

CHECK FOR EVAP LEAK

With CONSULT-II 1. Turn ignition switch ON. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II.

PEF658U

3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system.

PEF917U

4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43.

SEF200U

OK or NG OK

䊳

GO TO 11.

NG

䊳

Repair or replace.

EC-398

DTC P0455 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure (Cont’d)

10

CHECK FOR EVAP LEAK

Without CONSULT-II 1. Turn ignition switch OFF. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.)

GI MA EM LC

SEF503V

4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43.

FE CL MT AT TF PD AX

SEF200U

OK or NG OK

䊳

GO TO 12.

NG

䊳

Repair or replace.

SU BR ST RS BT HA SC EL

EC-399

IDX

DTC P0455 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

11 1. 2. 3. 4. 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100.0%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm.

SEF595Y

OK or NG OK

䊳

GO TO 14.

NG

䊳

GO TO 13.

12 1. 2. 3. 4. 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist. OK or NG

OK

䊳

GO TO 14.

NG

䊳

GO TO 13.

13

CHECK VACUUM HOSE

Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-33. OK or NG OK (With CONSULT-II)

䊳

GO TO 14.

OK (Without CONSULTII)

䊳

GO TO 15.

NG

䊳

Repair or reconnect the hose.

EC-400

DTC P0455 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure (Cont’d)

14

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

GI MA EM LC

SEF801Y

FE

OK or NG OK

䊳

GO TO 16.

NG

䊳

GO TO 15.

15

CL MT

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

AT TF PD AX SEF334X

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

SU BR ST RS BT

SEF335X

HA

OK or NG

SC

OK

䊳

GO TO 16.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EL

EC-401

IDX

DTC P0455 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

16

CHECK FUEL TANK TEMPERATURE SENSOR

Check resistance by heating with hot water or heat gun as shown in the figure.

SEF710Z

MTBL0234

AFE095

OK or NG OK

䊳

GO TO 17.

NG

䊳

Replace fuel tank temperature sensor, refer to FE-4.

EC-402

DTC P0455 EVAP CONTROL SYSTEM

KA24DE Diagnostic Procedure (Cont’d)

17

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

1. Remove EVAP control system pressure sensor with its harness connector connected.

GI MA EM LC SEF341V

2. 3. 4. 5.

Remove hose from EVAP control system pressure sensor. Turn ignition switch ON. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. Check input voltage between ECM terminal 62 and ground.

FE CL MT AT SEF894U

TF PD

MTBL0246

CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −20 kPa (−150 mmHg, −5.91 inHg) or over 20 kPa (150 mmHg, 5.91 inHg) of pressure. CAUTION: 쐌 Never apply force to the air hole protector of the sensor if equipped.

AX SU BR ST RS BT

SEF799W

쐌 Discard and EVAP control system pressure 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. OK or NG OK

䊳

GO TO 18.

NG

䊳

Replace EVAP control system pressure sensor.

EC-403

HA SC EL IDX

DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d)

18

CHECK FUEL LEVEL SENSOR

1. Remove fuel level sensor assembly. Refer to FE-4. 2. Refer to “FUEL LEVEL SENSOR UNIT CHECK”, EL-89. OK or NG OK

䊳

GO TO 19.

NG

䊳

Replace fuel level sensor.

19

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-404

KA24DE

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1032

This diagnosis detects very small leaks in the EVAP line between the fuel tank and the EVAP canister purge volume control solenoid valve using intake manifold vacuum (P0456) or vapor pressure in the fuel tank (P1456) in the same way as conventional EVAP small leak diagnosis. If the ECM judges a leak equivalent to a very small leak, the very small leak DTC P0456 or P1456 will be detected. If the ECM judges a leak equivalent to a small leak, the EVAP small leak DTC P0442 will be detected. Correspondingly, if the ECM judges there is no leak, the diagnosis result is OK.

GI MA EM LC

FE CL MT AT TF SEF865Z

Malfunction is detected when EVAP control system has a very small leak, EVAP control system does not operate properly. CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

PD AX SU BR ST RS

Possible Cause 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC1033

Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Fuel filler cap remains open or fails to close. Foreign matter caught in fuel filler cap. Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. Foreign matter caught in EVAP canister vent control valve. EVAP canister or fuel tank leaks EVAP purge line (pipe and rubber tube) leaks

EC-405

BT HA SC EL IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Possible Cause (Cont’d)

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

EVAP purge line rubber tube bent. Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit EVAP canister purge volume control solenoid valve Absolute pressure sensor Fuel tank temperature sensor O-ring of EVAP canister vent control valve is missing or damaged. Water separator EVAP canister is saturated with water. Fuel level sensor and the circuit EVAP control system pressure sensor Refueling control valve ORVR system leaks Fuel level sensor and the circuit

DTC Confirmation Procedure

SEC764C

SEC765C

NGEC1034

CAUTION: Never remove fuel filler cap during the DTC confirmation procedure. NOTE: 쐌 If DTC P0456 or P1456 is displayed with P0442, perform TROUBLE DIAGNOSIS FOR DTC P0456 or P1456 first. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. 쐌 After repair, make sure that the hoses and clips are installed properly. TESTING CONDITION: 쐌 Open engine hood before conducting following procedure. 쐌 If any of following condition is met just before the DTC confirmation procedure, leave the vehicle for more than 1 hour. a) Fuel filler cap is removed. b) Refilled or drained the fuel. c) EVAP component parts is/are removed. 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Make sure the following conditions are met. FUEL LEVEL SE: 1.08 - 0.2V COOLAN TEMP/S: 0 - 32°C (32 - 90°F) FUEL T/TMP SE: 0 - 32°C (32 - 90°F) INT A/TEMP SE: More than 0°C (32°F) If NG, turn ignition switch “OFF” and leave the vehicle in a cool

SEC766C

EC-406

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

DTC Confirmation Procedure (Cont’d)

place (soak the vehicle) or refilling/draining fuel until the output voltage condition of the “FUEL LEVEL SE” meets within the range above and leave the vehicle for more than 1 hour. Then start from step 1). 3) Turn ignition switch “OFF” and wait at least 5 seconds. 4) Turn ignition switch “ON”. 5) Select “EVAP V/S LEAK P0456/P1456” of “EVAP SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. 6) Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-408. NOTE: 쐌 If the engine speed cannot be maintained within the range displayed on CONSULT-II screen, go to “Basic inspection”, EC-112. 쐌 Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly.

OVERALL FUNCTION CHECK

NGEC1034S01

With GST Use this procedure to check the overall function of the EVAP very small leak function. During this check, a 1st trip DTC might not be confirmed.

SEF462UA

CAUTION: 쐌 Never use compressed air, doing so may damage the EVAP system. 쐌 Do not start engine. 쐌 Do not exceeded 4.12 kPa (0.042 kg/cm2, 0.6 psi). 1) Attach the EVAP service port adapter securely to the EVAP service port. 2) Set the pressure pump and a hose. 3) Also set a vacuum gauge via 3-way connector and a hose. 4) Turn ignition switch “ON”. 5) Connect GST and select mode 8. 6) Using mode 8 control the EVAP canister vent control valve (close) and vacuum cut valve bypass valve (open). 7) Apply pressure and make sure the following conditions are satisfied. Pressure to be applied: 2.7 kPa (20 mmHg, 0.79 inHg) Time to be waited after the pressure drawn in to the EVAP system and the pressure to be dropped: 60 seconds and the pressure should not be dropped more than 0.4 kPa (3 mmHg, 0.12 inHg) If NG, go to diagnostic procedure, EC-408. NOTE: For more information, refer to GST instruction manual.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-407

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1035

CHECK FUEL FILLER CAP DESIGN

1. Turn ignition switch “OFF”. 2. Check for genuine NISSAN fuel filler cap design.

SEF915U

OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace with genuine NISSAN fuel filler cap.

2

CHECK FUEL FILLER CAP INSTALLATION

Check that the cap is tightened properly by rotating the cap clockwise. OK or NG OK

䊳

GO TO 3.

NG

䊳

쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard.

3

CHECK FUEL FILLER CAP FUNCTION

Check for air releasing sound while opening the fuel filler cap. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-408

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK FUEL TANK VACUUM RELIEF VALVE

1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum.

GI MA EM LC

SEF427N

FE CL MT AT SEF943S

Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace fuel filler cap with a genuine one.

TF PD AX SU BR ST RS BT HA SC EL

EC-409

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

5

INSTALL THE PRESSURE PUMP

To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely.

SEF339V

SEF916U

NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. Models with CONSULT-II

䊳

GO TO 6.

Models without CONSULT-II

䊳

GO TO 7.

EC-410

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

6

CHECK FOR EVAP LEAK

With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system.

GI MA EM LC

FE PEF917U

4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43.

CL MT AT TF PD

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

AX SU BR ST RS BT HA SC EL

EC-411

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

7

CHECK FOR EVAP LEAK

Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.)

SEF503V

3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.) 4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-43.

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

EC-412

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

GI MA EM LC

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator.

FE CL

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace water separator.

MT AT

9

CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT

Refer to “DTC Confirmation Procedure”, EC-374.

TF OK or NG

OK

䊳

GO TO 10.

NG

䊳

Repair or replace EVAP canister vent control valve and O-ring or harness/connector.

10

PD AX

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Does water drain from the EVAP canister?

SU BR ST RS SEF596U

BT

Yes or No Yes

䊳

GO TO 11.

No (With CONSULT-II)

䊳

GO TO 13.

No (Without CONSULTII)

䊳

GO TO 14.

HA SC EL

EC-413

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

11

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK (With CONSULT-II)

䊳

GO TO 13.

OK (Without CONSULTII)

䊳

GO TO 14.

NG

䊳

GO TO 12.

12

DETECT MALFUNCTIONING PART

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

13 1. 2. 3. 4. 5.

Repair hose or replace EVAP canister.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100.0%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm.

SEF984Y

OK or NG OK

䊳

GO TO 16.

NG

䊳

GO TO 15.

14 1. 2. 3. 4. 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist. OK or NG

OK

䊳

GO TO 17.

NG

䊳

GO TO 15.

EC-414

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

15

CHECK VACUUM HOSE

Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-33.

GI

OK or NG OK (With CONSULT-II)

䊳

GO TO 16.

OK (Without CONSULTII)

䊳

GO TO 17.

NG

䊳

Repair or reconnect the hose.

EM

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

LC

16

MA

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.

FE CL MT AT SEF985Y

OK or NG OK

䊳

GO TO 18.

NG

䊳

GO TO 17.

TF PD AX SU BR ST RS BT HA SC EL

EC-415

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

17

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

SEF339V

SEF334X

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

SEF339V

SEF335X

OK or NG OK

䊳

GO TO 18.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EC-416

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

18

CHECK FUEL TANK TEMPERATURE SENSOR

1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit and fuel pump terminals 1 and 4 by heating with hot water or heat gun as shown in the figure.

GI MA EM LC

SEF710Z

FE CL MTBL0291

OK or NG OK

䊳

GO TO 19.

NG

䊳

Replace fuel level sensor unit.

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-417

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

19

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

1. Remove EVAP control system pressure sensor with its harness connector connected. CAUTION: 쐌 Never apply force to the air hole protector of the sensor if equipped.

SEF799W

2. Remove hose from EVAP control system pressure sensor. 3. Turn ignition switch “ON”. 4. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −20 kPa (−150 mmHg, −5.91 inHg) or over 20 kPa (150 mmHg, 5.91 inHg) of pressure. 5. Check input voltage between ECM terminal 62 and ground.

SEF705Z

CAUTION: 쐌 Discard and EVAP control system pressure 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. OK or NG OK

䊳

GO TO 20.

NG

䊳

Replace EVAP control system pressure sensor.

20

CHECK EVAP PURGE LINE

Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to “Evaporative Emission System”, EC-40. OK or NG OK

䊳

GO TO 21.

NG

䊳

Repair or reconnect the hose.

21

CLEAN EVAP PURGE LINE

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

GO TO 22.

EC-418

DTC P0456, P1456 EVAP CONTROL SYSTEM

KA24DE

Diagnostic Procedure (Cont’d)

22

CHECK FUEL LEVEL SENSOR

Refer to EL-8, “Fuel Level Sensor Unit Check”.

GI OK or NG

OK

䊳

GO TO 23.

NG

䊳

Replace fuel level sensor unit.

23

MA EM

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-419

IDX

DTC P0460 FUEL LEVEL SENSOR

KA24DE

Component Description

Component Description

NGEC1012

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

SEF800Z

On Board Diagnostic Logic

NGEC1013

When the vehicle is parked, naturally the fuel level in the fuel tank is stable. It means that output signal of the fuel level sensor does not change. If ECM senses sloshing signal from the sensor, fuel level sensor malfunction is detected. Malfunction is detected when even though the vehicle is parked, a signal being varied is sent from the fuel level sensor to ECM.

Possible Cause 쐌 쐌

NGEC1014

Fuel level sensor circuit (The fuel level sensor circuit is open or shorted.) Fuel level sensor

DTC Confirmation Procedure

NGEC1015

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test.

WITH CONSULT-II

SEF195Y

1) 2) 3) 4)

NGEC1015S01

Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait maximum of 2 consecutive minutes. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-422.

WITH GST Follow the procedure “WITH CONSULT-II” above.

EC-420

NGEC1015S02

DTC P0460 FUEL LEVEL SENSOR

KA24DE Wiring Diagram

Wiring Diagram

NGEC1016

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC976

EC-421

EL IDX

DTC P0460 FUEL LEVEL SENSOR

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4.

=NGEC1017

CHECK FUEL LEVEL SENSOR POWER SUPPLY CIRCUIT Turn ignition switch “OFF”. Disconnect fuel level sensor until harness connector. Turn ignition switch “ON”. Check voltage between fuel level sensor unit terminal 2 and ground with CONSULT-II or a tester.

SEF702ZA

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M67, B101 쐌 Harness for open or short between combination meter and fuel level sensor unit 䊳

3

Repair or replace harness or connectors.

CHECK FUEL LEVEL SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check harness continuity between fuel level sensor unit terminal 4 and body ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to power in harness or connectors.

4

CHECK FUEL LEVEL SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 46 and fuel level sensor unit terminal 2, ECM terminal 66 and fuel level sensor unit terminal 4. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

EC-422

DTC P0460 FUEL LEVEL SENSOR

KA24DE Diagnostic Procedure (Cont’d)

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness connectors M67, B101 쐌 Harness for open or short between ECM and fuel level sensor unit 䊳

GI MA

Repair open circuit or short to ground or short to power in harness or connectors.

EM 6

CHECK FUEL LEVEL SENSOR

Refer to EL-8, “Fuel Level Sensor Unit Check”. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace fuel level sensor unit.

7

LC

FE

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

CL

INSPECTION END

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-423

IDX

DTC P0461 FUEL LEVEL SENSOR

KA24DE

Component Description

Component Description

=NGEC1018

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

SEF800Z

On Board Diagnostic Logic

NGEC1019

Driving long distances naturally affect fuel gauge level. This diagnosis detects the fuel gauge malfunction of the gauge not moving even after a long distance has been driven. Malfunction is detected when the output signal of the fuel level sensor does not change within the specified range even though the vehicle has been driven a long distance.

Possible Cause 쐌 쐌

NGEC1020

Harness or connectors (The level sensor circuit is open or shorted.) Fuel level sensor

Overall Function Check

NGEC1021

Use this procedure to check the overall function of the fuel level sensor function. During this check, a 1st trip DTC might not be confirmed. WARNING: When performing following procedure, be sure to observe the handling of the fuel. Refer to FE-5, “Fuel Tank”. TESTING CONDITION: Before starting overall function check, preparation of draining fuel and refilling fuel is required.

WITH CONSULT-II

SEF195Y

NGEC1021S01

NOTE: Start from step 11, if it is possible to confirm that the fuel cannot be drained by 30 (7-7/8 US gal, 6-5/8 Imp gal) in advance. 1) Prepare a fuel container and a spare hose. 2) Release fuel pressure from fuel line, refer to “Fuel Pressure Release”, EC-57. 3) Remove the fuel feed hose on the fuel level sensor unit. 4) Connect a spare fuel hose where the fuel feed hose was removed.

EC-424

DTC P0461 FUEL LEVEL SENSOR

KA24DE Overall Function Check (Cont’d)

5)

Turn ignition switch “OFF” and wait at least 10 seconds then turn “ON”. 6) Select “FUEL LEVEL SE” in “DATA MONITOR” mode with CONSULT-II. 7) Check “FUEL LEVEL SE” output voltage and note it. 8) Select “FUEL PUMP” in “ACTIVE TEST” mode with CONSULT-II. 9) Touch “ON” and drain fuel approximately 30 (7-7/8 US gal, 6-5/8 Imp gal) and stop it. 10) Fill fuel into the fuel tank for 30 (7-7/8 US gal, 6-5/8 Imp gal). 11) Check “FUEL LEVEL SE” output voltage and note it. 12) Check “FUEL LEVEL SE” output voltage and confirm whether the voltage changes more than 0.03V during step 7 to 11. If NG, check the fuel level sensor, refer to EL-89, “FUEL LEVEL SENSOR UNIT CHECK”.

GI MA EM LC

FE CL MT WITH GST

SEF703Z

NGEC1021S02

NOTE: Start from step 11, if it is possible to confirm that the fuel cannot be drained by 30 (7-7/8 US gal, 6-5/8 Imp gal) in advance. 1) Prepare a fuel container and a spare hose. 2) Release fuel pressure from fuel line, refer to “Fuel Pressure Release”, EC-57. 3) Remove the fuel feed hose on the fuel level sensor unit. 4) Connect a spare fuel hose where the fuel feed hose was removed. 5) Turn ignition switch “OFF”. 6) Set voltmeters probe between ECM terminal 46 (fuel level sensor signal) and ground. 7) Turn ignition switch “ON”. 8) Check voltage between ECM terminal 46 and ground and note it. 9) Drain fuel by 30 (7-7/8 US gal, 6-5/8 Imp gal) from the fuel tank using proper equipment. 10) Fill fuel into the fuel tank for 30 (7-7/8 US gal, 6-5/8 Imp gal). 11) Confirm that the voltage between ECM terminal 46 and ground changes more than 0.03V during step 8 - 10. If NG, check component of fuel level sensor, refer to EL-89, “FUEL LEVEL SENSOR UNIT CHECK”.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-425

IDX

DTC P0462, P0463 FUEL LEVEL SENSOR

KA24DE

Component Description

Component Description

NGEC1022

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

SEF800Z

On Board Diagnostic Logic

NGEC1023

ECM receives two signals from the fuel level sensor circuit. One is fuel level sensor power supply circuit, and the other is fuel level sensor ground circuit. This diagnosis indicates the former, to detect open or short circuit malfunction. Malfunction is detected when an excessively low (P0462) or high (P0463) voltage is sent from the sensor is sent to ECM.

Possible Cause 쐌 쐌

NGEC1024

Fuel level sensor circuit (The fuel level sensor circuit is open or shorted.) Fuel level sensor

DTC Confirmation Procedure

NGEC1025

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at ignition switch “ON”.

WITH CONSULT-II 1) 2) 3) 4)

NGEC1025S01

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”, EC-428.

WITH GST Follow the procedure “WITH CONSULT-II” above. SEF195Y

EC-426

NGEC1025S02

DTC P0462, P0463 FUEL LEVEL SENSOR

KA24DE Wiring Diagram

Wiring Diagram

NGEC1026

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC977

EC-427

EL IDX

DTC P0462, P0463 FUEL LEVEL SENSOR

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4.

=NGEC1027

CHECK FUEL LEVEL SENSOR POWER SUPPLY CIRCUIT Turn ignition switch “OFF”. Disconnect fuel level sensor until harness connector. Turn ignition switch “ON”. Check voltage between fuel level sensor unit terminal 2 and ground with CONSULT-II or tester.

SEF702ZA

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M67, B101 쐌 Harness for open or short between combination meter and fuel level sensor until 䊳

3

Repair or replace harness or connectors.

CHECK FUEL LEVEL SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check harness continuity between fuel level sensor unit terminal 4 and body ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to power in harness or connectors.

4

CHECK FUEL LEVEL SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 46 and fuel level sensor unit 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

䊳

GO TO 6.

NG

䊳

GO TO 5.

EC-428

DTC P0462, P0463 FUEL LEVEL SENSOR

KA24DE

Diagnostic Procedure (Cont’d)

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness connectors M67, B101 쐌 Harness for open or short between ECM and fuel level sensor unit 䊳

GI MA

Repair open circuit or short to power in harness on connectors.

EM 6

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “Fuel Level Sensor Unit Check”. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace fuel level sensor unit.

7

LC

FE

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

CL

INSPECTION END

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-429

IDX

DTC P0500 VSS

KA24DE

Component Description

Component Description

NGEC0272

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.

SEF505U

ECM Terminals and Reference Value

NGEC0273

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) 1 - 4V

29

G/B

Vehicle speed sensor

[Engine is running] 쐌 Lift up the vehicle 쐌 In 2nd gear position 쐌 Vehicle speed is 40 km/h (25 MPH) SEF003W

On Board Diagnosis Logic DTC No. P0500

Malfunction is detected when ...

NGEC0274

Check Items (Possible Cause)

쐌 The almost 0 km/h (0 MPH) signal from vehicle speed 쐌 Harness or connector sensor is sent to ECM even when vehicle is being driven. (The vehicle speed sensor circuit is open or shorted.) 쐌 Vehicle speed sensor

DTC Confirmation Procedure

NGEC0275

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 5 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-430

DTC P0500 VSS

KA24DE DTC Confirmation Procedure (Cont’d)

1) 2)

3)

SEF196Y

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-433. 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 1 consecutive minute.

ENG SPEED

1,800 - 6,000 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

7 - 15msec

Selector lever

Suitable position

PW/ST SIGNAL

OFF

7)

SEF568P

MA EM LC

FE CL

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-433.

Overall Function Check

GI

NGEC0276

Use this procedure to check the overall function of the EVAP canister vent control valve circuit. During this check, a 1st trip DTC might not be confirmed. With GST 1) Lift up drive wheels. 2) Start engine. 3) Read vehicle speed sensor signal in “MODE 1” with GST. The vehicle speed sensor on GST should be able to exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. 4) If NG, go to “Diagnostic Procedure”, EC-433.

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-431

IDX

DTC P0500 VSS

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0277

WEC978

EC-432

DTC P0500 VSS

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0278

CHECK INPUT SIGNAL CIRCUIT

GI

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector and combination meter harness connector M38. 3. Check harness continuity between ECM terminal 29 and meter terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

EM LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness for open or short between ECM and combination meter 䊳

3

MA

FE

Repair open circuit or short to ground or short to power in harness or connectors.

CL

CHECK SPEEDOMETER FUNCTION

MT

Make sure that speedometer functions properly. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

AT TF

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors E32, E202 쐌 Harness for open or short between combination meter and vehicle speed sensor 䊳

5

AX

Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL-85.

SU

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

PD

INSPECTION END

BR ST RS BT HA SC EL

EC-433

IDX

DTC P0505 ISC SYSTEM

KA24DE

Description

Description

NGEC0279

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

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

Vehicle speed

Absolute pressure sensor

Ambient barometric pressure

Intake air temperature sensor

Intake air temperature

NGEC0279S01

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 bypasses the throttle valve via IACV-AAC valve. The IACV-AAC valve repeats ON/OFF operation according to the signal sent from the ECM. The camshaft position sensor detects the actual engine speed and sends a signal to the ECM. The ECM then controls the ON/OFF time 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 and cooling fan operation).

COMPONENT DESCRIPTION

NGEC0279S02

The IAC valve-AAC valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of air that will flow through the valve. The more air that flows through the valve, the higher the idle speed.

SEF040E

EC-434

DTC P0505 ISC SYSTEM

KA24DE

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NGEC0280

MONITOR ITEM

CONDITION 쐌 쐌 쐌 쐌

IACV-AAC/V

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

Approx. 30%

2,000 rpm

—

MA EM

ECM Terminals and Reference Value

NGEC0281

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

GI

SPECIFICATION

CONDITION

LC

FE

DATA (DC Voltage) 10.5 - 11.5V

CL

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

MT AT SEF015W

101

OR/L

IACV-AAC valve

1 - 13V

TF PD

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

AX SEF016W

On Board Diagnosis Logic DTC No. P0505

Malfunction is detected when ... A)

B)

The IACV-AAC valve does not operate properly.

The IACV-AAC valve does not operate properly.

Check Items (Possible Cause) 쐌 Harness or connectors (The IACV-AAC valve circuit is open.) 쐌 IACV-AAC valve 쐌 Harness or connectors (The IACV-AAC valve circuit is shorted.) 쐌 IACV-AAC valve

SU NGEC0282

BR ST RS BT HA SC EL

EC-435

IDX

DTC P0505 ISC SYSTEM

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC0283

NOTE: 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. 쐌 Perform “Procedure for malfunction A” first. If DTC cannot be confirmed, perform “Procedure for malfunction B”.

PROCEDURE FOR MALFUNCTION A

SEF058Y

PROCEDURE FOR MALFUNCTION B

SEF174Y

NGEC0283S01

TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 10.5V with ignition switch ON. With CONSULT-II 1) Turn ignition switch ON. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and run it at idle at least 2 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-438. With GST Follow the procedure “With CONSULT-II”.

NGEC0283S02

TESTING CONDITION: 쐌 Before performing the following procedure, make sure battery voltage is more than 11V at idle. 쐌 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 5 seconds. 3) Turn ignition switch ON again and select “DATA MONITOR” mode with CONSULT-II. 4) Start engine and run it for at least 6 minute at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-438. With GST Follow the procedure “With CONSULT-II”.

EC-436

DTC P0505 ISC SYSTEM

KA24DE Wiring Diagram

Wiring Diagram

NGEC0284

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC116A

EC-437

EL IDX

DTC P0505 ISC SYSTEM

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0285

CHECK POWER SUPPLY

1. Stop engine. 2. Disconnect IACV-AAC valve harness connector.

SEF342V

3. Turn ignition switch ON. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF247W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Fuse block (J/B) connector M27 쐌 10A fuse 쐌 Harness for open or short between IACV-AAC valve and 10A fuse 䊳

Repair harness or connectors.

EC-438

DTC P0505 ISC SYSTEM

KA24DE 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 101 and terminal 1.

GI MA EM LC SEF248W

Continuity should exist. 4. Also check harness for short to ground and short to power.

FE

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

4

CL MT

CHECK IACV-AAC VALVE

Disconnect IACV-AAC valve harness connector. 쐌 Check IACV-AAC valve resistance.

AT TF PD AX SEF249W

Resistance: Approximately 10 Ω [at 25°C (77°F)] 쐌 Check plunger for seizing or sticking. 쐌 Check for broken spring.

SU BR

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace IACV-AAC valve.

5

ST RS

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

BT HA SC EL

EC-439

IDX

DTC P0510 CTP SWITCH

KA24DE

Component Description

Component Description

NGEC0287

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 A/T 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.

SEF505V

ECM Terminals and Reference Value

NGEC0288

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.

28

WIRE COLOR

BR/W

ITEM

Throttle position switch (Closed position)

CONDITION

DATA (DC Voltage)

[Ignition switch ON] 쐌 Warm-up condition 쐌 Accelerator pedal released

BATTERY VOLTAGE (11 - 14V)

[Ignition switch ON] 쐌 Accelerator pedal depressed

Approximately 0V

On Board Diagnosis Logic DTC No. P0510

Malfunction is detected when ... 쐌 Battery voltage from the closed throttle position switch is sent to ECM with the throttle valve opened.

EC-440

Check Items (Possible Cause) 쐌 Harness or connectors (The closed throttle position switch circuit is shorted.) 쐌 Closed throttle position switch 쐌 Throttle position sensor

NGEC0289

DTC P0510 CTP SWITCH

KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

SEF197Y

=NGEC0290

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 5 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “CLSD THL/P SW” in “DATA MONITOR” mode with CONSULT-II and check the value under the following conditions. Condition

ON

Throttle valve: Slightly open

OFF

SEF198Y

If the result is NG, go to “Diagnostic Procedure”, EC-443. 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. More than 2.5V

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.

NGEC0291

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 28 (Closed throttle position switch signal) and ground under the following conditions. Condition

CL MT

TF

Overall Function Check

PD AX SU BR ST RS

Voltage

At idle

Battery voltage

At 2,000 rpm

Approximately 0 - 1V

3)

LC

AT

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-443.

SEF422Q

EM

FE

THRTL POS SEN

5)

MA

Signal indication

Throttle valve: Idle position

3) 4)

GI

If NG, go to “Diagnostic Procedure”, EC-443.

BT HA SC EL

EC-441

IDX

DTC P0510 CTP SWITCH

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0292

LEC117A

EC-442

DTC P0510 CTP SWITCH

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0293

CHECK POWER SUPPLY

GI

1. Turn ignition switch OFF. 2. Disconnect throttle position switch harness connector.

MA EM LC

SEF158S

3. Turn ignition switch ON. 4. Check voltage between terminal 5 and engine ground with CONSULT-II or tester.

FE CL MT AT

SEF250W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

TF PD AX

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Fuse block (J/B) connector M27 쐌 10A fuse 쐌 Harness for open or short between throttle position switch and 10A fuse 䊳

Repair harness or connectors.

SU BR ST RS BT HA SC EL

EC-443

IDX

DTC P0510 CTP SWITCH

KA24DE

Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 28 and terminal 6.

AEC571A

Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between throttle position switch and ECM. 䊳

5

Repair open circuit or short to ground or short to power in harness or connectors.

ADJUST THROTTLE POSITION SWITCH IDLE POSITION

1. Check the following items. Refer to “Basic Inspection”, EC-112.

MTBL0328

䊳

GO TO 6.

EC-444

DTC P0510 CTP SWITCH

KA24DE Diagnostic Procedure (Cont’d)

6 1. 2. 3. 4.

CHECK CLOSED THROTTLE POSITION SWITCH With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine and turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check indication of “CLSD THL/P SW” under the following conditions.

GI MA EM LC

SEF721Z

NOTE: Measurement must be made with closed throttle position switch installed in vehicle. If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-112. 5. If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch. 1. 2. 3. 4.

FE CL MT

Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect throttle position switch harness connector. Check continuity between terminals 5 and 6 under the following conditions.

AT TF PD AX SU SEF159S

BR ST MTBL0299

NOTE: Continuity measurement must be made with closed throttle position switch installed in vehicle. If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-112. 5. If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace throttle position switch.

RS BT HA SC EL

EC-445

IDX

DTC P0510 CTP SWITCH

KA24DE

Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4.

CHECK THROTTLE POSITION SENSOR With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine and turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check voltage of “THRTL POS SEN” under the following conditions.

SEF198Y

NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle. If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-112. 5. If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace throttle position sensor. Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Stop engine and turn ignition switch ON. 3. Check voltage between ECM terminal 23 (Throttle position sensor signal) and ground under the following conditions.

SEF767W

MTBL0329

NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle. If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-112. 4. If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace throttle position sensor. OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace throttle position sensor.

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-446

DTC P0605 ECM

KA24DE Component Description

Component Description

NGEC0295

The ECM consists of a microcomputer along with connectors for signal input and output and for power supply. The ECM controls the engine.

GI MA EM LC

SEC220B

On Board Diagnosis Logic DTC No. P0605

Malfunction is detected when ... 쐌 ECM calculation function is malfunctioning.

NGEC0296

Check Items (Possible Cause) 쐌 ECM

FE CL MT

DTC Confirmation Procedure

SEF058Y

NGEC0297

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. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine. 4) Run engine for at least 30 seconds at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-448. With GST Follow the procedure “With CONSULT-II”.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-447

IDX

DTC P0605 ECM

KA24DE

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

䊳

Replace ECM.

No

䊳

INSPECTION END

EC-448

NGEC0298

DTC P1143 HO2S1

KA24DE Component Description

Component Description

NGEC0103

The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V.

GI MA EM LC

SEF463R

FE CL MT

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

AT

CONDITION

TF

NGEC0104

Specification data are reference values. MONITOR ITEM

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

쐌 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

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1

AX

NGEC0105

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.

PD

[Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

SU BR ST RS BT

SEF008W

HA SC EL

EC-449

IDX

DTC P1143 HO2S1

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0106

To judge the malfunction, the output from the heated oxygen sensor 1 is monitored to determine whether the “rich” output is sufficiently high and whether the “lean” output is sufficiently low. When both the outputs are shifting to the lean side, the malfunction will be detected.

SEF300U

DTC No. P1143

Malfunction is detected when ... 쐌 The maximum and minimum voltages from the sensor are not reached to the specified voltages.

Check Items (Possible Cause) 쐌 쐌 쐌 쐌 쐌

Heated oxygen sensor 1 Heated oxygen sensor 1 heater Fuel pressure Injectors Intake air leaks

DTC Confirmation Procedure

SEC767C

SEC768C

NGEC0107

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 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 5 seconds. 3) Turn ignition switch ON and select “HO2S1 (B1) P1143” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3.0 minutes. NOTE: Never raise engine speed above 3,000 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

1,200 - 3,150 rpm

Vehicle speed

Less than 100 km/h (62 MPH)

B/FUEL SCHDL

3.5 - 15 msec

Selector lever

Suitable position

SEC769C

EC-450

DTC P1143 HO2S1

KA24DE 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-451.

GI MA EM LC

Overall Function Check

AEC873A

NGEC0108

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (Heated oxygen sensor 1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The maximum voltage is over 0.6V at least one time. 쐌 The minimum voltage is over 0.1V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-451.

FE CL MT AT TF PD AX

Diagnostic Procedure 1

NGEC0109

SU

RETIGHTEN HEATED OXYGEN SENSOR 1

1. Turn ignition switch OFF. 2. Loosen and retighten heated oxygen sensor 1.

BR ST RS BT SEF332VB

Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

HA SC

GO TO 2.

EL

EC-451

IDX

DTC P1143 HO2S1

KA24DE

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 “CLEAR”.

SEF215Z

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.

AEC131A

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure 1st trip DTC P0102 is displayed. 6. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-86. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171. Refer to EC-255.

No

䊳

GO TO 3.

EC-452

DTC P1143 HO2S1

KA24DE Diagnostic Procedure (Cont’d)

3

CHECK HEATED OXYGEN SENSOR 1 HEATER

Check resistance between terminals 3 and 1.

GI MA EM LC SEF220W

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. 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.

FE CL

OK or NG OK (With CONSULT-II)

䊳

GO TO 4.

OK (Without CONSULTII)

䊳

GO TO 5.

NG

䊳

Replace heated oxygen sensor 1.

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-453

IDX

DTC P1143 HO2S1

KA24DE

Diagnostic Procedure (Cont’d)

4 1. 2. 3. 4. 5. 6.

CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Reconnect all harness connectors. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode, and the trigger point is adjusted to 100%. Select “HO2S1 (B1)” AND “HO2S1 MNTR (B1)” in Item Selection. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “START” on CONSULT-II screen.

SEF646Y

7. Check the following. 쐌 “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:

SEF217YA

쐌 “HO2S1 (B1)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)” voltage never exceeds 1.0V.

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace heated oxygen sensor 1.

EC-454

DTC P1143 HO2S1

KA24DE Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Reconnect all harness connectors. 2. Start engine and warm it up to normal operating temperature. 3. Set voltmeter probes between ECM terminal 50 (Heated oxygen sensor 1 signal) and engine ground.

GI MA EM LC

AEC873A

4. Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than five times within 10 seconds. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 쐌 The maximum voltage is over 0.6V at least one time. 쐌 The minimum voltage is below 0.3V at least one time. 쐌 The voltage never exceeds 1.0V. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

FE CL MT AT TF

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace heated oxygen sensor 1.

6

PD AX

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. Refer to “Wiring Diagram”, EC-233, for circuit. 䊳

SU

INSPECTION END

BR ST RS BT HA SC EL

EC-455

IDX

DTC P1144 HO2S1

KA24DE

Component Description

Component Description

NGEC0111

The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NGEC0112

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

쐌 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

NGEC0113

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) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1

[Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-456

DTC P1144 HO2S1

KA24DE On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0114

To judge the malfunction, the output from the heated oxygen sensor 1 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.

GI MA EM LC

SEF299U

DTC No. P1144

Malfunction is detected when ... 쐌 The maximum and minimum voltages from the sensor are beyond the specified voltages.

Check Items (Possible Cause) 쐌 쐌 쐌 쐌

Heated oxygen sensor 1 Heated oxygen sensor 1 heater Fuel pressure Injectors

FE CL MT

DTC Confirmation Procedure

SEC770C

SEC771C

NGEC0115

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 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 5 seconds. 3) Turn ignition switch ON and select “HO2S1 P1144” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3.0 minutes. NOTE: Never raise engine speed above 3,000 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

1,200 - 3,150 rpm

Vehicle speed

Less than 100 km/h (62 MPH)

B/FUEL SCHDL

3.5 - 15 msec

Selector lever

Suitable position

AT TF PD AX SU BR ST RS BT HA SC EL

SEC772C

EC-457

IDX

DTC P1144 HO2S1

KA24DE

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-458.

Overall Function Check

AEC873A

Diagnostic Procedure 1

NGEC0116

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (Heated oxygen sensor 1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The maximum voltage is below 0.8V at least one time. 쐌 The minimum voltage is below 0.35V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-458.

NGEC0117

RETIGHTEN HEATED OXYGEN SENSOR 1

1. Turn ignition switch OFF. 2. Loosen and retighten heated oxygen sensor 1.

SEF332VB

Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

GO TO 2.

EC-458

DTC P1144 HO2S1

KA24DE 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 “CLEAR”.

GI MA EM LC

SEF215Z

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.

FE CL MT AT TF PD

SEF293W

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure 1st trip DTC P0102 is displayed. 6. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-86. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0172. Refer to EC-262.

No

䊳

GO TO 3.

3

AX SU BR ST RS

CHECK HARNESS CONNECTOR

1. Turn ignition switch OFF. 2. Disconnect heated oxygen sensor 1 harness connector. 3. Check harness connector for water. Water should not exit.

BT HA

OK or NG

SC

OK

䊳

GO TO 4.

NG

䊳

Repair or replace harness connector.

EL

EC-459

IDX

DTC P1144 HO2S1

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK HEATED OXYGEN SENSOR 1 HEATER

Check resistance between terminals 3 and 1.

SEF220W

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. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK (With CONSULT-II)

䊳

GO TO 5.

OK (Without CONSULTII)

䊳

GO TO 6.

NG

䊳

Replace heated oxygen sensor 1.

EC-460

DTC P1144 HO2S1

KA24DE Diagnostic Procedure (Cont’d)

5 1. 2. 3. 4. 5. 6.

CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Reconnect all harness connectors. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode, and the trigger point is adjusted to 100%. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)” in item selection. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen.

GI MA EM LC

FE SEF646Y

7. Check the following. 쐌 “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:

CL MT AT TF PD

SEF217YA

쐌 “HO2S1 (B1)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)” voltage never exceeds 1.0V.

AX SU BR ST RS

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BT HA

OK or NG

SC EL

OK

䊳

GO TO 7.

NG

䊳

Replace heated oxygen sensor 1.

EC-461

IDX

DTC P1144 HO2S1

KA24DE

Diagnostic Procedure (Cont’d)

6

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Reconnect all harness connectors. 2. Start engine and warm it up to normal operating temperature. 3. Set voltmeter probes between ECM terminal 50 (Heated oxygen sensor 1 signal) and engine ground.

AEC873A

4. Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than five times within 10 seconds. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 쐌 The maximum voltage is over 0.6V at least one time. 쐌 The minimum voltage is below 0.3V at least one time. 쐌 The voltage never exceeds 1.0V. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace heated oxygen sensor 1.

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. Refer to “Wiring Diagram”, EC-233, for circuit. 䊳

INSPECTION END

EC-462

DTC P1146 HO2S2

KA24DE Component Description

Component Description

SEF327R

NGEC0144

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

GI MA EM LC

CONSULT-II Reference Value in Data Monitor Mode

NGEC0145

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

FE

0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) 쐌 Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

CL

LEAN +, RICH

ECM Terminals and Reference Value

NGEC0146

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. 56

WIRE COLOR

OR

MT AT TF

ITEM

CONDITION

Heated oxygen sensor 2

DATA (DC Voltage)

[Engine is running] 쐌 After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 3,000 rpm quickly

On Board Diagnosis Logic

NGEC0147

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the minimum voltage of the sensor is sufficiently low during various driving conditions such as fuel-cut.

PD AX SU BR ST RS

SEF304U

DTC No. P1146

Malfunction is detected when ...

Check Items (Possible Cause)

쐌 The minimum voltage from the sensor does not reach the 쐌 Harness or connectors specified voltage. (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 2 쐌 Fuel pressure 쐌 Injectors

BT HA SC EL

EC-463

IDX

DTC P1146 HO2S2

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEC773C

SEC774C

NGEC0148

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. TESTING CONDITION: Open engine hood before conducting following procedure With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Make sure the “COOLANT TEMP/S” is more then 70°C (158°F). 6) Select “HO2S2 (B1) P1146”, of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 7) Start engine and follow the instructions of CONSULT-II. 8) Make sure the “OK” is displayed after touching “SELF-DIAG RESULTS”. If NG is displayed, refer to “Diagnostic Procedure”, EC-467. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. a) Stop engine and cool down “COOLANT TEMP/S” to less then 70°C (158°F). b) Turn ignition switch ON. c) Select “DATA MONITOR” mode with CONSULT-II. d) Start engine. e) Perform from step 6) again when the “COOLANT TEMP/S” reach to 70°C (158°F).

SEC775C

EC-464

DTC P1146 HO2S2

KA24DE Overall Function Check

Overall Function Check

AEC874A

=NGEC0149

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 56 (Heated oxygen sensor 2 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 0.54V 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 0.54V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-467.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-465

IDX

DTC P1146 HO2S2

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0150

WEC967

EC-466

DTC P1146 HO2S2

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0151

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

SEF325V

FE 䊳

GO TO 2.

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-467

IDX

DTC P1146 HO2S2

KA24DE

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 “CLEAR”.

SEF215Z

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.

AEC131A

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure 1st trip DTC P0102 is displayed. 6. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-86. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0172. Refer to EC-262.

No

䊳

GO TO 3.

EC-468

DTC P1146 HO2S2

KA24DE Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect heated oxygen sensor 2 harness connector and ECM harness connector. 3. Check harness continuity between ECM terminal 56 and terminal 1.

GI MA EM LC

SEF157V

Continuity should exist. 4. Check harness continuity between ECM terminal 56 (or terminal 1) and ground. Continuity should not exist. 5. Also check harness for short to ground and short to power.

FE CL

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

MT AT

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness for open or short between heated oxygen sensor 2 and ECM 䊳

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 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power.

TF PD AX SU

OK or NG OK (With CONSULT-II)

䊳

GO TO 7.

OK (Without CONSULTII)

䊳

GO TO 8.

NG

䊳

GO TO 6.

6

BR ST RS

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Joint connector-1 쐌 Harness for open or short between heated oxygen sensor 2 and engine ground 䊳

Repair open circuit or short to power in harness or connectors.

BT HA SC EL

EC-469

IDX

DTC P1146 HO2S2

KA24DE

Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4. 5.

CHECK HEATED OXYGEN SENSOR 2 With CONSULT-II Reconnect all harness connectors. 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%.

SEF662Y

“HO2S2 (B1)” should be above 0.56V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.54V at least once when the “FUEL INJECTION” is −25%. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

SEF244Y

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace heated oxygen sensor 2.

EC-470

DTC P1146 HO2S2

KA24DE Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without CONSULT-II Reconnect all harness connectors. 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. Set voltmeter probes between ECM terminals 56 (Heated oxygen sensor 2 signal) and ground.

GI MA EM LC

FE AEC874A

5. 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 0.56V at least once. If the voltage is above 0.56V at step 4, step 5 is not necessary. 6. Check the voltage when revving up to 5,000 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 0.54V at least once. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace heated oxygen sensor 2.

9

CL MT AT TF PD AX

CHECK SHIELD CIRCUIT

SU

1. Turn ignition switch OFF. 2. Disconnect harness connectors M58, F28. 3. Check harness continuity between harness connector F28 terminal 4 and ground.

BR ST RS BT SEF698Z

Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect harness connectors.

HA OK or NG

OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

SC EL

EC-471

IDX

DTC P1146 HO2S2

KA24DE

Diagnostic Procedure (Cont’d)

10

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) 쐌 Harness for open or short between harness connector F28 and engine ground 䊳

11

Repair open circuit, short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-472

DTC P1147 HO2S2

KA24DE Component Description

Component Description

SEF327R

NGEC0153

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

GI MA EM LC

CONSULT-II Reference Value in Data Monitor Mode

NGEC0154

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

FE

0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) 쐌 Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

CL

LEAN +, RICH

ECM Terminals and Reference Value

NGEC0155

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. 56

WIRE COLOR

OR

MT AT TF

ITEM

CONDITION

Heated oxygen sensor 2

DATA (DC Voltage)

[Engine is running] 쐌 After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 3,000 rpm quickly

On Board Diagnosis Logic

NGEC0156

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the maximum voltage of the sensor is sufficiently high during various driving conditions such as fuel-cut.

PD AX SU BR ST RS

SEF303U

DTC No. P1147

Malfunction is detected when ... 쐌 The maximum voltage from the sensor does not reach the specified voltage.

Check Items (Possible Cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 2 쐌 Fuel pressure 쐌 Injectors 쐌 Intake air leaks

BT HA SC EL

EC-473

IDX

DTC P1147 HO2S2

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEC776C

SEC777C

NGEC0157

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. TESTING CONDITION: Open engine hood before conducting following procedure With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Make sure the “COOLANT TEMP/S” is more then 70°C (158°F). 6) Select “HO2S1 (B1) P1147”, of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 7) Start engine and follow the instructions of CONSULT-II. 8) Make sure the “OK” is displayed after touching “SELF-DIAG RESULTS”. If NG is displayed, refer to “Diagnostic Procedure”, EC-477. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. a) Stop engine and cool down “COOLANT TEMP/S” to less then 70°C (158°F). b) Turn ignition switch ON. c) Select “DATA MONITOR” mode with CONSULT-II. d) Start engine. e) Perform from step 6) again when the “COOLANT TEMP/S” reach to 70°C (158°F).

SEC778C

EC-474

DTC P1147 HO2S2

KA24DE Overall Function Check

Overall Function Check

AEC874A

=NGEC0158

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 56 (Heated oxygen sensor 2 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 0.56V 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 above 0.56V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-477.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-475

IDX

DTC P1147 HO2S2

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0159

WEC967

EC-476

DTC P1147 HO2S2

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0160

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

SEF325V

FE 䊳

GO TO 2.

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-477

IDX

DTC P1147 HO2S2

KA24DE

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 “CLEAR”.

SEF215Z

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.

AEC131A

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure 1st trip DTC P0102 is displayed. 6. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-86. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171. Refer to EC-255.

No

䊳

GO TO 3.

EC-478

DTC P1147 HO2S2

KA24DE Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 2 harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 56 and terminal 1.

GI MA EM LC

SEF157V

Continuity should exist. 3. Check harness continuity between ECM terminal 56 (or terminal 1) and ground. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

CL MT AT

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness for open or short between ECM and heated oxygen sensor 2 䊳

FE

TF

Repair open circuit or short to ground or short to power in harness or connectors.

PD 5

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG

AX SU

OK (With CONSULT-II)

䊳

GO TO 7.

OK (Without CONSULTII)

䊳

GO TO 8.

BR

NG

䊳

GO TO 6.

ST

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Joint connector-1 쐌 Harness for open or short between heated oxygen sensor 2 and engine ground 䊳

RS BT

Repair open circuit or short to power in harness or connectors.

HA SC EL

EC-479

IDX

DTC P1147 HO2S2

KA24DE

Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4. 5.

CHECK HEATED OXYGEN SENSOR 2 With CONSULT-II Reconnect all harness connectors. 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%.

SEF662Y

“HO2S2 (B1)” should be above 0.56V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.54V at least once when the “FUEL INJECTION” is −25%. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

SEF244Y

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace heated oxygen sensor 2.

EC-480

DTC P1147 HO2S2

KA24DE Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without CONSULT-II Reconnect all harness connectors. 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. Set voltmeter probes between ECM terminals 56 (Heated oxygen sensor 2 signal) and ground.

GI MA EM LC

FE AEC874A

5. 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 0.56V at least once. If the voltage is above 0.56V at step 4, step 5 is not necessary. 6. Check the voltage when revving up to 5,000 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 0.54V at least once. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace heated oxygen sensor 2.

9

CL MT AT TF PD AX

CHECK SHIELD CIRCUIT

SU

1. Turn ignition switch OFF. 2. Disconnect harness connectors M58, F28. 3. Check harness continuity between harness connector F28 terminal 4 and ground.

BR ST RS BT SEF698Z

Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect harness connectors.

HA OK or NG

OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

SC EL

EC-481

IDX

DTC P1147 HO2S2

KA24DE

Diagnostic Procedure (Cont’d)

10

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) 쐌 Harness for open or short between harness connector F28 and engine ground 䊳

11

Repair open circuit, short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-482

DTC P1148 CLOSED LOOP CONTROL

KA24DE On Board Diagnosis Logic

On Board Diagnosis Logic ★ The closed loop control has the one trip detection logic. DTC No. P1148

Malfunction is detected when ... 쐌 The closed loop control function does not operate even when vehicle is driving in the specified condition.

NGEC0307

GI Check Items (Possible Cause) 쐌 The heated oxygen sensor 1 circuit is open or shorted. 쐌 Heated oxygen sensor 1 쐌 Heated oxygen sensor 1 heater

MA EM LC

DTC Confirmation Procedure

SEF682Y

NGEC0308

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Never raise engine speed above 3,000 rpm during the “DTC Confirmation Procedure”. If the engine speed limit is exceeded, retry the procedure from step 4. 쐌 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 “DATA MONITOR” mode with CONSULT-II. 3) Hold engine speed at 2,000 rpm and check the following. 쐌 “HO2S1 (B1)” voltage should go above 0.70V at least once. 쐌 “HO2S1 (B1)” voltage should go below 0.21V at least once. If the result is NG, perform “Diagnosis Procedure”, EC-484. If the result is OK, perform the following step. 4) Let engine idle at least 3 minutes. 5) Maintain the following condition at least 50 consecutive seconds. B/FUEL SCHDL

4 msec or more

ENG SPEED

1,800 - 3,000 rpm

Selector lever

Suitable position

VHCL SPEED SE

More than 70 km/h (43 MPH)

6)

During this test, DTC P0134 may be displayed on CONSULT-II screen. If DTC is detected, go to “Diagnostic Procedure”, EC-484.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-483

IDX

DTC P1148 CLOSED LOOP CONTROL

KA24DE

Overall Function Check

Overall Function Check

AEC873A

NGEC0309

Use this procedure to check the overall function of the closed loop control. During this check, a 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 50 (Heated oxygen sensor 1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage should go above 0.70V at least once. 쐌 The voltage should go below 0.21V at least once. 4) If NG, go to “Diagnostic Procedure”, EC-484.

Diagnostic Procedure Refer to “Diagnostic Procedure” for DTC P0133, EC-222.

EC-484

NGEC0310

DTC P1217 ENGINE OVER TEMPERATURE

KA24DE On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1496

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

MA

Check Items (Possible Cause)

Malfunction is detected when ... 쐌 Engine coolant temperature reaches an abnormally high temperature.

GI

쐌 Cooling fan (Crankshaft driven) 쐌 Radiator hose 쐌 Radiator 쐌 Radiator cap 쐌 Water pump 쐌 Thermostat 쐌 Engine coolant temperature sensor For more information, refer to “MAIN 11 CAUSES OF OVERHEATING”, EC-489.

EM LC

FE CAUTION: When a malfunction is indicated, be sure to replace the coolant. Refer to MA-17, “Changing Engine Coolant”. 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-15, “Anti-freeze Coolant Mixture Ratio”. 2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.

Overall Function Check

SEF621W

NGEC1497

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. 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-486. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-486.

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-485

IDX

DTC P1217 ENGINE OVER TEMPERATURE

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1498

CHECK COOLING SYSTEM FOR LEAK

Apply pressure to the cooling system with a tester, and check if the pressure drops. Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage.

SLC754A

Pressure should not drop. OK or NG OK

䊳

GO TO 2.

NG

䊳

Check the following for leak. 쐌 Hose 쐌 Radiator 쐌 Water pump Refer to LC-12, “Water Pump”.

2

CHECK RADIATOR CAP

Apply pressure to cap with a tester.

SLC755A

Radiator cap relief pressure: 78 - 98 kPa (0.8 - 1.0 kg/cm2, 11 - 14 psi) OK or NG OK

䊳

GO TO 3.

NG

䊳

Replace radiator cap.

EC-486

DTC P1217 ENGINE OVER TEMPERATURE

KA24DE

Diagnostic Procedure (Cont’d)

3

CHECK THERMOSTAT

1. Check valve seating condition at normal room temperatures. It should seat tightly. 2. Check valve opening temperature and valve lift.

GI MA EM LC

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-13, “Thermostat”. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace thermostat

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-487

IDX

DTC P1217 ENGINE OVER TEMPERATURE

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

SEF152P



MTBL0285

SEF012P

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace engine coolant temperature sensor.

5

CHECK COOLING FAN

Refer to LC-16, “Cooling Fan (Crankshaft driven)”. OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace cooling fan.

6

CHECK MAIN 11 CAUSES

If the cause cannot be isolated, go to “MAIN 11 CAUSES OF OVERHEATING”, EC-489. 䊳

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

EC-488

DTC P1217 ENGINE OVER TEMPERATURE

KA24DE

Diagnostic Procedure (Cont’d)

3.

systems for leaks by listening for noise or visually inspecting the components. Allow engine to cool and visually check for oil and coolant leaks. Then, perform “OVERALL FUNCTION CHECK”.

GI MA EM LC

Main 11 Causes of Overheating Engine

Step

OFF

1

Inspection item 쐌 쐌 쐌 쐌

Blocked Blocked Blocked Blocked

radiator condenser radiator grille bumper

Equipment

Standard

쐌 Visual

No blocking

NGEC1499

Reference page —

FE

2

쐌 Coolant mixture

쐌 Coolant tester

50 - 50% coolant mixture See MA-13, “RECOMMENDED FLUIDS AND LUBRICANTS”.

3

쐌 Coolant level

쐌 Visual

Coolant up to MAX level in reservoir tank and radiator filler neck

See MA-17, “Changing Engine Coolant”.

4

쐌 Radiator cap

쐌 Pressure tester

78 - 98 kPa (0.8 - 1.0 kg/cm2, 11 - 14 psi) 59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi) (Limit)

See LC-11, “System Check”.

MT AT TF PD

2

5

쐌 Coolant leaks

쐌 Visual

No leaks

See LC-11, “System Check”.

ON*2

6

쐌 Thermostat

쐌 Touch the upper and lower radiator hoses

Both hoses should be hot

See LC-13, “Thermostat” and LC-14, “Radiator”.

OFF

7

쐌 Combustion gas leak

쐌 Color checker chemical tester 4 Gas analyzer

Negative

—

ON*3

8

쐌 Coolant temperature gauge

쐌 Visual

Gauge less than 3/4 when driving

—

쐌 Coolant overflow to reservoir tank

쐌 Visual

No overflow during driving and idling

See MA-17, “Changing Engine Coolant”.

ON*

CL

AX SU BR ST

OFF*4

9

쐌 Coolant return from 쐌 Visual reservoir tank to radiator

Should be initial level in reservoir tank

See MA-16, “ENGINE MAINTENANCE”.

OFF

10

쐌 Cylinder head

0.1 mm (0.004 in) Maximum distortion (warping)

See EM-31, “Inspection”.

BT

11

쐌 Cylinder block and pis- 쐌 Visual tons

No scuffing on cylinder walls or piston

See EM-45, “Inspection”.

HA

쐌 Straight gauge feeler gauge

*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 LC-17, “OVERHEATING CAUSE ANALYSIS”.

EC-489

RS

SC EL IDX

DTC P1336 CKP SENSOR (OBD)

KA24DE

Component Description

Component Description

SEF956N

NGEC0327

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.

SEF335V

ECM Terminals and Reference Value

NGEC0328

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. 43

B/W

ITEM

Sensors’ ground

CONDITION [Engine is running] 쐌 Warm-up condition 쐌 Idle speed

DATA (DC Voltage)

Approximately 0V Approx. 0V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

47

L

Crankshaft position sensor (OBD)

Approx. 0V

[Engine is running] 쐌 Engine speed is 2,000 rpm

EC-490

DTC P1336 CKP SENSOR (OBD)

KA24DE On Board Diagnosis Logic

On Board Diagnosis Logic DTC No. P1336

Malfunction is detected when ... 쐌 A chipping of the flywheel or drive plate gear tooth (cog) is detected by the ECM.

NGEC0329

GI

Check Items (Possible Cause) 쐌 Harness or connectors 쐌 Crankshaft position sensor (OBD) 쐌 Drive plate/Flywheel

MA EM LC

DTC Confirmation Procedure

SEF058Y

NGEC0330

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 2 minutes at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-493. With GST Follow the procedure “With CONSULT-II”.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-491

IDX

DTC P1336 CKP SENSOR (OBD)

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0331

WEC778

EC-492

DTC P1336 CKP SENSOR (OBD)

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0332

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws. 䊳

2

MA

GO TO 2.

EM

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.

LC

FE CL SEF335V

2. Check continuity between ECM terminal 47 and terminal 2.

MT AT TF PD SEF175V

Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

SU BR

DETECT MALFUNCTIONING PART

ST

Check the following. 쐌 Harness connectors E202, E32 쐌 Harness connectors E41, F25 쐌 Harness for open or short between crankshaft position sensor (OBD) and ECM 䊳

AX

Repair open circuit or short to ground or short to power in harness or connectors.

RS BT HA SC EL

EC-493

IDX

DTC P1336 CKP SENSOR (OBD)

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK GROUND CIRCUIT

1. Reconnect ECM harness connectors. 2. Check harness continuity between crankshaft position sensor (OBD) terminal 1 and engine ground. Refer to the wiring diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E202, E32 쐌 Harness connectors E41, F25 쐌 Harness for open or short between crankshaft position sensor (OBD) and ECM 䊳

6

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK SHIELD CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect harness connectors E202, E32. 3. Check harness continuity between harness connector E32 terminal 2 and ground.

SEF552V

Continuity should exist 4. Also check harness for short to power. 5. Then reconnect harness connectors. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E41, F25 쐌 Joint connector-1 (Refer to “HARNESS LAYOUT”, EL-250.) 쐌 Harness for open or short between harness connector E32 and engine ground 䊳

8

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK IMPROPER INSTALLATION

Loosen and retighten the fixing bolt of the crankshaft position sensor (OBD). Then retest. Trouble is not fixed.

䊳

GO TO 9.

EC-494

DTC P1336 CKP SENSOR (OBD)

KA24DE Diagnostic Procedure (Cont’d)

9

CHECK 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.

GI MA EM LC

SEF960N

FE

5. Check resistance as shown in the figure.

CL MT AT TF SEF231W

Resistance: Approximately 512 - 632Ω [at 20°C (68°F)] OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace crankshaft position sensor (OBD).

10

PD AX SU

CHECK GEAR TOOTH

Visually check for chipping flywheel or drive plate gear tooth (cog). OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace the flywheel or drive plate.

11

CHECK INTERMITTENT INCIDENT

BR ST RS

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

BT HA SC EL

EC-495

IDX

DTC P1400 EGRC-SOLENOID VALVE

KA24DE

Component Description

Component Description

NGEC0334

The EGRC-solenoid valve responds to signals from the ECM. When the ECM sends an OFF signal, the vacuum signal passes through the solenoid valve. The signal then reaches the EGR valve. When the ECM sends an ON signal, a plunger will then move to cut the vacuum signal from the throttle body to the EGR valve.

SEF240PD

CONSULT-II Reference Value in Data Monitor Mode

NGEC0335

Specification data are reference values. MONITOR ITEM

CONDITION 쐌 쐌 쐌 쐌

EGRC SOL/V

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” (A/T models) No-load

SPECIFICATION

Idle

ON

Rev engine up from idle to 3,000 rpm quickly.

OFF

ECM Terminals and Reference Value

NGEC0336

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.

103

WIRE COLOR

G/W

ITEM

EGRC-solenoid valve

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

0 - 1V

[Engine is running] 쐌 Warm-up condition 쐌 M/T models: Lift up drive wheels and shift to 1st gear position. 쐌 Rev engine up from 2,000 to 4,000 rpm.

BATTERY VOLTAGE (11 - 14V)

On Board Diagnosis Logic DTC No. P1400

Malfunction is detected when ... 쐌 The improper voltage signal is sent to ECM through EGRC-solenoid valve.

EC-496

Check Items (Possible Cause) 쐌 Harness or connectors (The EGRC-solenoid valve circuit is open or shorted.) 쐌 EGRC-solenoid valve

NGEC0337

DTC P1400 EGRC-SOLENOID VALVE

KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

SEF174Y

NGEC0338

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. TESTING CONDITION: Always perform at a temperature above 0°C (32°F). With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Maintain the following conditions for at least 5 consecutive seconds. ENG SPEED

Less than 3,000 rpm

B/FUEL SCHDL

Less than 12.6 msec

VHCL SPEED SE

Suitable speed

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-499. With GST 쐌 Follow the procedure with “CONSULT-II”.

SEF201Y

SEF242V

MA EM LC

FE

4)

Overall Function Check

GI

NGEC0521

Use this procedure to check the overall function of the EGR temperature sensor. 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 103 and ground at idle. Voltage: 0 - 1V 3) Check that the voltage changes to battery voltage and returns to 0 - 1V when revving the engine from idle to 3,000 rpm quickly. 4) If NG, go to “Diagnostic Procedure”, EC-499.

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-497

IDX

DTC P1400 EGRC-SOLENOID VALVE

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0339

WEC118A

EC-498

DTC P1400 EGRC-SOLENOID VALVE

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0340

CHECK EGRC-SOLENOID VALVE

GI

With CONSULT-II 1. Turn ignition switch ON. 2. Turn EGRC-solenoid valve “ON” and “OFF” in “ACTIVE TEST” mode with CONSULT-II and check operating sound.

MA EM LC

SEF716Z

Without CONSULT-II 1. Start engine and rev engine up to 3,000 rpm quickly. 2. When disconnecting and reconnecting the EGRC-solenoid valve harness connector, make sure that the EGRC-solenoid valve makes operating sound. (The DTC or the 1st trip DTC for the EGRC-solenoid valve will be displayed, however, ignore it.)

FE CL MT

OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

GO TO 2.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-499

IDX

DTC P1400 EGRC-SOLENOID VALVE

KA24DE

Diagnostic Procedure (Cont’d)

2

CHECK POWER SUPPLY

1. Turn ignition switch OFF. 2. Disconnect EGRC-solenoid valve harness connector.

SEF336V

3. Turn ignition switch ON. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF192V

Voltage: Battery voltage OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M59, F27 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between EGRC-solenoid valve and 10A fuse 䊳

Repair harness or connectors.

EC-500

DTC P1400 EGRC-SOLENOID VALVE

KA24DE Diagnostic Procedure (Cont’d)

4

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 103 and terminal 1.

GI MA EM LC

SEF243V

FE

Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

GO TO 5.

CL MT AT

5

DETECT MALFUNCTIONING PART

Check the harness for open or short between EGRC-solenoid valve and ECM. 䊳

TF

Repair open circuit or short to ground or short to power in harness or connectors.

PD 6

CHECK EGRC-SOLENOID VALVE

With CONSULT-II Check air passage continuity. Perform “EGRC SOLENOID VALVE” in “ACTIVE TEST” mode.

AX SU BR ST RS SEC752C

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace EGRC-solenoid valve.

BT HA SC EL

EC-501

IDX

DTC P1400 EGRC-SOLENOID VALVE

KA24DE

Diagnostic Procedure (Cont’d)

7

CHECK EGRC-SOLENOID VALVE

Without CONSULT-II Check air passage continuity shown in the figure.

AEC919

MTBL0664

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace EGRC-solenoid valve.

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-502

DTC P1402 EGR FUNCTION

KA24DE Description

Description

NGEC0349

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

NGEC0349S01

GI

Actuator

MA EM

EGR control EGRC-solenoid valve

LC

This system cuts and controls vacuum applied to the EGR valve to suit engine operating conditions. This cut-and-control operation is accomplished through the ECM and the EGRC-solenoid valve. When the ECM detects any of the following conditions, current through the solenoid valve is cut. This causes the vacuum to be cut. The EGR valve remains closed. 쐌 Low engine coolant temperature 쐌 Engine starting 쐌 High-speed engine operation 쐌 Engine idling 쐌 Excessively high engine coolant temperature 쐌 Mass air flow sensor malfunction

FE CL MT AT TF PD AX

SEF641Q

SU BR ST RS

COMPONENT DESCRIPTION Exhaust Gas Recirculation (EGR) Valve

NGEC0349S02

BT

NGEC0349S0201

The EGR valve controls the amount of exhaust gas routed to the intake manifold. Vacuum is applied to the EGR valve in response to throttle valve opening. The vacuum controls the movement of a taper valve connected to the vacuum diaphragm in the EGR valve.

HA SC EL

SEF783K

EC-503

IDX

DTC P1402 EGR FUNCTION

KA24DE

Description (Cont’d)

EGRC-solenoid Valve

NGEC0349S0202

The EGRC-solenoid valve responds to signals from the ECM. When the ECM sends an OFF signal, the vacuum signal passes through the solenoid valve. A plunger will then move to cut the vacuum signal (from the throttle body to the EGR valve). When the ECM sends an ON signal, a plunger will then move to cut the vacuum signal from the throttle body to the EGR valve.

SEF240PD

On Board Diagnosis Logic

NGEC0350

If EGR temperature sensor detects EGR flow under the condition that does not call for EGR, a high-flow malfunction is diagnosed. NOTE: Diagnosis for this DTC will occur when engine coolant temperature is approx. 50 to 60°C (122 to 140°F). Therefore, it will be better to turn ignition switch “ON” (Start engine) at the engine coolant temperature below 40°C (104°F) when starting DTC confirmation procedure. SEF073P

DTC No. P1402

Malfunction is detected when ... 쐌 EGR flow is detected under conditions that do not call for 쐌 EGR. 쐌 쐌 쐌

Check Items (Possible Cause) EGRC-solenoid valve EGR valve leaking or stuck open EGR temperature sensor EGRC-BPT valve

DTC Confirmation Procedure

PEF803W

NGEC0351

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. TESTING CONDITION: 쐌 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 60°C (14 to 140°F)* EGR TEMP SEN: Less than 3.7V 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.

SEF202Y

EC-504

DTC P1402 EGR FUNCTION

KA24DE DTC Confirmation Procedure (Cont’d)

1) 2) 3) 4)

SEF203Y

5)

1) 2) 3) SEF204Y

4) 5) 6) 7) 8)

With CONSULT-II Turn ignition switch OFF and wait at least 5 seconds, then turn ignition switch ON. Select “EGR SYSTEM P1402” of “EGR SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Follow instruction of CONSULT-II. Start engine and let it idle until “TESTING” on CONSULT-II screen is turned to “COMPLETED”. (It will take 60 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-507. With GST Turn ignition switch ON and select “MODE 1” with GST. Check that engine coolant temperature is within the range of −10 to 35°C (14 to 95°F). Check that voltage between ECM terminal 63 (EGR temperature sensor signal) and ground is less than 4.8V. Start engine and let it idle for at least 60 seconds. Stop engine. Perform from step 1 to 4. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-507.

GI MA EM LC

FE CL MT AT TF PD AX

SEF236Y

SU BR ST RS BT HA SC EL

EC-505

IDX

DTC P1402 EGR FUNCTION

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0352

LEC114A

EC-506

DTC P1402 EGR FUNCTION

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0353

CHECK VACUUM HOSE

GI

Check vacuum hose for clogging, cracks or improper connection. Refer to “Vacuum Hose Drawing”, EC-33.

MA EM LC

SEF109L

FE

OK or NG OK (With CONSULT-II)

䊳

GO TO 2.

OK (Without CONSULTII)

䊳

GO TO 3.

NG

䊳

Repair or replace vacuum hose.

2

CL MT AT

CHECK EGRC-SOLENOID VALVE CIRCUIT

With CONSULT-II 1. Turn ignition switch ON. 2. Turn EGRC-solenoid valve “ON” and “OFF” in “ACTIVE TEST” mode with CONSULT-II and check operating sound.

TF PD AX SU

SEF716Z

BR

Clicking noise should be heard. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

3 1. 2. 3. 4.

ST RS

CHECK EGRC-SOLENOID VALVE CIRCUIT Without CONSULT-II Turn ignition switch OFF. Disconnect EGRC-solenoid valve harness connector. Turn ignition switch ON. Check operating sound of the solenoid valve when disconnecting and reconnecting EGRC-solenoid valve harness connector. (The DTC or the 1st trip DTC for the EGRC-solenoid valve will be displayed, however, ignore it.)

BT HA SC

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 4.

EL

EC-507

IDX

DTC P1402 EGR FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M59, F27 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between fuse block and EGRC-solenoid valve 쐌 Harness for open or short between ECM and EGRC-solenoid valve OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair open circuit or short to power in harness or connector.

5

CHECK EGRC-SOLENOID VALVE

With CONSULT-II Check air passage continuity. Perform “EGRC SOLENOID VALVE” in “ACTIVE TEST” mode.

SEC752C

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace EGRC-solenoid valve.

EC-508

DTC P1402 EGR FUNCTION

KA24DE Diagnostic Procedure (Cont’d)

6

CHECK EGRC-SOLENOID VALVE

Without CONSULT-II Check air passage continuity shown in the figure.

GI MA EM LC

AEC919

FE CL MTBL0664

MT

OK or NG

AT

OK

䊳

GO TO 7.

NG

䊳

Replace EGRC-solenoid valve.

TF 7

CHECK EGR VALVE

쐌 Apply vacuum to EGR vacuum port with a hand vacuum pump.

PD AX SU BR MEF137D

EGR valve spring should lift. 쐌 Check for sticking. OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace EGR valve.

ST RS BT HA SC EL

EC-509

IDX

DTC P1402 EGR FUNCTION

KA24DE

Diagnostic Procedure (Cont’d)

8

CHECK EGRC-BPT VALVE

1. Plug one of two ports of EGRC-BPT valve. 2. Vacuum from the other port and check for leakage while applying a pressure above 0.981 kPa (100 mmH2O, 3.94 inH2O) from under EGRC-BPT valve.

SEF083P

3. If a leakage is noted, replace the valve. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace EGRC-BPT valve.

EC-510

DTC P1402 EGR FUNCTION

KA24DE Diagnostic Procedure (Cont’d)

9

CHECK EGR TEMPERATURE SENSOR

Check resistance change and resistance value.

GI MA EM LC SEF643Q



FE CL MTBL0549

MT AT TF PD AX SU BR ST SEF068XB

OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EGR temperature sensor.

10

RS BT HA

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

SC

INSPECTION END

EL

EC-511

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Description

Description

NGEC0359

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

Throttle position switch

Closed throttle position

Heated oxygen sensor 1

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Fuel tank temperature sensor

Fuel temperature in fuel tank

Vehicle speed sensor

Vehicle speed

NGEC0359S01

ECM function

Actuator

EVAP canEVAP canister purge volume ister purge control solenoid valve flow control

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

NGEC0359S02

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

NGEC0360

Specification data are reference values. MONITOR ITEM

PURG VOL C/V

CONDITION 쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch “OFF” Shift lever: “N” No-load

SPECIFICATION

Idle (Vehicle stopped)

0%

2,000 rpm (200 seconds after starting engine)

—

EC-512

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE ECM Terminals and Reference Value

ECM Terminals and Reference Value

NGEC0361

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

4

LG/R

ITEM

CONDITION

GI MA

DATA (DC Voltage)

EM ECM relay (Self-shutoff)

[Engine is running] [Ignition switch “OFF”] 쐌 For a few seconds after turning ignition switch “OFF”

0 - 1V

[Ignition switch “OFF”] 쐌 A few seconds passed after turning ignition switch “OFF”

BATTERY VOLTAGE (11 - 14V)

LC

BATTERY VOLTAGE (11 - 14V)

FE CL

[Engine is running] 쐌 Idle speed

MT 5

R/Y

EVAP canister purge volume control solenoid valve

AT

BATTERY VOLTAGE (11 - 14V)

TF [Engine is running] 쐌 Engine speed is 2,000 rpm

PD AX

67

B/P

72

B/P

117

B/P

Power supply for ECM

[Ignition switch “ON”]

BATTERY VOLTAGE (11 - 14V)

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

On Board Diagnosis Logic DTC No. P1444

Malfunction is detected when ... The canister purge flow is detected during the specified driving conditions, even when EVAP canister purge volume control solenoid valve is completely closed.

SU BR NGEC0362

Check Items (Possible Cause) 쐌 EVAP control system pressure sensor 쐌 EVAP canister purge volume control solenoid valve (The valve is stuck open.) 쐌 EVAP canister vent control valve 쐌 EVAP canister 쐌 Hoses (Hoses are connected incorrectly or clogged.)

ST RS BT HA SC EL

EC-513

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC0363

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. TESTING CONDITION: Always perform test at a temperature of 5°C (41°F) or more.

SEF194Y

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Check that “FUEL T/TMP SE” is 0°C (32°F) or more. 6) Select “PURG VOL C/V P1444” of “EVAP SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. 7) Touch “START”. 8) Start engine and let it idle until “TESTING” on CONSULT-II changes to “COMPLETED”. (It will take for at least 10 seconds.) If “TESTING” is not displayed after 5 minutes, retry from step 2. 9) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-516. With GST Follow the procedure “With CONSULT-II”.

SEF205Y

SEF206Y

SEF237Y

EC-514

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Wiring Diagram

Wiring Diagram

NGEC0504

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC974

EC-515

EL IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Diagnostic Procedure

Diagnostic Procedure 1

=NGEC0364

CHECK POWER SUPPLY

1. Turn ignition switch OFF. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector.

SEF339V

3. Turn ignition switch ON. 4. Check voltage between terminal 2 and engine ground with CONSULT-II or tester.

SEF192V

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM relay 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM 䊳

Repair harness or connectors.

EC-516

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE 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 5 and terminal 1.

GI MA EM LC

SEF193V

Continuity should exist. 4. Aslo check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

FE CL MT

DETECT MALFUNCTIONING PART

Check the harness for open or short between EVAP canister purge volume control solenoid valve and ECM. 䊳

AT

Repair open circuit or short to ground or short to power in harness or connectors.

TF PD AX SU BR ST RS BT HA SC EL

EC-517

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Diagnostic Procedure (Cont’d)

5

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

1. Remove EVAP control system pressure sensor with its harness connector connected.

SEF341V

2. Remove hose from EVAP control system pressure sensor. 3. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. 4. Check output voltage between ECM terminal 62 and engine ground.

SEF198V

MTBL0295

CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −20 kPa (−150 mmHg, −5.91 inHg) or over 20 kPa (150 mmHg, 5.91 inHg) of pressure.

SEF799W

쐌 Never apply force to the air hole protector of the sensor, if equipped. 쐌 Discard any EVAP control system pressure 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. OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

Replace EVAP control system pressure sensor.

EC-518

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Diagnostic Procedure (Cont’d)

6

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

GI MA EM LC

SEF801Y

FE

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

CL MT

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

AT TF PD AX SEF334X

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

SU BR ST RS BT

SEF335X

HA

OK or NG

SC

OK

䊳

GO TO 8.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EL

EC-519

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Diagnostic Procedure (Cont’d)

8

CHECK EVAP CANISTER VENT CONTROL VALVE-I

1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted.

SEF337X

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace EVAP canister vent control valve.

9 1. 2. 3. 4.

CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II Reconnect harness connectors disconnected. Turn ignition switch “ON”. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time.

SEF803Y

Without CONSULT-II Check air passage continuity and operation delay time under the following conditions.

SEF339X

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

EC-520

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Diagnostic Procedure (Cont’d)

10

CHECK EVAP CANISTER VENT CONTROL VALVE-III

1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 13 again.

GI

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP canister vent control valve.

11

MA EM

CHECK RUBBER TUBE

Check for obstructed water separator and rubber tube connected to EVAP canister vent control valve and clean the rubber tube using air blower. Check water separator. 1. Check visually for insect nests in the water separator air inlet. 2. Check visually for cracks or flaws in the appearance. 3. Check visually for cracks or flaws in the hose. 4. Check that A and C are not clogged by blowing air into B with A, and then C plugged.

LC

FE CL MT AT

SEF829T

5. In case of NG in items 2 - 4, replace the parts. 쐌 Do not disassemble water separator.

PD

OK or NG OK

䊳

GO TO 12.

NG

䊳

Clean, repair or replace rubber tube and/or water separator.

12

TF

AX

CHECK IF EVAP CANISTER SATURATED WITH WATER

SU

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

BR ST RS BT SEF596U

Yes or No Yes

䊳

GO TO 13.

No

䊳

GO TO 15.

HA SC EL

EC-521

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE KA24DE Diagnostic Procedure (Cont’d)

13

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 15.

NG

䊳

GO TO 14.

14

DETECT MALFUNCTIONING PART

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

15

Repair hose or replace EVAP canister.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-522

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Component Description

Component Description

SEF378Q

NGEC0366

The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid (the EVAP canister vent control valve) responds to signals from the ECM. When the ECM sends an ON signal, the coil in the solenoid valve is energized. A plunger will then move to seal the canister vent. The ability to seal the vent is necessary for the on board diagnosis of other evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis.

GI MA EM LC

FE CL MT

SEF143S

CONSULT-II Reference Value in Data Monitor Mode

AT

CONDITION

TF

NGEC0367

Specification data are reference values. MONITOR ITEM

SPECIFICATION

쐌 Ignition switch: ON

VENT CONT/V

OFF

ECM Terminals and Reference Value

PD NGEC0368

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. 108

WIRE COLOR R/G

ITEM EVAP canister vent control valve

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

[Ignition switch “ON”]

On Board Diagnosis Logic DTC No. P1446

Malfunction is detected when ... 쐌 EVAP canister vent control valve remains closed under specified driving conditions.

AX SU BR ST

NGEC0369

Check Items (Possible Cause) 쐌 EVAP canister vent control valve 쐌 EVAP control system pressure sensor and the circuit 쐌 Blocked rubber tube to EVAP canister vent control valve 쐌 Water separator 쐌 EVAP canister is saturated with water.

RS BT HA SC EL

EC-523

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF189Y

SEF196V

NGEC0370

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 5 seconds before conducting the next test. TESTING CONDITION: Always perform at a temperature above 0°C (32°F). With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Check that “FUEL T/TMP SE” is 0°C (32°F) or more. 6) Drive vehicle at a speed of approximately 80 km/h (50 MPH) for a maximum of 15 minutes. 7) If 1st trip DTC is detected, go to “Diagnostic Procedure” on EC-525. NOTE: If a malfunction exists, NG result may be displayed quicker. With GST 1) Start engine and warm it up to normal operating temperature. 2) Check that voltage between ECM terminal 60 (fuel tank temperature sensor signal) and ground is less than 4.2V. 3) Drive vehicle at a speed of approximately 80 km/h (50 MPH) for 15 minutes. 4) Select “MODE 7” with GST. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure” on EC-525.

EC-524

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

=NGEC0371

CHECK RUBBER TUBE FOR CLOGGING

GI

Check obstructed water separator and rubber tube to EVAP canister vent control valve and clean the rubber tube using air blower. Check water separator. 1. Check visually for insect nests in the water separator air inlet. 2. Check visually for cracks or flaws in the appearance. 3. Check visually for cracks or flaws in the hose. 4. Check that A and C are not clogged by blowing air into B with A, and then C plugged.

MA EM LC

FE CL SEF829T

5. In case of NG in items 2 - 4, replace the parts. 쐌 Do not disassemble water separator.

MT OK or NG

AT

OK

䊳

GO TO 2.

NG

䊳

Clean, repair or replace rubber tube and/or water separator.

TF 2

CHECK EVAP CANISTER VENT CONTROL VALVE-I

PD

1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted.

AX SU BR SEF337X

ST

OK or NG

RS

OK

䊳

GO TO 3.

NG

䊳

Replace EVAP canister vent control valve.

BT HA SC EL

EC-525

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure (Cont’d)

3 1. 2. 3. 4.

CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II Reconnect harness connectors disconnected. Turn ignition switch “ON”. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time.

SEF991Y

Without CONSULT-II Check air passage continuity and operation delay time under the following conditions.

SEF339X

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

CHECK EVAP CANISTER VENT CONTROL VALVE-III

1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 13 again. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace EVAP canister vent control valve.

EC-526

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure (Cont’d)

5

CHECK IF EVAP CANISTER IS SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

GI MA EM LC

SEF596U

Yes or No Yes

䊳

GO TO 6.

No

䊳

GO TO 8.

6

CL

CHECK EVAP CANISTER

Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

MT AT TF

DETECT MALFUNCTIONING PART

PD

Check the following. 쐌 Visually check the EVAP canister for damage. 쐌 Check hose connection between EVAP canister and water separator for clogging and poor connection. 䊳

FE

AX

Repair hose or replace EVAP canister.

SU 8

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

Check disconnection or improper connection of hose connected to EVAP control system pressure sensor.

BR

OK or NG OK

䊳

GO TO 9.

NG

䊳

Install hose properly or replace it.

9

ST RS

CHECK HARNESS CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector. 2. Check harness connector for water. Water should not exist. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

BT HA SC EL

EC-527

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure (Cont’d)

10

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR AND CIRCUIT

Refer to “DTC Confirmation Procedure”, EC-382. OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP control system pressure sensor and repair or replace harness and connector.

11

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-528

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Component Description

Component Description

SEF378Q

NGEC0379

NOTE: If DTC P1448 is displayed with P0442, perform trouble diagnosis for DTC P1448 first. The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid (the EVAP canister vent control valve) responds to signals from the ECM. When the ECM sends an ON signal, the coil in the solenoid valve is energized. A plunger will then move to seal the canister vent. The ability to seal the vent is necessary for the on board diagnosis of other evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis.

GI MA EM LC

FE CL MT

SEF143S

CONSULT-II Reference Value in Data Monitor Mode

AT

CONDITION

TF

NGEC0380

Specification data are reference values. MONITOR ITEM

SPECIFICATION

쐌 Ignition switch: ON

VENT CONT/V

OFF

ECM Terminals and Reference Value

PD NGEC0381

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. 108

WIRE COLOR R/G

ITEM EVAP canister vent control valve

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

[Ignition switch “ON”]

On Board Diagnosis Logic DTC No. P1448

Malfunction is detected when ... 쐌 EVAP canister vent control valve remains opened under specified driving conditions.

AX SU BR ST

NGEC0382

Check Items (Possible Cause) 쐌 EVAP canister vent control valve 쐌 EVAP control system pressure sensor 쐌 Blocked rubber tube to EVAP canister vent control valve 쐌 Water separator 쐌 EVAP canister is saturated with water. 쐌 Vacuum cut valve

RS BT HA SC EL

EC-529

IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

KA24DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEC760C

SEC761C

COOLAN TEMP/S

0 - 70°C (32 - 158°F)

INT/A TEMP SE

0 - 60°C (32 - 140°F)

5)

SEC762C

SEC763C

NGEC0383

NOTE: 쐌 If DTC P1448 is displayed with P0442, perform trouble diagnosis for DTC P1448 first. 쐌 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 TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is less than 3/4 full and vehicle is placed on flat level surface. 쐌 Always perform test at a temperature of 0 to 30°C (32 to 86°F). 쐌 It is better that the fuel level is low. 1) Turn ignition switch ON. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 4) Check that the following conditions are met.

Select “EVAP SML LEAK P0442/P1442” of “EVAP SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. NOTE: 쐌 If the CONSULT-II screen shown at left is displayed, stop the engine and stabilize the vehicle temperature at 25°C (77°F) or cooler. After “FUEL T/TMP SE” becomes less than 30°C (86°F), retest. (Use a fan to reduce the stabilization time.) 쐌 If the engine speed cannot be maintained within the range displayed on CONSULT-II screen, go to “Basic Inspection”, EC-112. 쐌 The engine idle portion of this test (See illustration at left.) will take approximately 5 minutes. 6) Make sure that “OK” is displayed. If “NG” is displayed, go to following step. NOTE: Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. 7) Stop engine and wait at least 5 seconds, then turn “ON”. 8) Disconnect hose from water separator. 9) Select “VENT CONTROL/V” of “ACTIVE TEST” mode with CONSULT-II. 10) Touch “ON” and “OFF” alternately.

EC-530

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

KA24DE

DTC Confirmation Procedure (Cont’d)

11) Make sure of the following. Condition

Air passage continuity between A and B

Touching “ON”

No

Touching “OFF”

Yes

GI MA

If the result is NG, go to “Diagnostic Procedure”, EC-531. If the result is OK, go to “Diagnostic Procedure” for DTC P0442, EC-353.

EM LC

SEF805Y

Overall Function Check

NGEC0384

Use this procedure to check the overall function of the EVAP canister vent control valve circuit. During this check, a DTC might not be confirmed. Without CONSULT-II 1) Disconnect hose from water separator. 2) Disconnect EVAP canister vent control valve harness connector. 3) Verify the following. Condition

Air passage continuity

12V direct current supply between terminals 1 and 2

No

No supply

Yes

AEC783A

FE CL MT AT

If the result is NG, go to “Diagnostic Procedure”, EC-531. If the result is OK, perform trouble diagnosis for DTC P0442. Refer to EC-350.

TF PD AX

Diagnostic Procedure 1

NGEC0385

SU

CHECK RUBBER TUBE

1. Turn ignition switch OFF. 2. Check disconnection or obstruction of rubber tube connected to EVAP canister vent control valve. OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair or clean rubber tube.

BR ST RS BT HA SC EL

EC-531

IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure (Cont’d)

2

CHECK EVAP CANISTER VENT CONTROL VALVE-I

1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted.

SEF337X

OK or NG OK

䊳

GO TO 3.

NG

䊳

Replace EVAP canister vent control valve.

3 1. 2. 3. 4.

CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II Reconnect harness connectors disconnected. Turn ignition switch “ON”. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time.

SEF991Y

Without CONSULT-II Check air passage continuity and operation delay time under the following conditions.

SEF339X

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-532

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK EVAP CANISTER VENT CONTROL VALVE-III

1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 13 again.

GI

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace EVAP canister vent control valve.

5

MA EM

CHECK VACUUM CUT VALVE

LC

Check vacuum cut valve as follows:

FE CL SEF186S

MT AT TF PD AX

SEF379Q

1. 2. 3. 4. 5. 6. 7.

Plug port C and D with fingers. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Open port C and D. Blow air in port A check that air flows freely out of port C. Blow air in port B check that air flows freely out of port D. OK or NG

OK

䊳

GO TO 6.

NG

䊳

Replace vacuum cut valve.

SU BR ST RS BT HA SC EL

EC-533

IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure (Cont’d)

6

CHECK IF EVAP CANISTER IS SATURATED WITH WATER

1. Remove EVAP canister with the vent control valve attached. 2. Check if water will drain from the EVAP canister.

SEF596U

Yes or No Yes

䊳

GO TO 9.

No

䊳

GO TO 7.

7

CHECK EVAP CANISTER

Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

DETECT MALFUNCTIONING PART

Check the following. 1. Visually check the EVAP canister for damage. 2. Check hose connection between EVAP canister and water separator for clogging and poor connection. 3. Check water separator. a. Check visually for insect nests in the water separator air inlet. b. Check visually for cracks or flaws in the appearance. c. Check visually for cracks or flaws in the hose. d. Check that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

e. In case of NG in items 2 - 4, replace the parts. 쐌 Do not disassemble water separator. 䊳

Repair hose or replace EVAP canister or water separator.

EC-534

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

KA24DE

Diagnostic Procedure (Cont’d)

9

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

Check disconnection or improper connection of hose connected to EVAP control system pressure sensor.

GI

OK or NG OK

䊳

GO TO 10.

NG

䊳

Install hose property or replace it.

10

MA EM

CHECK HARNESS CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector. 2. Check harness connector for water. Water should not exist.

LC

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP control system pressure sensor.

11

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

Perform “DTC Confirmation Procedure”, EC-382. OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace EVAP control system pressure sensor and repair or replace harness and connector.

12

CHECK INTERMITTENT INCIDENT

FE CL MT AT TF

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

PD AX SU BR ST RS BT HA SC EL

EC-535

IDX

DTC P1464 FUEL LEVEL SENSOR

KA24DE

Component Description

Component Description

NGEC1036

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

SEF800Z

On Board Diagnostic Logic

NGEC1037

ECM receives two signals from the fuel level sensor. One is fuel level sensor power supply circuit, and the other is fuel level sensor ground circuit. This diagnosis indicates the latter to detect open circuit malfunction. Malfunction is detected when a high voltage from the sensor is sent to ECM.

Possible Cause 쐌

NGEC1038

Fuel level sensor circuit (The fuel level sensor circuit is open or shorted.)

DTC Confirmation Procedure

NGEC1039

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test.

WITH CONSULT-II 1) 2) 3) 4)

NGEC1039S01

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”, EC-538.

WITH GST Follow the procedure “WITH CONSULT-II” above. SEF195Y

EC-536

NGEC1039S02

DTC P1464 FUEL LEVEL SENSOR

KA24DE Wiring Diagram

Wiring Diagram

NGEC1040

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC979

EC-537

EL IDX

DTC P1464 FUEL LEVEL SENSOR

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

CHECK FUEL LEVEL SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 66 and body ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

1. Check the following. 쐌 Harness connectors F36, M81 쐌 Harness connectors M67, B101 쐌 Harness for open and short between ECM and body ground 䊳

3

Replace open circuit or short to power in harness or connectors.

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “Fuel Level Sensor Unit Check”. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace fuel level sensor unit.

4

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. OK or NG 䊳

INSPECTION END

EC-538

=NGEC1041

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

KA24DE Description

Description

NGEC0387

COMPONENT DESCRIPTION

SEF186S

NGEC0387S01

The vacuum cut valve and vacuum cut valve bypass valve are installed in parallel on the EVAP purge line between the fuel tank and the EVAP canister. The vacuum cut valve prevents the intake manifold vacuum from being applied to the fuel tank. The vacuum cut valve bypass valve is a solenoid type valve and generally remains closed. It opens only for on board diagnosis. The vacuum cut valve bypass valve responds to signals from the ECM. When the ECM sends an ON (ground) signal, the valve is opened. The vacuum cut valve is then bypassed to apply intake manifold vacuum to the fuel tank.

EVAPORATIVE EMISSION SYSTEM DIAGRAM

GI MA EM LC

NGEC0387S02

FE CL MT AT TF PD SEF865Z

CONSULT-II Reference Value in Data Monitor Mode

AX SU

NGEC0388

Specification data are reference values. MONITOR ITEM VC/V BYPASS/V

CONDITION

BR

SPECIFICATION

쐌 Ignition switch: ON

OFF

ST

ECM Terminals and Reference Value

NGEC0389

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. 120

WIRE COLOR P/B

ITEM Vacuum cut valve bypass valve

CONDITION

[Ignition switch “ON”]

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

RS BT HA SC EL

EC-539

IDX

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic DTC No. P1490

Malfunction is detected when ... 쐌 An improper voltage signal is sent to ECM through vacuum cut valve bypass valve.

NGEC0390

Check Items (Possible Cause) 쐌 Harness or connectors (The vacuum cut valve bypass valve circuit is open or shorted.) 쐌 Vacuum cut valve bypass valve

DTC Confirmation Procedure

NGEC0391

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. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle.

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-542. With GST Follow the procedure “With CONSULT-II”. 1) 2) 3) 4)

SEF058Y

EC-540

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

KA24DE Wiring Diagram

Wiring Diagram

NGEC0392

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC AEC007B

EC-541

EL IDX

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0393

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

CHECK VACUUM CUT VALVE BYPASS VALVE CIRCUIT

1. Turn ignition switch ON. 2. Perform “VC/V BYPASS/V” in “ACTIVE TEST” mode.

SEF806Y

3. Make sure that clicking sound is heard from the vacuum cut valve bypass valve. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 3.

EC-542

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Diagnostic Procedure (Cont’d)

3

CHECK POWER SUPPLY

1. Turn ignition switch OFF. 2. Disconnect vacuum cut valve bypass valve harness connector.

GI MA EM LC

SEF186S

3. Turn ignition switch ON. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.

FE CL MT AT SEF192V

TF

Voltage: Battery voltage OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

AX

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M67, B101 쐌 Harness connectors B113, C3 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between vacuum cut valve bypass valve and 10A fuse 䊳

PD

SU BR ST

Repair harness or connectors.

RS BT HA SC EL

EC-543

IDX

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Diagnostic Procedure (Cont’d)

5

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 120 and terminal 1.

SEF253V

Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness connectors M67, B101 쐌 Harness connectors B113, C3 쐌 Harness for open or short between vacuum cut valve bypass valve and ECM 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-544

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Diagnostic Procedure (Cont’d)

7

CHECK VACUUM CUT VALVE BYPASS VALVE

With CONSULT-II Check air passage continuity. Perform “VC/V BYPASS/V” in “ACTIVE TEST” mode.

GI MA EM LC

SEF807Y

FE

Without CONSULT-II Check air passage continuity shown in the figure.

CL MT AT TF SEF557Y

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace vacuum cut valve bypass valve.

8

PD AX

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

SU

INSPECTION END

BR ST RS BT HA SC EL

EC-545

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Description

Description

NGEC0395

COMPONENT DESCRIPTION

SEF186S

NGEC0395S01

The vacuum cut valve and vacuum cut valve bypass valve are installed in parallel on the EVAP purge line between the fuel tank and the EVAP canister. The vacuum cut valve prevents the intake manifold vacuum from being applied to the fuel tank. The vacuum cut valve bypass valve is a solenoid type valve and generally remains closed. It opens only for on board diagnosis. The vacuum cut valve bypass valve responds to signals from the ECM. When the ECM sends an ON (ground) signal, the valve is opened. The vacuum cut valve is then bypassed to apply intake manifold vacuum to the fuel tank.

EVAPORATIVE EMISSION SYSTEM DIAGRAM

NGEC0395S02

SEF865Z

CONSULT-II Reference Value in Data Monitor Mode

NGEC0396

Specification data are reference values. MONITOR ITEM VC/V BYPASS/V

CONDITION

SPECIFICATION

쐌 Ignition switch: ON

OFF

ECM Terminals and Reference Value

NGEC0397

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. 120

WIRE COLOR P/B

ITEM Vacuum cut valve bypass valve

CONDITION

[Ignition switch “ON”]

EC-546

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

KA24DE

On Board Diagnosis Logic

On Board Diagnosis Logic DTC No. P1491

Malfunction is detected when ... Vacuum cut valve bypass valve does not operate properly.

NGEC0398

GI

Check Items (Possible Cause) 쐌 쐌 쐌 쐌 쐌 쐌

Vacuum cut valve bypass valve Vacuum cut valve Bypass hoses for clogging EVAP control system pressure sensor EVAP canister vent control valve Hose between fuel tank and vacuum cut valve clogged 쐌 Hose between vacuum cut valve and EVAP canister clogged 쐌 EVAP canister 쐌 EVAP purge port of fuel tank for clogging

MA EM LC

FE CL MT

DTC Confirmation Procedure

SEF210Y

SEF211Y

SEF239Y

NGEC0399

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform test at a temperature of 5 to 30°C (41 to 86°F). 쐌 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. 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Turn ignition switch ON. 2) Start engine and warm it up to normal operating temperature. 3) Turn ignition switch OFF and wait at least 5 seconds. 4) Start engine and let it idle for at least 60 seconds. 5) Select “VC CUT/V BP/V P1491” of “EVAP SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. 6) Touch “START”. 7) 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 at least 30 seconds.) ENG SPEED

More than 1,000 rpm

Selector lever

Suitable position

Vehicle speed

36 - 120 km/h (22 - 75 MPH)

B/FUEL SCHDL

Less than 10 msec

EC-547

AT TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

KA24DE

DTC Confirmation Procedure (Cont’d)

8)

If “TESTING” is not displayed after 5 minutes, retry from step 3. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”.

Overall Function Check

NGEC0400

Use this procedure to check the overall function of vacuum cut valve bypass valve. During this check, the 1st trip DTC might not be confirmed. Without CONSULT-II 1. Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. 2. Apply vacuum to port A and check that there is no suction from port B. 3. Apply vacuum to port B and check that there is suction from port A. 4. Blow air in port B and check that there is a resistance to flow out of port A. 5. Supply battery voltage to the terminal. 6. Blow air in port A and check that air flows freely out of port B. 7. Blow air in port B and check that air flows freely out of port A. 8. If NG, go to “DIAGNOSTIC PROCEDURE” on EC-550.

SEF530Q

EC-548

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

KA24DE Wiring Diagram

Wiring Diagram

NGEC0505

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC AEC007B

EC-549

EL IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0401

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2 1. 2. 3. 4. 5. 6. 7. 8. 9.

CHECK COMPONENT With CONSULT-II Turn ignition switch OFF. Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Turn ignition switch ON. Select “VC/V BYPASS/V” in “ACTIVE TEST” mode with CONSULT-II and touch “ON”. Blow air in port A and check that air flows freely out of port B. Blow air in port B and check that air flows freely out of port A.

SEF808Y

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 5.

EC-550

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Diagnostic Procedure (Cont’d)

3 1. 2. 3. 4. 5. 6. 7. 8. 9.

CHECK COMPONENT Without CONSULT-II Turn ignition switch OFF. Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Disconnect vacuum cut valve bypass valve harness connector. Supply battery voltage to the terminal. Blow air in port A and check that air flows freely out of port B. Blow air in port B and check that air flows freely out of port A.

GI MA EM LC

FE CL MT SEF914U

AT

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 5.

TF PD

4

CHECK EVAP PURGE LINE

1. Check EVAP purge line between EVAP canister and fuel tank for clogging or disconnection. 2. Check EVAP purge port of fuel tank for clogging. 3. Check EVAP canister. Refer to EC-40. OK or NG OK

䊳

GO TO 8.

NG (Step 1)

䊳

Repair it.

NG (Step 2)

䊳

Clean EVAP purge port.

NG (Step 3)

䊳

Replace EVAP canister.

5

AX SU BR

CHECK BYPASS HOSE

ST RS

Check bypass hoses for clogging. OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair or replace hoses.

BT HA SC EL

EC-551

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Diagnostic Procedure (Cont’d)

6

CHECK VACUUM CUT VALVE BYPASS VALVE

With CONSULT-II Check air passage continuity. Perform “VC/V BYPASS/V” in “ACTIVE TEST” mode.

SEF807Y

Without CONSULT-II Check air passage continuity shown in the figure.

SEF557Y

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace vacuum cut valve bypass valve.

EC-552

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Diagnostic Procedure (Cont’d)

7

CHECK VACUUM CUT VALVE

Check vacuum cut valve as follows:

GI MA EM LC SEF186S

FE CL MT SEF379Q

1. 2. 3. 4. 5. 6. 7.

Plug port C and D with fingers. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Open port C and D. Blow air in port A check that air flows freely out of port C. Blow air in port B check that air flows freely out of port D. OK or NG

OK

䊳

GO TO 8.

NG

䊳

Replace vacuum cut valve.

8

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

1. Turn ignition switch OFF. 2. Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair it

AT TF PD AX SU BR ST RS BT HA SC EL

EC-553

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Diagnostic Procedure (Cont’d)

9

CHECK CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

SEF341V

2. Check connectors for water. Water should not exist. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

10

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

Perform “DTC Confirmation Procedure”, EC-382. OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP control system pressure sensor.

11

CHECK EVAP CANISTER VENT CONTROL VALVE-I

1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted.

SEF337X

OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace EVAP canister vent control valve.

EC-554

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

KA24DE

Diagnostic Procedure (Cont’d)

12

CHECK EVAP CANISTER VENT CONTROL VALVE-II

With CONSULT-II 1. Turn ignition switch ON. 2. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. 3. Check air passage continuity and operation delay time.

GI MA EM LC

SEF803Y

Without CONSULT-II Check air passage continuity and operation delay time under the following conditions.

FE CL MT AT TF

SEF339X

PD

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 14.

NG

䊳

GO TO 13.

13

SU

CHECK EVAP CANISTER VENT CONTROL VALVE-III

1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 3 again. OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace EVAP canister vent control valve.

14

AX

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

BR ST RS BT HA SC EL

EC-555

IDX

DTC P1706 PNP SWITCH

KA24DE

Component Description

Component Description

NGEC0424

When the gear position is “N”, park/neutral position (PNP) switch is “ON”. ECM detects the park/neutral position when continuity with ground exists.

AEC877A

CONSULT-II Reference Value in Data Monitor Mode

NGEC0425

Specification data are reference values. MONITOR ITEM P/N POSI SW

CONDITION 쐌 Ignition switch: ON

SPECIFICATION

Shift lever: “N”

ON

Except above

OFF

ECM Terminals and Reference Value

NGEC0426

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.

22

L/B

ITEM

PNP switch

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”] 쐌 Gear position is “Neutral position”

Approximately 0V

[Ignition switch “ON”] 쐌 Except the above gear position

Approximately 5V

On Board Diagnosis Logic DTC No. P1706

Malfunction is detected when ... 쐌 The signal of the PNP switch is not changed in the process of engine starting and driving.

EC-556

Check Items (Possible Cause) 쐌 Harness or connectors (The PNP switch circuit is open or shorted.) 쐌 PNP switch

NGEC0427

DTC P1706 PNP SWITCH

KA24DE DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC0428

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 5 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch ON.

MA EM LC

SEF212Y

2)

Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions. Position (Selector lever)

SEF213Y

GI

Known-good signal

Neutral position

ON

Except the above position

OFF

3) 4) 5)

If NG, go to “Diagnostic Procedure”, EC-560. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds.

ENG SPEED

1,400 - 4,000 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

3.5 - 17 msec

VHCL SPEED SE

More than 64 km/h (40 MPH)

Selector lever

Suitable position

6)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-560.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-557

IDX

DTC P1706 PNP SWITCH

KA24DE

Overall Function Check

Overall Function Check

=NGEC0429

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 22 (PNP switch signal) and body ground under the following conditions. Condition (Gear position) SEF964N

Voltage (V) (Known-good data)

Neutral position

Approx. 0

Except the above position

Approx. 5

3)

If NG, go to “Diagnostic Procedure”, EC-560.

EC-558

DTC P1706 PNP SWITCH

KA24DE Wiring Diagram

Wiring Diagram

NGEC0430

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC980

EC-559

EL IDX

DTC P1706 PNP SWITCH

KA24DE

Diagnostic Procedure For M/T Models

Diagnostic Procedure For M/T Models 1

NGEC0431

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect PNP switch harness connector.

AEC877A

3. Check harness continuity between terminal 2 and body ground.

SEF218V

Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E33, E201 쐌 Harness for open or short between PNP switch and body ground 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-560

DTC P1706 PNP SWITCH

KA24DE

Diagnostic Procedure For M/T Models (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 22 and terminal 1.

GI MA EM LC

SEF219V

Continuity should exist. 3. Also check harness for short to ground and short to power.

FE

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

CL MT

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F36, M81 쐌 Harness connectors M65, E43 쐌 Harness connectors E33, E201 쐌 Harness for open or short between ECM and PNP switch 䊳

AT TF

Repair open circuit or short to ground or short to power in harness or connectors.

PD 5

CHECK PNP SWITCH

AX

Refer to MT-8. OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace PNP switch.

SU BR

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

ST

INSPECTION END

RS BT HA SC EL

EC-561

IDX

IGNITION SIGNAL

KA24DE

Component Description

Component Description

NGEC0319

IGNITION COIL & POWER TRANSISTOR

SEF928V

NGEC0319S01

The ignition signal from the ECM is sent to the power transistor. The power transistor switches the ignition coil primary circuit on and off. 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. NOTE: The rotor screw which secures the distributor rotor head to the distributor shaft must be tightened properly. : 3.3 - 3.9 N·m (0.34 - 0.40 kg-m, 29.5 - 34.7 in-lb)

CONSULT-II Reference Value in Data Monitor Mode

NGEC0320

MONITOR ITEM

IGN TIMING

CONDITION 쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

SPECIFICATION

Idle

Approx. 20° BTDC

2,000 rpm

More than 25° BTDC

EC-562

IGNITION SIGNAL

KA24DE ECM Terminals and Reference Value

ECM Terminals and Reference Value

=NGEC0321

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)

GI MA EM

0 - 0.5V

LC [Engine is running] 쐌 Warm-up condition 쐌 Idle speed

SEF996V

1

PU/W

FE

Ignition signal 0.2 - 1.0V

CL [Engine is running] 쐌 Engine speed is 2,000 rpm

MT SEF997V

AT

12 - 14V

TF [Engine is running] 쐌 Warm-up condition 쐌 Idle speed

PD SEF998V

2

B

Ignition check

AX

12 - 13V

SU [Engine is running] 쐌 Engine speed is 2,000 rpm

BR SEF999V

ST RS BT HA SC EL

EC-563

IDX

IGNITION SIGNAL

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0324

LEC981

EC-564

IGNITION SIGNAL

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0325

INSPECTION START

GI

Turn ignition switch “OFF”, and restart engine. Is engine running?

MA

Yes or No Yes (With CONSULT-II)

䊳

GO TO 2.

Yes (Without CONSULTII)

䊳

GO TO 3.

No

䊳

GO TO 4.

2

EM LC

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.

FE CL MT AT SEF981Z

TF

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 7.

PD AX

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Let engine idle. 2. Read the voltage signal between ECM terminal 1 and ground with an oscilloscope. 3. Verify that the oscilloscope screen shows the signal wave as shown below.

SU BR ST RS BT SEF984Z

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 7.

HA SC EL

EC-565

IDX

IGNITION SIGNAL

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK POWER SUPPLY

1. Turn ignition switch OFF. 2. Disconnect ignition coil harness connector.

SEF344V

3. Turn ignition switch ON. 4. Check voltage between terminal 7 and ground with CONSULT-II or tester.

AEC698

Voltage: Battery voltage OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M59, F27 쐌 Harness for open or short between ignition coil and ignition switch 䊳

6

Repair harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect power transistor harness connector. 3. Check harness continuity between power transistor terminal 2 and engine ground. Refer to the wiring diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to power in harness or connectors.

EC-566

IGNITION SIGNAL

KA24DE Diagnostic Procedure (Cont’d)

7

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 1 and power transistor terminal 1.

GI MA EM LC AEC700

Continuity should exist. 3. Also check harness for short to ground and short to power.

FE

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

8

CL MT

CHECK IGNITION COIL

1. Disconnect ignition coil harness connector. 2. Remove distributor cap. 3. Check resistance as shown in the figure.

AT TF PD AX

AEC150A

SU BR

MTBL0300

ST

OK or NG

RS

OK

䊳

GO TO 9.

NG

䊳

Replace distributor assembly as a unit.

BT HA SC EL

EC-567

IDX

IGNITION SIGNAL

KA24DE

Diagnostic Procedure (Cont’d)

9

CHECK POWER TRANSISTOR

1. Disconnect camshaft position sensor & power transistor harness connector and ignition coil harness connector. 2. Check power transistor resistance between terminals 2 and 8.

AEC151A

MTBL0301

OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace distributor assembly.

EC-568

IGNITION SIGNAL

KA24DE Diagnostic Procedure (Cont’d)

10 1. 2. 3. 4.

CHECK INPUT SIGNAL CIRCUIT Stop engine. Disconnect ignition coil harness connector. Strip tape covering resistor. Disconnect resistor harness connector.

GI MA EM LC

SEF344V

5. Disconnect ECM harness connector. 6. Check harness continuity between ignition coil terminal 8 and resistor terminal 1, resistor terminal 2 and ECM terminal 2.

FE CL MT AT TF PD

SEF179X

Continuity should exist. 7. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 11.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

AX SU BR ST RS BT HA SC EL

EC-569

IDX

IGNITION SIGNAL

KA24DE

Diagnostic Procedure (Cont’d)

11

CHECK RESISTOR

1. Disconnect resistor harness connector. 2. Check resistance between terminals 1 and 2.

SEF240V

Resistance: Approximately 2.2 kΩ [at 25°C (77°F)] OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace resistor.

12

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

EC-570

INJECTOR

KA24DE Component Description

Component Description

NGEC0435

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 ball 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.

ECM Terminals and Reference Value

EM

NGEC0437

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. ITEM

MA

LC

SEF812J

TERMIWIRE NAL COLOR NO.

GI

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

FE CL MT

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

AT TF

102 104 109 111

W/B W/R W/L W/PU

Injector Injector Injector Injector

No. No. No. No.

1 3 2 4

SEF011W

PD

BATTERY VOLTAGE (11 - 14V)

AX [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

SU SEF012W

BR ST RS BT HA SC EL

EC-571

IDX

INJECTOR

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0434

LEC119A

EC-572

INJECTOR

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0438

CHECK OVERALL FUNCTION

GI

With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

MA EM LC

SEF190Y

FE

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.

CL MT AT TF PD MEC703B

Clicking noise should be heard.

AX OK or NG

OK

䊳

INSPECTION END

NG

䊳

GO TO 2.

SU BR ST RS BT HA SC EL

EC-573

IDX

INJECTOR

KA24DE

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 injector terminal 1 and ground with CONSULT-II or tester.

SEF271W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F27, M59 쐌 Fuse block (J/B) connector M26 쐌 10A fuse 쐌 Harness for open or short between injector and fuse 䊳

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 terminal 2 and ECM terminals 102, 104, 109, 111. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and injector. 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-574

INJECTOR

KA24DE Diagnostic Procedure (Cont’d)

6

CHECK INJECTOR

1. Disconnect injector harness connector. 2. Check resistance between terminals as shown in the figure.

GI MA EM LC

SEF273W

Resistance: 7.3 - 9.9Ω [at 25°C (77°F)] OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace injector.

7

FE CL MT

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

AT

INSPECTION END

TF PD AX SU BR ST RS BT HA SC EL

EC-575

IDX

START SIGNAL

KA24DE

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NGEC0441

Specification data are reference values. MONITOR ITEM START SIGNAL

CONDITION

SPECIFICATION

쐌 Ignition switch: ON , START , ON

OFF , ON , OFF

ECM Terminals and Reference Value

NGEC0442

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.

20

WIRE COLOR

L/OR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”]

Approximately 0V

[Ignition switch “START”]

BATTERY VOLTAGE (11 - 14V)

Start signal

EC-576

START SIGNAL

KA24DE Wiring Diagram

Wiring Diagram

NGEC0440

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC982

EC-577

EL IDX

START SIGNAL

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

=NGEC0443

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

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.

SEF227Y

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Turn ignition switch to START. 2. Check voltage between ECM terminal 20 and ground under the following conditions.

SEF109P

MTBL0143

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

EC-578

START SIGNAL

KA24DE Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the 7.5A fuse.

GI OK or NG

OK

䊳

GO TO 5.

NG

䊳

Replace 7.5A fuse.

5

MA EM

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector and 7.5A fuse. 3. Check harness continuity between ECM terminal 20 and fuse block.

LC

FE CL MT SEF224V

Continuity should exist. 4. Also check harness for short to ground and short to power.

AT

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

TF PD

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Fuse block (J/B) connector M26 쐌 Harness for open or short between ECM and fuse block 䊳

AX SU

Repair open circuit or short to ground or short to power in harness or connectors.

BR 7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

ST RS BT HA SC EL

EC-579

IDX

FUEL PUMP

KA24DE

System Description

System Description Sensor

Input Signal to ECM

Camshaft position sensor

Engine speed

Ignition switch

Start signal

NGEC0444

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 5 seconds.

Engine running and cranking

Operates.

Except as shown above

Stops.

Component Description

NGEC0501

The fuel pump with a fuel damper is an in-tank type (the pump and damper are located in the fuel tank).

SFE425A

CONSULT-II Reference Value in Data Monitor Mode

NGEC0445

MONITOR ITEM

FUEL PUMP RLY

CONDITION

SPECIFICATION

쐌 Ignition switch is turned to ON (Operates for 5 seconds) 쐌 Engine running and cranking

ON

쐌 Except as shown above

OFF

EC-580

FUEL PUMP

KA24DE ECM Terminals and Reference Value

ECM Terminals and Reference Value

=NGEC0446

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.

11

WIRE COLOR

W/R

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”] 쐌 For 5 seconds after turning ignition switch “ON” [Engine is running]

0 - 1V

[Ignition switch “ON”] 쐌 More than 5 seconds after turning ignition switch “ON”

BATTERY VOLTAGE (11 - 14V)

GI MA EM LC

Fuel pump relay

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-581

IDX

FUEL PUMP

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0447

AEC011B

EC-582

FUEL PUMP

KA24DE Diagnostic Procedure

Diagnostic Procedure 1

NGEC0448

CHECK OVERALL FUNCTION

GI

1. Turn ignition switch ON. 2. Pinch fuel feed hose with two fingers.

MA EM LC

SEF348V

Fuel pressure pulsation should be felt on the fuel feed hose for 5 seconds after ignition switch is turned “ON”.

FE

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 2.

CL MT

2

CHECK POWER SUPPLY

1. Turn ignition switch OFF. 2. Disconnect fuel pump relay.

AT TF PD AX SEF349V

3. Turn ignition switch ON. 4. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.

SU BR ST RS BT

SEF225V

Voltage: Battery voltage

HA

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

SC EL

EC-583

IDX

FUEL PUMP

KA24DE

Diagnostic Procedure (Cont’d)

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 15A fuse 쐌 Fuse block (J/B) connector M31 쐌 Harness for open or short between fuse and fuel pump relay 䊳

4

Repair harness or connectors.

CHECK FUEL PUMP POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect fuel pump harness connector.

AFE095

3. Check harness continuity between terminal 2 and body ground, terminal 1 and fuel pump relay connector terminal 3.

SEF700Z

Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

EC-584

FUEL PUMP

KA24DE Diagnostic Procedure (Cont’d)

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors B101, M67 쐌 Harness for open or short between fuel pump and body ground 쐌 Harness for open or short between fuel pump and fuel pump relay 䊳

GI MA

Repair open circuit or short to power in harness or connectors.

EM 6

CHECK OUTPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 11 and fuel pump relay connector terminal 1.

LC

FE CL SEF227V

Continuity should exist. 3. Also check harness for short to ground and short to power.

MT AT

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

TF PD

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F36, M81 쐌 Harness for open or short between ECM and fuel pump relay 䊳

Repair open circuit or short to power in harness or connectors.

AX SU BR ST RS BT HA SC EL

EC-585

IDX

FUEL PUMP

KA24DE

Diagnostic Procedure (Cont’d)

8

CHECK FUEL PUMP RELAY

With CONSULT-II 1. Reconnect fuel pump relay, fuel pump harness connector and ECM harness connector. 2. Turn ignition switch ON. 3. Turn fuel pump relay “ON” and “OFF” in “ACTIVE TEST” mode with CONSULT-II and check operating sound.

SEF724Z

Without CONSULT-II Check continuity between terminals 3 and 5.

SEF511P

MTBL0306

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace fuel pump relay.

EC-586

FUEL PUMP

KA24DE Diagnostic Procedure (Cont’d)

9

CHECK FUEL PUMP

1. Disconnect fuel pump harness connector.

GI MA EM LC SEF701Z

2. Check resistance between terminals 1 and 2. Resistance: 0.2 - 5.0Ω [at 25°C (77°F)] OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace fuel pump.

10

FE CL

CHECK INTERMITTENT INCIDENT

MT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

INSPECTION END

AT TF PD AX SU BR ST RS BT HA SC EL

EC-587

IDX

POWER STEERING OIL PRESSURE SWITCH

KA24DE

Component Description

Component Description

NGEC0451

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.

SEF351V

CONSULT-II Reference Value in Data Monitor Mode

NGEC0452

Specification data are reference values. MONITOR ITEM

PW/ST SIGNAL

CONDITION 쐌 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

NGEC0453

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.

39

WIRE COLOR

GY/R

ITEM

CONDITION

[Engine is Power steering oil pressure 쐌 Steering switch [Engine is 쐌 Steering

DATA (DC Voltage)

running] wheel is fully turned

Approximately 0V

running] wheel is not turned

Approximately 5V

EC-588

POWER STEERING OIL PRESSURE SWITCH

KA24DE Wiring Diagram

Wiring Diagram

NGEC0450

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC AEC012B

EC-589

EL IDX

POWER STEERING OIL PRESSURE SWITCH

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

=NGEC0454

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

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.

SEF054Y

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Start engine. 2. Check voltage between ECM terminal 39 and ground under the following conditions.

SEF662P

MTBL0142

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

EC-590

POWER STEERING OIL PRESSURE SWITCH

KA24DE

Diagnostic Procedure (Cont’d)

4

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 39 and terminal 1.

GI MA EM LC

SEF662P

Continuity should exist. 4. Also check harness for short to ground and short to power.

FE

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

CL MT

5

DETECT MALFUNCTIONING PART

AT

Check the harness for open or short between ECM and power steering oil pressure switch. 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

TF 6

CHECK POWER STEERING OIL PRESSURE SWITCH

1. Disconnect power steering oil pressure switch harness connector then start engine. 2. Check continuity between terminals 1 and ground.

PD AX SU BR ST SEF230V

RS MTBL0307

BT

OK or NG

HA

OK

䊳

GO TO 7.

NG

䊳

Replace power steering oil pressure switch.

SC 7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

EL

INSPECTION END

EC-591

IDX

IACV-FICD SOLENOID VALVE

KA24DE

Component Description

Component Description

NGEC0462

When the air conditioner is on, the IAC valve-FICD solenoid valve supplies additional air to adjust to the increased load.

SEF342V

ECM Terminals and Reference Value

NGEC0463

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.

12

WIRE COLOR

P

ITEM

Air conditioner relay

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Both A/C switch and blower switch are ON★

Approximately 0V

[Engine is running] 쐌 A/C switch is OFF

BATTERY VOLTAGE (11 - 14V)

★ Ambient air temperature above 10°C (50°F) and in any mode except OFF.

EC-592

IACV-FICD SOLENOID VALVE

KA24DE Wiring Diagram

Wiring Diagram

NGEC0461

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC983

EC-593

EL IDX

IACV-FICD SOLENOID VALVE

KA24DE

Diagnostic Procedure

Diagnostic Procedure 1

=NGEC0464

CHECK OVERALL FUNCTION

1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 800±50 rpm If NG, adjust idle speed. 3. Push air conditioner switch ON and turn fan switch to 4-speed. 4. Recheck idle speed.

MEF634E

875 rpm or more OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 2.

2

CHECK AIR CONDITIONER FUNCTION

Check if air conditioner compressor functions normally. OK or NG OK

䊳

GO TO 3.

NG

䊳

Refer to “Symptom Table” in “TROUBLE DIAGNOSIS”, HA-28.

EC-594

IACV-FICD SOLENOID VALVE

KA24DE Diagnostic Procedure (Cont’d)

3

CHECK POWER SUPPLY

1. Stop engine. 2. Disconnect IACV-FICD solenoid valve harness connector.

GI MA EM LC SEF342V

3. Start engine, then push A/C switch ON and turn fan switch to 4-speed. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.

FE CL MT AT SEF133V

Voltage: Battery voltage OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

TF PD AX

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between IACV-FICD solenoid valve and harness connector F27 䊳

Repair open circuit, short to ground or short to power in harness or connectors.

SU BR ST RS BT HA SC EL

EC-595

IDX

IACV-FICD SOLENOID VALVE

KA24DE

Diagnostic Procedure (Cont’d)

5

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Check harness continuity between solenoid valve terminal 1 and body ground.

SEF134V

Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

6

DETECT MALFUNCTIONING PART

Check the harness for open or short between IACV-FICD solenoid valve and body ground. 䊳

Repair open circuit or short to power in harness or connectors.

EC-596

IACV-FICD SOLENOID VALVE

KA24DE Diagnostic Procedure (Cont’d)

7

CHECK IACV-FICD SOLENOID VALVE

Disconnect IACV-FICD solenoid valve harness connector.

GI MA EM LC SEF231V

쐌 Check for clicking sound when applying 12V direct current to terminals. 쐌 Check plunger for seizing or sticking. 쐌 Check for broken spring.

FE CL MT AT SEF097K

TF

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace IACV-FICD solenoid valve.

PD AX

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-150. 䊳

SU

INSPECTION END

BR ST RS BT HA SC EL

EC-597

IDX

MIL & DATA LINK CONNECTORS

KA24DE

Wiring Diagram

Wiring Diagram

NGEC0466

WEC984

EC-598

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE Fuel Pressure Regulator

Fuel Pressure Regulator Fuel pressure at idling kPa (kg/cm2, psi)

NGEC0467

Vacuum hose is connected

Approximately 235 (2.4, 34)

Vacuum hose is disconnected

Approximately 294 (3.0, 43)

MA

Idle Speed and Ignition Timing Base idle speed*1

rpm

NGEC0468

No-load*3 (in “P” or “N” position)

750±50 800±50

Target idle speed*2

rpm

No-load*3 (in “P” or “N” position)

Air conditioner: ON

rpm

In “P” or “N” position

875 or more

In “P” or “N” position

20°±2° BTDC

Ignition timing*1

*1: *2: *3: 쐌 쐌 쐌

GI

EM LC

Throttle position sensor harness connector disconnected or using CONSULT-II “WORK SUPPORT” mode Throttle position sensor harness connector connected Under the following conditions: Air conditioner switch: OFF Electrical load: OFF (Lights, heater fan & rear window defogger) Steering wheel: Kept in straight-ahead position

CL

Ignition Coil Primary voltage

FE

NGEC0469

V

Battery voltage 12

Primary resistance [at 20°C (68°F)]

Ω

Secondary resistance [at 20°C (68°F)]

kΩ

Approximately 10

Mass Air Flow Sensor

AT NGEC0470

Supply voltage

V

Battery voltage (11 - 14)

Output voltage

V

0.9 - 1.8*

Mass air flow (Using CONSULT-II or GST)

MT

Approximately 1.0

TF PD

0.9 - 5.8 at idle* 7.5 - 13.2 at 2,500 rpm*

g·m/sec

*: Engine is warmed up to normal operating temperature and idling under no-load.

AX

Engine Coolant Temperature Sensor Temperature

°C (°F)

Resistance

20 (68)

2.1 - 2.9

50 (122)

0.68 - 1.00

90 (194)

0.236 - 0.260

BR ST NGEC0472

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

Fuel Pump Ω

RS BT HA NGEC0473

SC

0.2 - 5.0

IACV-AAC Valve Resistance [at 25°C (77°F)]

SU

kΩ

EGR Temperature Sensor

Resistance [at 25°C (77°F)]

NGEC0471

Ω

NGEC0474

EL

Approximately 10.0

EC-599

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE

Injector

Injector Resistance [at 25°C (77°F)]

NGEC0475

Ω

7.3 - 9.9

Resistor Resistance [at 25°C (77°F)]

NGEC0476

kΩ

Approximately 2.2

Throttle Position Sensor Throttle valve conditions

NGEC0477

Voltage (at normal operating temp., engine off, ignition switch on)

Completely closed (a)

0.15 - 0.85V

Partially open

Between (a) and (b)

Completely open (b)

3.5 - 4.7V

Heated Oxygen Sensor 1 Heater Resistance [at 25°C (77°F)]

Ω

NGEC0478

2.3 - 4.3

Calculated Load Value

NGEC0479

Calculated load value % (Using CONSULT-II or GST) At idle

9.5 - 34.0%

At 2,500 rpm

13.9 - 24.9%

Intake Air Temperature Sensor Temperature

°C (°F)

Resistance

NGEC0480

kΩ

20 (68)

2.1 - 2.9

80 (176)

0.27 - 0.38

Heated Oxygen Sensor 2 Heater Resistance [at 25°C (77°F)]

Ω

2.3 - 4.3

Crankshaft Position Sensor (OBD) Resistance [at 20°C (68°F)]

NGEC0483

Ω

NGEC0484

512 - 632

Fuel Tank Temperature Sensor Temperature

°C (°F)

Resistance

kΩ

20 (68)

2.3 - 2.7

50 (122)

0.79 - 0.90

EC-600

NGEC0485

TROUBLE DIAGNOSIS — INDEX

VG33E Alphabetical & P No. Index for DTC

Alphabetical & P No. Index for DTC

NGEC0522

ALPHABETICAL INDEX FOR DTC

NGEC0522S01

GI

DTC*1*2

Items (CONSULT-II screen terms)

Reference page

MA

CONSULT-II GST

Unable to access ECM

—

EC-716

A/T 1ST GR FNCTN

P0731

AT-125

A/T 2ND GR FNCTN

P0732

AT-131

A/T 3RD GR FNCTN

P0733

AT-137

A/T 4TH GR FNCTN

P0734

AT-143

A/T COMM LINE

P0600*4

EC-1019

A/T DIAG COMM LINE

P1605

EC-1126

A/T TCC S/V FNCTN

P0744

AT-157

ATF TEMP SEN/CIRC

P0710

AT-110

CKP SEN/CIRCUIT

P0335

EC-895

CKP SENSOR (COG)

P1336

EC-1071

CLOSED LOOP-B1

P1148

EC-1064

CLOSED LOOP-B2

P1168

EC-1064

CLOSED TP SW/CIRC

P0510

EC-1012

CMP SEN/CIRCUIT

P0340

EC-901

CYL1 MISFIRE

P0301

EC-882

CYL2 MISFIRE

P0302

EC-882

CYL3 MISFIRE

P0303

EC-882

CYL4 MISFIRE

P0304

EC-882

CYL5 MISFIRE

P0305

EC-882

CYL6 MISFIRE

P0306

EC-882

ECM

P0605

EC-1024

ECT SEN/CIRCUIT

P0117*3

EC-775

ECT SEN/CIRCUIT

P0118*3

EC-775

ECT SENSOR

P0125

EC-793

ENG OVER TEMP

P0217

EC-875

ENG OVER TEMP

P1217

EC-1066

ENGINE SPEED SIG

P0725

AT-121

EVAP GROSS LEAK

P0455

EC-963

EVAP PURG FLOW/MON

P0441

EC-913

EVAP SMALL LEAK

P0442

EC-925

EVAP SMALL LEAK

P1442

EC-1078

EVAP SYS PRES SEN

P0452

EC-952

EVAP SYS PRES SEN

P0453

EC-952

EVAP VERY SML LEAK

P0456

EC-976

EC-601

EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — INDEX

VG33E

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2

Items (CONSULT-II screen terms)

Reference page CONSULT-II GST

EVAP VERY SML LEAK

P1456

EC-976

FTT SEN/CIRCUIT

P0182

EC-870

FTT SEN/CIRCUIT

P0183

EC-870

FTT SENSOR

P0181

EC-870

FUEL LEV SEN SLOSH

P0460

EC-990

FUEL LEVEL SEN/CIRC

P1464

EC-1107

FUEL LEVEL SENSOR

P0461

EC-995

FUEL LEVL SEN/CIRC

P0462

EC-997

FUEL LEVL SEN/CIRC

P0463

EC-997

FUEL SYS-LEAN-B1

P0171

EC-853

FUEL SYS-LEAN-B2

P0174

EC-853

FUEL SYS-RICH-B1

P0172

EC-862

FUEL SYS-RICH-B2

P0175

EC-862

HO2S1 (B1)

P0132

EC-800

HO2S1 (B1)

P0133

EC-808

HO2S1 (B1)

P0134

EC-822

HO2S1 (B1)

P1143

EC-1026

HO2S1 (B1)

P1144

EC-1035

HO2S1 (B2)

P0152

EC-800

HO2S1 (B2)

P0153

EC-808

HO2S1 (B2)

P0154

EC-822

HO2S1 (B2)

P1163

EC-1026

HO2S1 (B2)

P1164

EC-1035

HO2S1 HTR (B1)

P0031

EC-746

HO2S1 HTR (B1)

P0032

EC-746

HO2S1 HTR (B2)

P0051

EC-746

HO2S1 HTR (B2)

P0052

EC-746

HO2S2 HTR (B1)

P0037

EC-753

HO2S2 HTR (B1)

P0038

EC-753

HO2S2 HTR (B2)

P0057

EC-753

HO2S2 HTR (B2)

P0058

EC-753

HO2S2 (B1)

P0138

EC-833

HO2S2 (B1)

P0139

EC-843

HO2S2 (B1)

P1146

EC-1044

HO2S2 (B1)

P1147

EC-1054

HO2S2 (B2)

P0158

EC-833

HO2S2 (B2)

P0159

EC-843

EC-602

TROUBLE DIAGNOSIS — INDEX

VG33E

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2

Items (CONSULT-II screen terms)

Reference page CONSULT-II GST

HO2S2 (B2)

P1166

EC-1044

HO2S2 (B2)

P1167

EC-1054

IAT SEN/CIRCUIT

P0112

EC-770

IAT SEN/CIRCUIT

P0113

EC-770

IAT SENSOR

P0127

EC-770

ISC SYSTEM/CIRC

P0505

EC-1006

KNOCK SEN/CIRC-B1

P0327

EC-891

KNOCK SEN/CIRC-B1

P0328

EC-891

L/PRES SOL/CIRC

P0745

MAF SEN/CIRCUIT

P0101

EC-761

MAF SEN/CIRCUIT

P0102*3

EC-761

MAF SEN/CIRCUIT

P0103*3

EC-761

MULTI CYL MISFIRE

P0300

EC-882

NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED.

P0000

—

P-N POS SW/CIRCUIT

P1706

EC-1129

PNP SW/CIRC

P0705

AT-104

PURG VOLUME CONT/V

P0444

EC-939

PURG VOLUME CONT/V

P0445

EC-939

PURG VOLUME CONT/V

P1444

EC-1080

AT-164

SFT SOL A/CIRC

P0750*3

AT-169

SFT SOL B/CIRC

P0755*3

AT-174

TCC SOLENOID/CIRC

P0740

AT-152

THERMSTAT FNCTN

P0128 P1705*5

TP SEN/CIRCUIT

P0121

EC-780

TP SEN/CIRCUIT

P0122*3

EC-780

TP SEN/CIRCUIT

P0123*3

EC-780

TW CATALYST SYS-B1

P0420

EC-908

TW CATALYST SYS-B2

P0430

EC-908

VC CUT/V BYPASS/V

P1491

EC-1117

VC/V BYPASS/V

P1490

EC-1111

VEH SPD SEN/CIR AT

P0720

AT-116

VEH SPEED SEN/CIRC

P0500*5

EC-1002

VENT CONTROL VALVE

P0447

EC-946

VENT CONTROL VALVE

P1446

EC-1092

VENT CONTROL VALVE

P1448

EC-1099

EC-603

MA EM LC

FE CL MT AT TF PD AX SU

EC-798

TP SEN/CIRC A/T

*1: 1st trip DTC No. 1 is the same as DTC No.

GI

AT-179

BR ST RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — INDEX

VG33E

Alphabetical & P No. Index for DTC (Cont’d) *2: These numbers are prescribed by SAE J2012. *3: When the fail-safe operation occurs, the MIL illuminates. *4: This DTC is displayed with CONSULT-II only. *5: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. NOTE: Regarding D22 models, “B1” indicates bank 1, “B2” indicates bank 2.

EC-604

TROUBLE DIAGNOSIS — INDEX

VG33E

Alphabetical & P No. Index for DTC (Cont’d)

P NO. INDEX FOR DTC

=NGEC0522S02

DTC*1*2

Items (CONSULT-II screen terms)

CONSULT-II GST —

Unable to access ECM

Reference page EC-716

P0000

NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED.

P0031

HO2S1 HTR (B1)

EC-746

P0032

HO2S1 HTR (B1)

EC-746

P0037

HO2S2 HTR (B1)

EC-753

P0038

HO2S2 HTR (B1)

EC-753

P0051

HO2S1 HTR (B2)

EC-746

P0052

HO2S1 HTR (B2)

EC-746

P0057

HO2S2 HTR (B2)

EC-753

P0058

HO2S2 HTR (B2)

EC-753

P0101

MAF SEN/CIRCUIT

EC-761

P0102*3

MAF SEN/CIRCUIT

EC-761

P0103*3

MAF SEN/CIRCUIT

EC-761

P0112

IAT SEN/CIRCUIT

EC-770

P0113

IAT SEN/CIRCUIT

EC-770

P0117*3

ECT SEN/CIRCUIT

EC-775

P0118*3

ECT SEN/CIRCUIT

EC-775

P0121

TP SEN/CIRCUIT

EC-780

P0122*3

TP SEN/CIRCUIT

EC-780

P0123*3

TP SEN/CIRCUIT

EC-780

P0125

ECT SENSOR

EC-793

P0127

IAT SENSOR

EC-770

P0128

THERMSTAT FNCTN

EC-798

P0132

HO2S1 (B1)

EC-800

P0133

HO2S1 (B1)

EC-808

P0134

HO2S1 (B1)

EC-822

P0138

HO2S2 (B1)

EC-833

P0139

HO2S2 (B1)

EC-843

P0152

HO2S1 (B2)

EC-746

P0153

HO2S1 (B2)

EC-808

P0154

HO2S1 (B2)

EC-822

P0158

HO2S2 (B2)

EC-833

P0159

HO2S2 (B2)

EC-843

P0171

FUEL SYS-LEAN-B1

EC-853

P0172

FUEL SYS-RICH-B1

EC-853

EC-605

GI MA

—

EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — INDEX

VG33E

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2

Items (CONSULT-II screen terms)

CONSULT-II GST

Reference page

P0174

FUEL SYS-LEAN-B2

EC-862

P0175

FUEL SYS-RICH-B2

EC-862

P0181

FTT SENSOR

EC-870

P0182

FTT SEN/CIRCUIT

EC-870

P0183

FTT SEN/CIRCUIT

EC-870

P0217

ENG OVER TEMP

EC-875

P0300

MULTI CYL MISFIRE

EC-882

P0301

CYL1 MISFIRE

EC-882

P0302

CYL2 MISFIRE

EC-882

P0303

CYL3 MISFIRE

EC-882

P0304

CYL4 MISFIRE

EC-882

P0305

CYL5 MISFIRE

EC-882

P0306

CYL6 MISFIRE

EC-882

P0327

KNOCK SEN/CIRC-B1

EC-891

P0328

KNOCK SEN/CIRC-B1

EC-891

P0335

CKP SEN/CIRCUIT

EC-895

P0340

CMP SEN/CIRCUIT

EC-901

P0420

TW CATALYST SYS-B1

EC-908

P0430

TW CATALYST SYS-B2

EC-908

P0441

EVAP PURG FLOW/MON

EC-913

P0442

EVAP SMALL LEAK

EC-925

P0444

PURG VOLUME CONT/V

EC-939

P0445

PURG VOLUME CONT/V

EC-939

P0447

VENT CONTROL VALVE

EC-946

P0452

EVAP SYS PRES SEN

EC-952

P0453

EVAP SYS PRES SEN

EC-952

P0455

EVAP GROSS LEAK

EC-963

P0456

EVAP VERY SML LEAK

EC-976

P0460

FUEL LEV SEN SLOSH

EC-990

P0461

FUEL LEVEL SENSOR

EC-995

P0462

FUEL LEVL SEN/CIRC

EC-997

P0463

FUEL LEVL SEN/CIRC

EC-997

P0500*5

VEH SPEED SEN/CIRC

EC-1002

P0505

ISC SYSTEM/CIRC

EC-1006

P0510

CLOSED TP SW/CIRC

EC-1012

A/T COMM LINE

EC-1019

ECM

EC-1024

P0600*4 P0605

EC-606

TROUBLE DIAGNOSIS — INDEX

VG33E

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2

Items (CONSULT-II screen terms)

CONSULT-II GST

Reference page

P0705

PNP SW/CIRC

AT-104

P0710

ATF TEMP SEN/CIRC

AT-110

P0720

VEH SPD SEN/CIR AT

AT-116

P0725

ENGINE SPEED SIG

AT-121

P0731

A/T 1ST GR FNCTN

AT-125

P0732

A/T 2ND GR FNCTN

AT-131

P0733

A/T 3RD GR FNCTN

AT-137

P0734

A/T 4TH GR FNCTN

AT-143

P0740

TCC SOLENOID/CIRC

AT-152

P0744

A/T TCC S/V FNCTN

P0745

L/PRESS SOL/CIRC

AT-164

P0750*3

SFT SOL A/CIRC

AT-169

P0755*3

SFT SOL B/CIRC

AT-174

EC-169

P1143

HO2S1 (B1)

EC-1026

P1144

HO2S1 (B1)

EC-1035

P1146

HO2S2 (B1)

EC-1044

P1147

HO2S2 (B1)

EC-1054

P1148

CLOSED LOOP-B1

EC-1064

P1163

HO2S1 (B2)

EC-1026

P1164

HO2S1 (B2)

EC-1035

P1166

HO2S2 (B2)

EC-1044

P1167

HO2S2 (B2)

EC-1054

P1168

CLOSED LOOP-B2

EC-1064

P1217

ENG OVER TEMP

EC-1066

P1336

CKP SENSOR (COG)

EC-1071

P1442

EVAP SMALL LEAK

EC-1078

P1444

PURG VOLUME CONT/V

EC-1080

P1446

VENT CONTROL VALVE

EC-1092

P1448

VENT CONTROL VALVE

EC-1099

P1456

EVAP VERY SML LEAK

EC-976

P1464

FUEL LEVEL SEN/CIRK

EC-1107

P1490

VC/V BYPASS/V

EC-1111

P1491

VC CUT/V BYPASS/V

EC-1117

P1605

A/T DIAG COMM LINE

EC-1126

P1705*5

TP SEN/CIRC A/T

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC

AT-179

P1706

P-N POS SW/CIRCUIT

EC-1129

P1760

O/R CLTCH SOL/CIRC

AT-188

EC-607

EL IDX

TROUBLE DIAGNOSIS — INDEX

VG33E

Alphabetical & P No. Index for DTC (Cont’d) *1: 1st trip DTC No. 1 is the same as DTC No. *2: These numbers are prescribed by SAE J2012. *3: When the fail-safe operation occurs, the MIL illuminates. *4: This DTC is displayed with CONSULT-II only. *5: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. NOTE: Regarding D22 models, “B1” indicates bank 1, “B2” indicates bank 2.

EC-608

PRECAUTIONS

VG33E

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGEC0523

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: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

Precautions for On Board Diagnostic (OBD) System of Engine and A/T

NGEC0524

The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the driver of a malfunction causing emission deterioration. CAUTION: 쐌 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 MIL to light up. 쐌 Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MIL to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) 쐌 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”. 쐌 Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MIL to light up due to the short circuit. 쐌 Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MIL to light up due to the malfunction of the EGR system or fuel injection system, etc. 쐌 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.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-609

IDX

PRECAUTIONS

VG33E

Engine Fuel & Emission Control System

Engine Fuel & Emission Control System

NGEC0525

AEC045B

EC-610

PRECAUTIONS

VG33E Precautions

Precautions 쐌

NGEC0526

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.

GI MA EM LC

SEF289H

쐌

When connecting ECM harness connector, tighten securing bolt until the gap between orange indicators disappears. : 3 - 5 N·m (0.3 - 0.5 kg-m, 26 - 43 in-lb)

FE CL MT

SEF308Q

쐌

When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on ECM pin terminal, when connecting pin connectors.

AT TF PD AX

SEF291H

쐌

Before replacing ECM, perform “ECM Terminals and Reference Value” inspection and make sure ECM functions properly. Refer to EC-726.

SU BR ST RS

MEF040D

쐌

After performing each TROUBLE DIAGNOSIS, perform “DTC Confirmation Procedure” or “Overall Function Check”. The DTC should not be displayed in the “DTC Confirmation Procedure” if the repair is completed. The “Overall Function Check” should be a good result if the repair is completed.

BT HA SC EL

SEF217U

EC-611

IDX

PRECAUTIONS

VG33E

Precautions (Cont’d)

쐌

쐌

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 the ECM terminals, such as the ground.

SEF348N

쐌

Regarding model D22, “-B1” indicates the right bank and “-B2” indicates the left bank as shown in the figure.

SEF099W

Wiring Diagrams and Trouble Diagnosis When you read Wiring diagrams, refer to the following: 쐌 “HOW TO READ WIRING DIAGRAMS” in GI section 쐌 “POWER SUPPLY ROUTING” for power distribution circuit in EL section When you perform trouble diagnosis, refer to the following: 쐌 “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES” in GI section 쐌 “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” in GI section

EC-612

NGEC0527

PREPARATION

VG33E Special Service Tools

Special Service Tools

NGEC0528

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

GI

Description

MA Loosening or tightening front heated oxygen sensor with 22 mm (0.87 in) hexagon nut

KV10117100 (J36471-A) Heated oxygen sensor wrench

EM LC

NT379

Loosening or tightening rear heated oxygen sensor a: 22 mm (0.87 in)

KV10114400 (J-38365) Heated oxygen sensor wrench

FE CL

NT636

(J-44321) Fuel pressure gauge kit

Checking fuel pressure

MT AT TF

LEC642

PD

Used to test the throttle position sensor

(J-45178) TPS test connector

AX SU LEC120A

Commercial Service Tools Tool name (Kent-Moore No.)

BR NGEC0529

ST

Description Locating the EVAP leak

Leak detector (J41416)

RS BT HA

NT703

SC EL

EC-613

IDX

PREPARATION

VG33E

Commercial Service Tools (Cont’d) Tool name (Kent-Moore No.)

Description Applying positive pressure through EVAP service port

EVAP service port adapter (J41413-OBD)

NT704

Clamping the EVAP purge hose between the fuel tank and EVAP canister applied to DTC P1442 [EVAP control system (small leak-positive pressure)]

Hose clipper

NT720

Checking fuel tank vacuum relief valve opening pressure

Fuel filler cap adapter

NT653

Removing and installing engine coolant temperature sensor

Socket wrench

NT705

Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with antiseize lubricant shown in “Commercial Service Tools”. a: J-43897-18 18 mm diameter, for Zirconia Oxygen Sensor b: J-43897-12 12 mm diameter, for Titania Oxygen Sensor

Oxygen sensor thread cleaner (J-43897-18) (J-43897-12)

AEM488

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads.

Anti-seize lubricant (Permatex姟 133AR or equivalent meeting MIL specification MIL-A-907)

AEM489

EC-614

PREPARATION

VG33E Commercial Service Tools (Cont’d)

Tool name (Kent-Moore No.)

Description

GI Cleaning fuel injectors

Fuel injector cleaner kit (J-45701)

MA EM LC

LEC161A

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-615

IDX

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33E

Engine Control Component Parts Location

Engine Control Component Parts Location

NGEC0530

WEC544

EC-616

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33E

Engine Control Component Parts Location (Cont’d)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEF792ZA

EL

EC-617

IDX

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33E

Circuit Diagram

Circuit Diagram

NGEC0531

WEC162A

EC-618

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33E System Diagram

System Diagram

NGEC0532

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC193A

EC-619

EL IDX

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33E

Vacuum Hose Drawing

Vacuum Hose Drawing

NGEC0533

Refer to “System Diagram”, EC-619 for Vacuum Control System.

SEF794Z

EC-620

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33E System Chart

System Chart Input (Sensor) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

*1: *2: *3: *4:

Camshaft position sensor Mass air flow sensor Engine coolant temperature sensor Heated oxygen sensor 1 Ignition switch Throttle position sensor Closed throttle position switch *4 Park/neutral position (PNP) switch Air conditioner switch Knock sensor Intake air temperature sensor EVAP control system pressure sensor *1 Battery voltage Power steering oil pressure switch Vehicle speed sensor Fuel tank temperature sensor *1 Crankshaft position sensor (OBD) *1 Rear heated oxygen sensor *3 TCM (Transmission control module) *2 Ambient air temperature switch

NGEC0534

ECM Function

Output (Actuator)

Fuel injection & mixture ratio control

Injectors

Distributor ignition system

Power transistor

Idle air control system

IACV-AAC valve and IACV-FICD solenoid valve

Fuel pump control

Fuel pump relay

On board diagnostic system

MIL (On the instrument panel)

Heated oxygen sensor 1 heater control

Heated oxygen sensor 1 heater

Heated oxygen sensor 2 heater control

Heated oxygen sensor 2 heater

EVAP canister purge flow control

EVAP canister purge volume control solenoid valve

Air conditioning cut control

Air conditioner relay

Cooling fan control

Cooling fan relays

쐌 EVAP canister vent control ON BOARD DIAGNOSIS for EVAP system valve 쐌 Vacuum cut valve bypass valve

These sensors are not used to control the engine system. They are used only for the on board diagnosis. The DTC related to A/T will be sent to ECM. This sensor is not used to control the engine system under normal conditions. This switch will operate in place of the throttle position sensor to control EVAP parts if the sensor malfunctions.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-621

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Multiport Fuel Injection (MFI) System

Multiport Fuel Injection (MFI) System DESCRIPTION Input/Output Signal Chart

NGEC0535 NGEC0535S01

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

Park/neutral position (PNP) switch

Gear position

Vehicle speed sensor

Vehicle speed

Ignition switch

Start signal

Air conditioner switch

Air conditioner operation

Knock sensor

Engine knocking condition

Battery

Battery voltage

Power steering oil pressure switch

Power steering operation

Heated oxygen sensor 2 (rear)*

Density of oxygen in exhaust gas

ECM function

Actuator

Fuel injection & mixInjectors ture ratio control

* Under normal conditions, this sensor is not for engine control operation.

Basic Multiport Fuel Injection System

NGEC0535S02

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

NGEC0535S03

In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. 쐌 During warm-up 쐌 When starting the engine 쐌 During acceleration 쐌 Hot-engine operation 쐌 When selector lever is changed from “N” to “D” 쐌 High-load, high-speed operation 쐌 During deceleration 쐌 During high engine speed operation

EC-622

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Multiport Fuel Injection (MFI) System (Cont’d)

Mixture Ratio Feedback Control (Closed loop control)

NGEC0535S04

GI MA EM LC SEF336WB

The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The warm-up three way catalyst can then better reduce CO, HC and NOx emissions. This system uses a heated oxygen sensor 1 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, refer to EC-822. This maintains the mixture ratio within the range of stoichiometric (ideal air-fuel mixture). This stage is referred to as the closed loop control condition. Heated oxygen sensor 2 is located downstream of the warm-up three way catalyst. Even if the switching characteristics of the heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal from the heated oxygen sensor 2.

Open Loop Control

NGEC0535S05

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. 쐌 Deceleration and acceleration 쐌 High-load, high-speed operation 쐌 Malfunction of heated oxygen sensor 1 or its circuit 쐌 Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature 쐌 High engine coolant temperature 쐌 During warm-up 쐌 When starting the engine

Mixture Ratio Self-learning Control

NGEC0535S06

The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the heated oxygen sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot wire) and characteristic changes during operation (i.e., 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 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.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-623

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Multiport Fuel Injection (MFI) System (Cont’d)

Fuel Injection Timing

NGEC0535S07

SEF179U

Two types of systems are used. Sequential Multiport Fuel Injection System NGEC0535S0701 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 NGEC0535S0702 Fuel is injected simultaneously into all six cylinders twice each engine cycle. In other words, pulse signals of the same width are simultaneously transmitted from the ECM. The six 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

NGEC0535S08

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

NGEC0536 NGEC0536S01

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

Vehicle speed

Ignition switch

Start signal

Knock sensor

Engine knocking

Park/neutral position (PNP) switch

Gear position

Battery

Battery voltage

EC-624

ECM function

Actuator

Ignition timing con- Power transistor trol

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Distributor Ignition (DI) System (Cont’d)

System Description

NGEC0536S02

GI MA EM LC 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. 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. 쐌 At starting 쐌 During warm-up 쐌 At idle 쐌 At low battery voltage 쐌 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.

FE CL MT AT TF PD

Air Conditioning Cut Control AX

DESCRIPTION Input/Output Signal Chart Sensor

NGEC0537 NGEC0537S01

Input Signal to ECM

Air conditioner switch

Air conditioner “ON” signal

Throttle position sensor

Throttle valve opening angle

Camshaft position sensor

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Vehicle speed sensor

Vehicle speed

Power steering oil pressure switch

Power steering operation

ECM function

Actuator

SU BR

Air conditioner cut control

System Description

Air conditioner relay

ST RS BT

NGEC0537S02

This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned OFF. 쐌 When the accelerator pedal is fully depressed. 쐌 When cranking the engine. 쐌 At high engine speeds. 쐌 When the engine coolant temperature becomes excessively high. 쐌 When operating power steering during low engine speed or low vehicle speed. 쐌 When engine speed is excessively low.

EC-625

HA SC EL IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Fuel Cut Control (at no load & high engine speed)

Fuel Cut Control (at no load & high engine speed) DESCRIPTION Input/Output Signal Chart Sensor

NGEC0538 NGEC0538S01

Input Signal to ECM

Vehicle speed sensor

Vehicle speed

Park/neutral position (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 2,500 rpm with no load (for example, in neutral and engine speed over 2,500 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed. Fuel cut will operate until the engine speed reaches 2,000 rpm, then fuel cut is cancelled. NOTE: This function is different from deceleration control listed under “Multiport Fuel Injection (MFI) System”, EC-622.

Evaporative Emission System DESCRIPTION

NGEC0539

SEF569XA

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-626

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Evaporative Emission System (Cont’d)

INSPECTION EVAP Canister

NGEC0540 NGEC0540S01

Check EVAP canister as follows: 1. Pinch the fresh air hose. 2. Blow air into port A and check that it flows freely out of port B.

GI MA EM LC

AEC630A

Tightening Torque

NGEC0540S02

Tighten EVAP canister as shown in the figure. Make sure new O-ring is installed properly between EVAP canister and EVAP canister vent control valve.

FE CL MT

AEC631A

Fuel Tank Vacuum Relief Valve (Built into fuel fillerNGEC0540S03 cap) 1. 2.

SEF445Y

Wipe clean valve housing. Check valve opening pressure and vacuum. Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) 3. If out of specification, replace fuel filler cap as an assembly. CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come ON

AT TF PD AX SU BR ST RS

SEF943S

Vacuum Cut Valve and Vacuum Cut Valve Bypass NGEC0540S04 Valve BT Refer to EC-1117.

Evaporative Emission (EVAP) Canister Purge Volume HA Control Solenoid Valve NGEC0540S05 Refer to EC-939.

Tank Fuel Temperature Sensor

SC NGEC0540S06

Refer to EC-870.

EL

EC-627

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Evaporative Emission System (Cont’d)

Evap Service Port

NGEC0540S07

Positive pressure is delivered to the EVAP system through the EVAP service port. If fuel vapor leakage in the EVAP system occurs, use a leak detector to locate the leak.

SEF462UA

How to Detect Fuel Vapor Leakage

SEF200U

PEF838U

NGEC0540S08

CAUTION: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in EVAP system. NOTE: 쐌 Do not start engine. 쐌 Improper installation of EVAP service port adapter to the EVAP service port may cause a leak. With CONSULT-II 1) Attach the EVAP service port adapter securely to the EVAP service port. 2) Also attach the pressure pump and hose to the EVAP service port adapter. 3) Turn ignition switch ON. 4) Select the “EVAP SYSTEM CLOSE” of “WORK SUPPORT MODE” with CONSULT-II. 5) Touch “START”. A bar graph (Pressure indicating display) will appear on the screen. 6) Apply positive pressure to the EVAP system until the pressure indicator reaches the middle of the bar graph. 7) Remove EVAP service port adapter and hose with pressure pump. 8) Locate the leak using a leak detector. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-630.

PEF917U

EC-628

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Evaporative Emission System (Cont’d)

1) 2) 3)

4) SEF462UA

5) 6)

Without CONSULT-II Attach the EVAP service port adapter securely to the EVAP service port. Also attach the pressure pump with pressure gauge to the EVAP service port adapter. Apply battery voltage to between the terminals of both EVAP canister vent control valve and vacuum cut valve bypass valve to make a closed EVAP system. To locate the leak, deliver positive pressure to the EVAP system until pressure gauge points reach 1.38 to 2.76 kPa (0.014 to 0.028 kg/cm2, 0.2 to 0.4 psi). Remove EVAP service port adapter and hose with pressure pump. Locate the leak using a leak detector. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-630.

GI MA EM LC

FE CL MT

AEC632A

AT TF PD AX SU BR ST RS BT HA SC EL

EC-629

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Evaporative Emission System (Cont’d)

EVAPORATIVE EMISSION LINE DRAWING

NGEC0541

SEF795Z

EC-630

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Evaporative Emission System (Cont’d)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC AEC886A

EL

EC-631

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR)

On Board Refueling Vapor Recovery (ORVR)

NGEC0957

SYSTEM DESCRIPTION

NGEC0957S01

SEF206VA

From the beginning of refueling, the fuel tank pressure goes up. When the pressure reaches the setting value of the refueling control valve (RCV) opening pressure, the RCV is opened. After RCV opens, the air and vapor inside the fuel tank go through refueling EVAP vapor cut valve, RCV and refueling vapor line to the EVAP canister. The vapor is absorbed by the EVAP canister and the air is released to the atmosphere. When the refueling has reached the full level of the fuel tank, the refueling EVAP vapor cut valve is closed and refueling is stopped because of auto shut-off. The vapor which was absorbed by the EVAP canister is purged during driving. The RCV is always closed during driving and the evaporative emission control system is operated the same as conventional system. WARNING: When conducting inspections below, be sure to observe the following: 쐌 Put a “CAUTION: INFLAMMABLE” sign in workshop. 쐌 Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. 쐌 Be sure to furnish the workshop with a CO2 fire extinguisher. CAUTION: 쐌 Before removing fuel line parts, carry out the following procedures: a) Put drained fuel in an explosion-proof container and put lid on securely. b) Release fuel pressure from fuel line. Refer to “Fuel Pressure Release”, EC-644. c) Disconnect battery ground cable. 쐌 Always replace O-ring when the fuel gauge retainer is removed. 쐌 Do not kink or twist hose and tube when they are installed. 쐌 Do not tighten hose and clamps excessively to avoid damaging hoses. 쐌 After installation, run engine and check for fuel leaks at connection. 쐌 Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire.

EC-632

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

DIAGNOSTIC PROCEDURE Symptom: Fuel Odor from EVAP Canister Is Strong. 1

NGEC0957S02 NGEC0957S0201

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb).

MA

OK or NG OK

䊳

GO TO 2.

NG

䊳

GO TO 3.

2

GI

CHECK EVAP CANISTER

EM LC

CHECK IF EVAP CANISTER SATURATED WITH WATER

Does water drain from the EVAP canister?

FE CL MT AT SEF596U

Yes or No Yes

䊳

GO TO 3.

No (With CONSULT-II)

䊳

GO TO 6.

No (Without CONSULTII)

䊳

GO TO 7.

TF PD AX

3

REPLACE EVAP CANISTER

SU

Replace EVAP canister with a new one. 䊳

GO TO 4.

BR ST RS BT HA SC EL

EC-633

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

4 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace water separator.

5

DETECT MALFUNCTIONING PART

Check the EVAP hose between EVAP canister and water separator for clogging or poor connection. 䊳

Repair or replace EVAP hose.

EC-634

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

6 1. 2. a. b. c. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE With CONSULT-II Remove fuel tank. Refer to FE-5, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel feed hose located on the fuel gauge retainer. Connect a spare fuel hose, one side to fuel gauge retainer where the hose was removed and the other side to a fuel container. Drain fuel using “FUEL PUMP RELAY” in “ACTIVE TEST” mode with CONSULT-II. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable.

GI MA EM LC

FE CL MT AT TF PD AX

SEF707Z

SU

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

BR ST RS BT HA SC EL

EC-635

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

7 1. 2. a. b. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE Without CONSULT-II Remove fuel tank. Refer to FE-5, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel gauge retainer. Drain fuel from the tank using a hand pump into a fuel container. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable.

SEF707Z

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

EC-636

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

8

CHECK REFUELING CONTROL VALVE

1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage.

GI MA EM LC

FE CL MT AT SEF706Z

TF

OK or NG OK

䊳

INSPECTION END

NG

䊳

Replace refueling control valve with fuel tank.

Symptom: Cannot Refuel/Fuel Odor From The Fuel Filler Opening Is Strong While Refueling. 1

CHECK EVAP CANISTER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb).

PD AX NGEC0957S0202

SU BR

OK or NG OK

䊳

GO TO 2.

NG

䊳

GO TO 3.

ST RS BT HA SC EL

EC-637

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

2

CHECK IF EVAP CANISTER SATURATED WITH WATER

Does water drain from the EVAP canister?

SEF596U

Yes or No Yes

䊳

GO TO 3.

No

䊳

GO TO 6.

3

REPLACE EVAP CANISTER

Replace EVAP canister with a new one. 䊳

4 1. 2. 3. 4.

GO TO 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace water separator.

5

DETECT MALFUNCTIONING PART

Check the EVAP hose between EVAP canister and water separator for clogging or poor connection. 䊳

Repair or replace EVAP hose.

EC-638

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

6

CHECK VENT HOSES AND VENT TUBES

Check hoses and tubes between EVAP canister and refueling control valve for clogging, kink, looseness and improper connection. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair or replace hoses and tubes.

7

GI MA EM

CHECK FILLER NECK TUBE

LC

Check signal line and recirculation line for clogging, dents and cracks. OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace filler neck tube.

FE 8

CHECK REFUELING CONTROL VALVE

1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage.

CL MT AT TF PD AX SU BR ST

SEF706Z

OK or NG

RS

OK (With CONSULT-II)

䊳

GO TO 9.

OK (Without CONSULTII)

䊳

GO TO 10.

BT

NG

䊳

Replace refueling control valve with fuel tank.

HA SC EL

EC-639

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

9 1. 2. a. b. c. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE With CONSULT-II Remove fuel tank. Refer to FE-5, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel feed hose located on the fuel gauge retainer. Connect a spare fuel hose, one side to fuel gauge retainer where the hose was removed and the other side to a fuel container. Drain fuel using “FUEL PUMP RELAY” in “ACTIVE TEST” mode with CONSULT-II. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable.

SEF707Z

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

EC-640

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

10 1. 2. a. b. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE Without CONSULT-II Remove fuel tank. Refer to FE-5, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel gauge retainer. Drain fuel from the tank using a hand pump into a fuel container. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable.

GI MA EM LC

FE CL MT AT TF PD AX SEF707Z

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

11

SU BR

CHECK FUEL FILLER TUBE

Check filler neck tube and hose connected to the fuel tank for clogging, dents and cracks.

ST

OK or NG

RS

OK

䊳

GO TO 12.

NG

䊳

Replace fuel filler tube.

BT 12

CHECK ONE-WAY FUEL VALVE-I

HA

Check one-way valve for clogging. OK or NG OK

䊳

GO TO 13.

NG

䊳

Repair or replace one-way fuel valve with fuel tank.

SC EL

EC-641

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

13

CHECK ONE-WAY FUEL VALVE-II

1. Make sure that fuel is drained from the tank. 2. Remove fuel filler tube and hose. 3. Check one-way fuel valve for operation as follows. When a stick is inserted, the valve should open, when removing stick it should close.

SEF665U

Do not drop any material into the tank. OK or NG OK

䊳

INSPECTION END

NG

䊳

Replace fuel filler tube or replace one-way fuel valve with fuel tank.

Positive Crankcase Ventilation DESCRIPTION

SEC631AA

NGEC0542

This system returns blow-by gas to the intake manifold. The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection in the reverse direction. On vehicles with an excessively high blow-by, the valve does not meet the requirement. This is because some of the flow will go through the hose connection to the air inlet tubes under all conditions.

SEF559A

INSPECTION PCV (Positive Crankcase Ventilation) Valve

NGEC0543 NGEC0543S01

With engine running at idle, remove PCV valve ventilation hose from PCV valve; if the valve is working properly, 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.

SEC137A

EC-642

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33E

Positive Crankcase Ventilation (Cont’d)

PCV Valve Ventilation Hose 1. 2.

NGEC0543S02

Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.

GI MA EM LC

ET277

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-643

IDX

BASIC SERVICE PROCEDURE

VG33E

Fuel Pressure Release

Fuel Pressure Release

NGEC0544

Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.

WITH CONSULT-II 1. 2. 3. 4. SEF163X

5.

NGEC0544S01

Turn ignition switch ON. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode with CONSULT-II. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF.

PEF823K

WITHOUT CONSULT-II 1. 2. 3. 4. 5.

NGEC0544S02

Remove fuel pump fuse located in fuse box. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. Reinstall fuel pump fuse after servicing fuel system.

SEF164X

Fuel Pressure Check 쐌 쐌

1. 2.

3. 4. 5.

NGEC0545

Use Fuel Pressure Gauge J-44321 to check fuel pressure. Do not perform fuel pressure check with electrical systems operating (i.e. lights, rear defog., A/C ect.). Fuel pressure gauge may indicate false readings due to varying engine loads and changes in manifold vacuum. Release fuel pressure to zero. Install the inline fuel quick disconnect fitting between the connection of the fuel feed hose (from tank) and the fuel hose (to engine). Connect the fuel pressure test gauge (quick connect adapter hose) to quick disconnect fitting. Start engine and check for fuel leakage. Read the indication of fuel pressure gauge. At idling: With vacuum hose connected Approximately 235 kPa (2.4 kg/cm2, 34 psi) With vacuum hose disconnected Approximately 294 kPa (3.0 kg/cm2, 43 psi)

WEC875

EC-644

BASIC SERVICE PROCEDURE

VG33E Fuel Pressure Regulator Check

If results are unsatisfactory, perform Fuel Pressure Regulator Check.

GI MA EM LC

Fuel Pressure Regulator Check 1. 2. 3.

NGEC0546

Stop engine and disconnect fuel pressure regulator vacuum hose from intake manifold. Plug intake manifold with a blind cap. Connect variable vacuum source to fuel pressure regulator.

FE CL MT

SEF928U

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.

AT TF PD AX

SEF718BA

Injector REMOVAL AND INSTALLATION 1. 2. 3. 4. AEC635A

SEF966R

a. 쐌 쐌 쐌 쐌 b. c. 쐌 쐌 d. 쐌

SU NGEC0547

Release fuel pressure to zero. Refer to EC-644. Drain coolant by removing drain plugs from both sides of cylinder block. Separate ASCD and accelerator control wire from intake manifold collector. Remove intake manifold collector from engine. The following parts should be disconnected or removed. Harness connectors for IACV-AAC valve IACV-FICD solenoid valve Throttle position sensor and closed throttle position switch assembly Ground harness PCV valve ventilation hoses Vacuum hoses for Brake booster Fuel pressure regulator Air hoses from Air duct

EC-645

BR ST RS BT HA SC EL IDX

BASIC SERVICE PROCEDURE

VG33E

Injector (Cont’d)

쐌 e. 쐌 쐌 f. 5. 쐌 쐌 쐌 쐌 쐌 쐌

IACV-AAC valve Water hoses for Throttle body Air relief plug EVAP canister purge hose Remove injector fuel tube assembly. The following parts should be disconnected or removed. Vacuum hose for fuel pressure regulator Fuel feed and return hose All injectors harness connectors Push injector tail piece. Do not pull on connector. Do not extract injector by pinching.

6. 7. 쐌 쐌 8.

Push out any malfunctioning injector from injector fuel tube. Replace or clean injector as necessary. Always replace O-rings with new ones. Lubricate O-rings with engine oil. Install injector to injector fuel tube assembly.

SEF927X

9.

Install injectors with fuel tube assembly to intake manifold. Tighten in numerical order shown in the figure. a. First, tighten all bolts to 4.9 to 6.0 N·m (0.5 to 0.61 kg-m, 3.6 to 4.4 ft-lb). b. Then, tighten all bolts to 10.8 to 14.7 N·m (1.1 to 1.5 kg-m, 8 to 11 ft-lb). 10. Reinstall any part removed in reverse order of removal. CAUTION: After properly connecting fuel hose to injector and fuel tube, check connection for fuel leakage. SEF867W

Fast Idle Cam (FIC) INSPECTION AND ADJUSTMENT With CONSULT-II 1. 2. 3.

NGEC0548 NGEC0548S01

Turn ignition switch ON. See “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. When engine coolant temperature is 20 to 30°C (68 to 86°F), make sure that the center of mark A is aligned with mark B as shown in the figure.

SEF013Y

EC-646

BASIC SERVICE PROCEDURE

VG33E Fast Idle Cam (FIC) (Cont’d)

쐌

If NG, adjust by turning adjusting screw. Lock nut: : 0.98 - 1.96 N·m (10 - 20 kg-cm, 8.7 - 17.4 in-lb)

GI MA EM LC

SEF970R

4. 5. 쐌 쐌 쐌

Start engine and warm it up. When engine coolant temperature is 75 to 85°C (167 to 185°F), check the following. The center of mark A is aligned with mark C. The cam follower lever’s roller is not touching the fast idle cam. If NG, replace thermo-element and perform the above inspection and adjustment again.

FE CL MT

SEF971R

Without CONSULT-II 1. 2. 3.

NGEC0548S02

Turn ignition switch ON. Check voltage between ECM terminal 59 (Engine coolant temperature sensor signal) and ground. When the voltage is between 3.12 to 3.52V, make sure that the center of mark A is aligned with mark B as shown in the figure.

AT TF PD AX

SEF774U

쐌

If NG, adjust by turning adjusting screw. Lock nut: : 0.98 - 1.96 N·m (10 - 20 kg-cm, 8.7 - 17.4 in-lb)

SU BR ST RS

SEF970R

4. 5. 쐌 쐌 쐌

Start engine and warm it up. When the voltage is between 1.10 to 1.36V, check the following. The center of mark A is aligned with mark C. The cam follower lever’s roller is not touching the fast idle cam. If NG, replace thermo-element and perform the above inspection and adjustment again.

BT HA SC EL

SEF971R

EC-647

IDX

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment

NGEC0549

PREPARATION 1) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 2) 3) 4) 5) 6) 7)

NGEC0549S01

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 Evaporative emission system On air conditioner equipped models, checks should be carried out while the air conditioner is OFF. On automatic transmission equipped models, when checking idle rpm, ignition timing and mixture ratio, checks should be carried out while shift lever is in “N” position. When measuring “CO” percentage, insert probe more than 40 cm (15.7 in) into tail pipe. Turn off headlamps, heater blower, rear defogger. Keep front wheels pointed straight ahead. Make the check after the cooling fan has stopped.

EC-648

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

Overall Inspection Sequence

NGEC0549S0101

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST SEF554YA

NOTE: If a vehicle contains a part which is operating outside of design specifications with no MIL 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.

RS BT HA SC EL

EC-649

IDX

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

INSPECTION PROCEDURE 1

=NGEC0549S02

INSPECTION START

1. Visually check the following: 쐌 Air cleaner clogging 쐌 Hoses and ducts for leaks 쐌 Electrical connectors 쐌 Gasket 쐌 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 stays below 1,000 rpm.

SEF976U

3. Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load.

SEF977U

4. Make sure that no DTC is displayed with CONSULT-II or GST. OK or NG OK

䊳

GO TO 2.

NG

䊳

1. Repair or replace components as necessary. 2. GO TO 2.

EC-650

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

2

CHECK IGNITION TIMING

1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed.

GI MA EM LC SEF978U

3. Turn off engine and disconnect throttle position sensor harness connector.

FE CL MT SEF975R

4. Start and rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run at idle speed. 5. Check ignition timing with a timing light.

AT TF PD AX SU

SEF927Z

10°±2° BTDC (in “P” or “N” position)

BR

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

ST RS BT HA SC EL

EC-651

IDX

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

3

ADJUST IGNITION TIMING

1. Adjust ignition timing by turning distributor after loosening securing bolts. 2. Turn off engine and connect throttle position sensor harness connector to throttle position sensor.

SEF972R

䊳

4

GO TO 2.

CHECK BASE IDLE SPEED

With CONSULT-II 1. Read idle speed in “DATA MONITOR” mode with CONSULT-II.

SEF058Y

700±50 rpm (in “P” or “N” position) Without CONSULT-II 1. Check idle speed. 700±50 rpm (in “P” or “N” position) OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

EC-652

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

5

ADJUST BASE IDLE SPEED

1. Rev engine (2,000 to 3,000 rpm) 2 or 3 times under no-load then run engine at idle speed. 2. Adjust idle speed by turning idle speed adjusting screw.

GI MA EM LC

LEC513

700±50 rpm (in “P” or “N” position)

FE 䊳

GO TO 6.

CL 6

CHECK TARGET IDLE SPEED

With CONSULT-II 1. Turn off engine and connect throttle position sensor harness connector. 2. Start and rev engine (2,000 to 3,000 rpm) 2 or 3 times under no-load then run at idle speed. 3. Read idle speed in “DATA MONITOR” mode with CONSULT-II.

MT AT TF PD AX SEF058Y

750±50 rpm (in “P” or “N” position) Without CONSULT-II 1. Turn off engine and connect throttle position sensor harness connector. 2. Start and rev engine (2,000 to 3,000 rpm) 2 or 3 times under no-load then run at idle speed. 3. Check idle speed. 750±50 rpm (in “P” or “N” position) OK or NG OK (With CONSULT-II)

䊳

GO TO 8.

OK (Without CONSULTII)

䊳

GO TO 9.

NG

䊳

GO TO 7.

SU BR ST RS BT HA SC EL

EC-653

IDX

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

7

DETECT MALFUNCTIONING PART

Check the following. 1. Check IACV-AAC valve and replace if necessary. Refer to EC-1006. 2. Check IACV-AAC valve harness and repair if necessary. Refer to EC-1006. 3. Check ECM function by substituting another known-good ECM. (ECM may be the cause of a problem, but this is rarely the case.) With CONSULT-II

䊳

GO TO 8.

Without CONSULT-II

䊳

GO TO 9.

8

CHECK HEATED OXYGEN SENSOR 1 (BANK 2) SIGNAL

With CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. See “HO2S1 MNTR (B2)” in “DATA MONITOR” mode. 3. Running 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 5 times during 10 seconds.

SEF945Y

OK or NG OK

䊳

GO TO 12.

NG (Monitor does not fluctuate.)

䊳

GO TO 17.

NG (Monitor fluctuates less than 5 times.)

䊳

GO TO 10.

9

CHECK HEATED OXYGEN SENSOR 1 (BANK 2) SIGNAL

Without CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Set voltmeter probe between ECM terminal 62 and ground. 3. Make sure that the voltage fluctuates between 0 - 0.3V and 0.6 - 1.0V more than 5 times during 10 seconds at 2,000 rpm. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V OK or NG OK

䊳

GO TO 12.

NG (Voltage does not fluctuate.)

䊳

GO TO 17.

NG (Voltage fluctuates less than 5 times.)

䊳

GO TO 10.

EC-654

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

10 1. 2. 3. 4. 5. 6.

1. 2. 3. 4. 5. 6.

CHECK HEATED OXYGEN SENSOR 1 (BANK 2) SIGNAL With CONSULT-II Stop engine. Replace heated oxygen sensor 1 (bank 2). Start engine and warm it up to normal operating temperature. Run engine at approx. 2,000 rpm for approx. 2 minutes under no-load. See “HO2S1 MNTR (B2)” in “DATA MONITOR” mode. Running 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 5 times during 10 seconds. 1 time: RICH → LEAN → RICH 2 times: RICH → LEAN → RICH → LEAN → RICH Without CONSULT-II Stop engine. Replace heated oxygen sensor 1 (bank 2). Start engine and warm it up to normal operating temperature. Run engine at approx. 2,000 rpm for approx. 2 minutes under no-load. Set voltmeter probe between ECM terminal 62 and ground. Make sure that the voltage fluctuates between 0 - 0.3V and 0.6 - 1.0V more than 5 times during 10 seconds at 2,000 rpm. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V OK or NG

OK (With CONSULT-II)

䊳

GO TO 12.

OK (Without CONSULTII)

䊳

GO TO 13.

NG

䊳

GO TO 11.

GI MA EM LC

FE CL MT AT TF

11

DETECT MALFUNCTIONING PART

Check the following. 1. Check fuel pressure regulator. Refer to EC-645. 2. Check mass air flow sensor and its circuit. Refer to EC-761. 3. Check injector and its circuit. Refer to EC-1145. Clean or replace if necessary. 4. Check engine coolant temperature sensor and its circuit. Refer to EC-793. 5. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.) 䊳

PD AX SU

GO TO 2.

BR ST RS BT HA SC EL

EC-655

IDX

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

12

CHECK HEATED OXYGEN SENSOR 1 (BANK 1) SIGNAL

With CONSULT-II 1. See “HO2S1 (B1)” in “DATA MONITOR” mode. 2. Maintaining 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 5 times during 10 seconds.

SEF945Y

OK or NG OK

䊳

INSPECTION END

NG (Monitor does not fluctuate.)

䊳

GO TO 16.

NG (Monitor fluctuates less than 5 times.)

䊳

GO TO 14.

13

CHECK HEATED OXYGEN SENSOR 1 (BANK 1) SIGNAL

Without CONSULT-II 1. Set voltmeter probe between ECM terminal 63 and ground. 2. Make sure that the voltage fluctuates between 0 - 0.3V and 0.6 - 1.0V more than 5 times during 10 seconds at 2,000 rpm. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V OK or NG OK

䊳

INSPECTION END

NG (Voltage does not fluctuate.)

䊳

GO TO 16.

NG (Voltage fluctuates less than 5 times.)

䊳

GO TO 14.

EC-656

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

14 1. 2. 3. 4. 5. 6.

1. 2. 3. 4. 5. 6.

CHECK HEATED OXYGEN SENSOR 1 (BANK 1) SIGNAL With CONSULT-II Stop engine. Replace heated oxygen sensor 1 (bank 1). Start engine and warm it up to normal operating temperature. Run engine at approx. 2,000 rpm for approx. 2 minutes under no-load. See “HO2S1 MNTR (B1)” in “DATA MONITOR” mode. Maintaining 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 5 times during 10 seconds. 1 time: RICH → LEAN → RICH 2 times: RICH → LEAN → RICH → LEAN → RICH Without CONSULT-II Stop engine. Replace heated oxygen sensor 1 (bank 1). Start engine and warm it up to normal operating temperature. Run engine at approx. 2,000 rpm for approx. 2 minutes under no-load. Set voltmeter probe between ECM terminal 63 and ground. Make sure that the voltage fluctuates between 0 - 0.3V and 0.6 - 1.0V more than 5 times during 10 seconds at 2,000 rpm. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V OK or NG

OK

䊳

INSPECTION END

NG

䊳

GO TO 15.

15

MA EM LC

FE CL MT AT

DETECT MALFUNCTIONING PART

Check the following. 1. Check fuel pressure regulator. Refer to EC-645. 2. Check mass air flow sensor and its circuit. Refer to EC-761. 3. Check injector and its circuit. Refer to EC-1145. Clean or replace if necessary. 4. Check engine coolant temperature sensor and its circuit. Refer to EC-793. 5. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.) 䊳

16 1. 2. 3. 4.

GI

GO TO 2.

TF PD AX SU

CHECK HEATED OXYGEN SENSOR 1 (BANK 1) HARNESS Turn off engine and disconnect battery ground cable. Disconnect ECM harness connector. Disconnect heated oxygen sensor 1 (bank 1) harness connector. Check harness continuity between ECM terminal 50 and heated oxygen sensor 1 (bank 1) harness connector. Continuity should exist. OK or NG

OK

䊳

1. Connect ECM harness connector. 2. GO TO 18.

NG

䊳

1. Repair or replace harness. 2. GO TO 8. (With CONSULT-II) GO TO 9. (Without CONSULT-II)

BR ST RS BT HA SC EL

EC-657

IDX

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

17 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 1 (BANK 2) HARNESS Turn off engine and disconnect battery ground cable. Disconnect ECM harness connector. Disconnect heated oxygen sensor 1 (bank 2) harness connector. Check harness continuity between ECM terminal 51 and heated oxygen sensor 1 (bank 2) harness connector. Continuity should exist. OK or NG

OK

䊳

1. Connect ECM harness connector. 2. GO TO 18.

NG

䊳

1. Repair or replace harness. 2. GO TO 8. (With CONSULT-II) GO TO 9. (Without CONSULT-II)

18

PREPARATION FOR “CO” % CHECK

With CONSULT-II 1. Select “COOLANT TEMP” in “ACTIVE TEST” mode. 2. Set “COOLANT TEMP” to 5°C (41°F) by touching “DWN” and “Qd”.

SEF172Y

Without CONSULT-II 1. Disconnect engine coolant temperature sensor harness connector. 2. Connect a resistor (4.4 kΩ) between terminals of engine coolant temperature sensor harness connector.

AEC036B

䊳

GO TO 19.

EC-658

BASIC SERVICE PROCEDURE

VG33E

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

19

CHECK “CO” %

1. Start engine and warm it up until engine coolant temperature indicator points to the middle of gauge.

GI MA EM LC SEF976U

2. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed.

FE CL SEF978U

3. Check “CO” %. Idle CO: 1.5 - 9.5% 4. Without CONSULT-II After checking CO%, a. Disconnect the resistor from terminals of engine coolant temperature sensor. b. Connect engine coolant temperature sensor harness connector to engine coolant temperature sensor.

MT AT TF

OK or NG OK

䊳

1. Replace front heated oxygen sensor LH. 2. GO TO 10.

PD

NG

䊳

GO TO 20.

AX

20

DETECT MALFUNCTIONING PART

Check the following. 1. Connect front heated oxygen sensor harness connectors to front heated oxygen sensors. 2. Check fuel pressure regulator. Refer to EC-645. 3. Check mass air flow sensor and its circuit. Refer to EC-761. 4. Check injector and its circuit. Refer to EC-1145. Clean or replace if necessary. 5. Check engine coolant temperature sensor and its circuit. Refer to EC-793. 6. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.) 䊳

GO TO 2.

SU BR ST RS BT HA SC EL

EC-659

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Introduction

Introduction

NGEC0550

The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including: Emission-related diagnostic information

SAE Mode

Diagnostic Trouble Code (DTC)

Mode 3 of SAE J1979

Freeze Frame data

Mode 2 of SAE J1979

System Readiness Test (SRT) code

Mode 1 of SAE J1979

1st Trip Diagnostic Trouble Code (1st Trip DTC)

Mode 7 of SAE J1979

1st Trip Freeze Frame data Test values and Test limits

Mode 6 of SAE J1979

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

CONSULT-II

X

X

X

X

X

—

GST

X

X*1

X

—

X

X

*1: 1st trip DTCs for self-diagnoses concerning SRT items cannot be shown on the GST display.

The malfunction indicator lamp (MIL) 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-716.)

Two Trip Detection Logic

NGEC0551

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 MIL 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 MIL lights up. The MIL 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 MIL, and store DTC and Freeze Frame data, even in the 1st trip, as shown below. X: Applicable MIL Items

DTC

1st trip

—: Not applicable 1st trip DTC

2nd trip

1st trip 2nd trip 1st trip 2nd trip Lighting up displaying displaying displaying displaying

Blinking

Lighting up

Blinking

Coolant overtemperature enrichment protection — DTC: P0217

—

X

—

—

X

—

X

—

Misfire (Possible three way catalyst damage) — DTC: P0300 P0306 is being detected

X

—

—

—

—

—

X

—

Misfire (Possible three way catalyst damage) — DTC: P0300 P0306 is being detected

—

—

X

—

—

X

—

—

Closed loop control — DTC: P1148, P1168

—

X

—

—

X

—

X

—

Fail-safe items (Refer to EC-716.)

—

X

—

—

X*1

—

X*1

—

Except above

—

—

—

X

—

X

X

—

*1: Except “ECM”

EC-660

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information

Emission-related Diagnostic Information DTC AND 1ST TRIP DTC

NGEC0552 NGEC0552S01

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 MIL 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 MIL lights up. In other words, the DTC is stored in the ECM memory and the MIL 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 MIL 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”, EC-673. For malfunctions in which 1st trip DTCs are displayed, refer to EC-670. 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 SAE J1979. 1st trip DTC detection occurs without lighting up the MIL 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 EC-699. 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

GI MA EM LC

FE CL MT AT

NGEC0552S0101

DTC and 1st trip DTC can be read by the following methods. With CONSULT-II With GST CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P0705, P0750, etc. These DTCs are prescribed by SAE J2012. (CONSULT-II also displays the malfunctioning component or system.) 쐌 1st trip DTC No. is the same as DTC No. 쐌 Output of a DTC indicates a malfunction. However, 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 and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. If the DTC is being detected currently, the time data will be “0”. If a 1st trip DTC is stored in the ECM, the time data will be “[1t]”.

TF PD AX SU BR ST RS BT HA

SEC652C

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA

SC NGEC0552S02

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 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.

EC-661

EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d)

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-686. 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/MIL on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data. Priority 1 2 3

Items Freeze frame data

Misfire — DTC: P0300 - P0306 Fuel Injection System Function — DTC: P0171, P0172, P0174, P0175 Except the above items (Includes A/T related items)

1st trip freeze frame data

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”, EC-673.

SYSTEM READINESS TEST (SRT) CODE

NGEC0552S03

System Readiness Test (SRT) code is specified in Mode 1 of SAE J1979. As part of enhanced emissions test for Inspection and Maintenance (I/M), certain states require that the status of srt be used to indicate whether the ECM has completed self-diagnosis of major emission systems and components. Completion must be verified in order for the emissions inspection to proceed. If a vehicle is rejected for a State emissions inspection due to one or more SRT items indicating “INCMP”, use the information in this service manual to set the SRT to “CMPLT”. In most cases, the ECM will automatically complete its self-diagnosis cycle during normal usage and the SRT status will indicate “CMPLT” for each application system. Once set as “CMPLT”, the SRT status remains “CMPLT” until the self-diagnosis memory is erased. Occasionally, certain portions of the self-diagnostic test may not be completed as a result of the customer’s normal driving pattern and the SRT will indicate “INCMP” for these items. NOTE: The SRT will also indicate “INCMP” if the self-diagnosis memory is erased for any reason or if the ECM memory power supply is interrupted for several hours. If, during the state emissions inspection, the SRT indicates “CMPLT” for all test items, the inspector will continue with the emissions test. However, if the SRT indicates “INCMP” for one or more of the SRT items, the vehicle is returned to the customer untested. NOTE: If MIL is “ON” during the state emissions inspection, the vehicle is also returned to the customer untested even though the SRT indicates “CMPLT” for all test items. Therefore, it is important to check SRT (“CMPLT”) and DTC (No DTCs) before the inspection.

EC-662

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d)

SRT Item

=NGEC0552S0314

The following table shows required self-diagnostic items to set the SRT to “CMPLT”. SRT item (CONSULT-II indication)

Performance Priority *

Required self-diagnostic items to set the SRT to ″CMPLT″

Corresponding DTC No.

CATALYST

3

Three way catalyst function

P0420, P0430

EVAP SYSTEM

2

EVAP control system (small leak) (negative pressure)

P0442

3

EVAP control system (very small leak) (negative pressure)/ (positive pressure)

P0456, P1456

3

EVAP control system purge flow monitoring

P0441

3

Heated oxygen sensor 1 (circuit)

P0134, P0154

Heated oxygen sensor 1 (lean shift monitoring)

P1143, P1163

Heated oxygen sensor 1 (rich shift monitoring)

P1144, P1164

Heated oxygen sensor 1 (response monitoring)

P0133, P0153

Heated oxygen sensor 1 (high voltage)

P0132, P0152

Heated oxygen sensor 2 (min. voltage monitoring)

P1146, P1166

Heated oxygen sensor 2 (max. voltage monitoring)

P1147, P1167

Heated oxygen sensor 2 (response monitoring)

P0139, P0159

Heated oxygen sensor 2 (high voltage)

P0138, P0158

Heated oxygen sensor 1 heater (front)

P0031, P0032, P0051, P0052

Heated oxygen sensor 2 heater (rear)

P0037, P0038, P0057, P0058

HO2S

HO2S HEATER

3

GI MA EM LC

FE CL MT AT

*: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure) one by one based on the priority for models with CONSULT-II.

SRT Set Timing

NGEC0552S0301

SRT is set as “CMPLT” after self-diagnosis has been performed one or more times. Completion of SRT will occur if the result is OK or NG. The set timing is different between them and is shown in the following table.

TF PD AX SU BR ST RS BT HA SC EL

EC-663

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d) Self-diagnosis result

Example Ignition OFF – ON – OFF

Diagnosis All OK

Ignition OFF – ON – OFF

Ignition OFF – ON – OFF

Ignition OFF – ON – OFF

P0400

OK (1)

– (1)

OK (2)

– (2)

P0402

OK (1)

– (1)

– (1)

OK (2)

P1402

OK (1)

OK (2)

– (2)

– (2)

“CMPLT”

“CMPLT”

“CMPLT”

“CMPLT”

P0400

OK (1)

– (1)

– (1)

– (1)

P0402

– (0)

– (0)

OK (1)

– (1)

P1402

OK (1)

OK (2)

– (2)

– (2)

“INCMP”

“INCMP”

“CMPLT”

“CMPLT”

P0400

OK

OK

–

–

P0402

–

–

–

–

NG

–

NG

NG (Consecutive NG)

(1st trip) DTC

1st trip DTC

–

1st trip DTC

DTC (=MIL “ON”)

SRT of EGR

“INCMP”

“INCMP”

“INCMP”

“CMPLT”

Case 1 SRT of EGR

Case 2 SRT of EGR NG exists

Case 3

P1402

OK: Self-diagnosis is carried out and the result is OK. NG: Self-diagnosis is carried out and the result is OK. –: Self-diagnosis is not carried out.

When all SRT related self-diagnoses showed OK results in a same cycle (Ignition OFF – ON – OFF), the SRT will indicate “CMPLT”. , Case 1 above When all SRT related self-diagnoses show OK results through several different cycles, the SRT will indicate “CMPLT” at the time the respective self-diagnoses have at least one OK result. , Case 2 above If one or more SRT related self-diagnoses showed NG results in 2 consecutive cycles, the SRT will also indicate “CMPLT”. , Case 3 above The previous table shows that the minimum number of cycles for setting SRT as “INCMP” is one (1) for each self-diagnosis (Case 1 and 2) or two (2) for one self-diagnosis (Case 3). However, in preparation for the State emissions inspection, it is unnecessary of each self-diagnosis to be executed twice (Case 3) because of the following reasons; 쐌 The SRT will indicate “CMPLT” at the time the respective self-diagnoses have one (1) OK result. 쐌 The emissions inspection requires “CMPLT” of the SRT only with OK self-diagnosis result. 쐌 When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to “CMPLT” of SRT, the self-diagnosis memory must be erased from ECM after repair. 쐌 If the 1st trip DTC is erased, all the SRT will indicate “INCMP”. NOTE: SRT can be set as “CMPLT” together with the DTC(s). Therefore, DTC check must always be carried out prior to the State emission inspection even though the SRT indicates “CMPLT”.

SRT Service Procedure

NGEC0552S0302

If a vehicle has been rejected for the State emissions inspection due to one or more SRT items indicating “INCMP”, review the following flowchart diagnostic sequence on the next page.

EC-664

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST SEF170Z

*1

EC-661

*2

EC-665

*3

RS

EC-666

BT

How to Display SRT Code

NGEC0552S0303

1.

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. 2. With GST Selecting Mode 1 with GST (Generic Scan Tool) A sample of CONSULT-II display for SRT code is shown below. “INCMP” means the self-diagnosis is incomplete and SRT is not set. “CMPLT” means the self-diagnosis is complete and SRT is set.

EC-665

HA SC EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d)

SEF949Z

How to Set SRT Code

NGEC0552S0304

To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each diagnosis may require a long period of actual driving under various conditions. With CONSULT-II Perform corresponding DTC confirmation procedure one by one based on “Performance Priority” in the table on EC-661. Without CONSULT-II The most efficient driving pattern in which SRT codes can be properly set is explained on EC-667. The driving pattern should be performed one or more times to set all SRT codes.

EC-666

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d)

Driving Pattern

NGEC0552S0305

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEF947YA

EC-667

EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d)

쐌

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: 쐌 The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F) (where the voltage between the ECM terminal 59 and ground is 3.0 - 4.3V). 쐌 The engine must be operated at idle speed until the engine coolant temperature is greater than 70°C (158°F) (where the voltage between the ECM terminal 59 and ground is lower than 1.4V). 쐌 The engine is started at the tank fuel temperature of warmer than 0°C (32°F) (where the voltage between the ECM terminal 60 and ground is less than 4.1V). Pattern 2: 쐌 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. Pattern 3: 쐌 The driving pattern outlined in *2 must be repeated at least 3 times. Pattern 4: 쐌 Tests are performed after the engine has been operated for at least 17 minutes. 쐌 The accelerator pedal must be held very steady during steady-state driving. 쐌 If the accelerator pedal is moved, the test must be conducted all over again. *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: Operate the vehicle in the following driving pattern. 1) Decelerate vehicle to 0 km/h (0 MPH) and let engine idle. 2) Repeat driving pattern shown below at least 10 times. 쐌 During acceleration, hold the accelerator pedal as steady as possible.

SEF414S

*3: Checking the vehicle speed with CONSULT-II or GST is advised. Suggested Transmission Gear Position for A/T Models Set the selector lever in the “D” position with the overdrive switch turned ON. 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.

EC-668

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d) For normal acceleration in low altitude areas [less than 1,219 m (4,000 ft)]:

For quick acceleration in low altitude areas and high altitude areas [over 1,219 m (4,000 ft)]:

ACCEL shift point km/h (MPH)

CRUISE shift point km/h (MPH)

km/h (MPH)

1st to 2nd

24 (15)

24 (15)

24 (15)

2nd to 3rd

40 (25)

29 (18)

40 (25)

3rd to 4th

58 (36)

48 (30)

64 (40)

4th to 5th

64 (40)

63 (39)

72 (45)

Gear change

MA EM LC

Suggested Maximum Speed in Each Gear Downshift to a lower gear if the engine is not running smoothly, or if you need to accelerate. Do not exceed the maximum suggested speed (shown below) in any gear. For level road driving, use the highest gear suggested for that speed. Always observe posted speed limits and drive according to the road conditions to ensure safe operation. Do not over-rev the engine when shifting to a lower gear as it may cause engine damage or loss of vehicle control. Gear

km/h (MPH) 2WD (AUTO mode)

1st

50 (30)

2nd

95 (60)

GI

FE CL MT

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)

NGEC0552S04

The following is the information specified in Mode 6 of SAE J1979. 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 (30 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.

AT TF PD

—: Not applicable

AX

Test limit

Application

SU BR

X: Applicable Test value (GST display) SRT item

Self-diagnostic test item TID

CID

Three way catalyst function (Right bank)

01H

01H

Max.

X

Three way catalyst function (Left bank)

03H

02H

Max.

X

EVAP control system (Small leak)

05H

03H

Max.

X

EVAP control system purge flow monitoring

06H

83H

Min.

X

CATALYST

ST

EVAP SYSTEM

RS BT HA SC EL

EC-669

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d) Test value (GST display) SRT item

Self-diagnostic test item

Test limit

Application

04H

Max.

X

0AH

84H

Min.

X

0BH

04H

Max.

X

0CH

04H

Max.

X

0DH

04H

Max.

X

11H

05H

Max.

X

12H

85H

Min.

X

13H

05H

Max.

X

14H

05H

Max.

X

15H

05H

Max.

X

19H

86H

Min.

X

1AH

86H

Min.

X

1BH

06H

Max.

X

1CH

06H

Max.

X

21H

87H

Min.

X

22H

87H

Min.

X

23H

07H

Max.

X

24H

07H

Max.

X

29H

08H

Max.

X

2AH

88H

Min.

X

2BH

09H

Max.

X

2CH

89H

Min.

X

Heated oxygen sensor 2 heater (bank 1)

2DH

0AH

Max.

X

2EH

8AH

Min.

X

Heated oxygen sensor 2 heater (bank 2)

2FH

0BH

Max.

X

30H

8BH

Min.

X

Heated oxygen sensor 1 (bank 1)

Heated oxygen sensor 1 (bank 2)

TID

CID

09H

HO2S

Heated oxygen sensor 2 (bank 1)

Heated oxygen sensor 2 (bank 2)

Heated oxygen sensor 1 heater (bank 1) Heated oxygen sensor 1 heater (bank 2) HO2S HEATER

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS

NGEC0552S05

X: Applicable Items (CONSULT-II screen terms)

—: Not applicable

SRT code

Test value/ Test limit (GST only)

1st trip DTC*1

Reference page

DTC*1*2 CONSULT-II GST

NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED.

P0000

—

—

—

—

HO2S1 HTR (B1)

P0031

X

X

X*5

EC-746

HO2S1 HTR (B1)

P0032

X

X

X*5

EC-746

HO2S2 HTR (B1)

P0037

X

X

X*5

EC-753

HO2S2 HTR (B1)

P0038

X

X

X*5

EC-753

EC-670

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d) Items (CONSULT-II screen terms)

SRT code

Test value/ Test limit (GST only)

1st trip DTC*1

Reference page

DTC*1*2 CONSULT-II GST

HO2S1 HTR (B2)

P0051

X

X

X*5

EC-746

HO2S1 HTR (B2)

P0052

X

X

X*5

EC-746

HO2S2 HTR (B2)

P0057

X

X

X*5

EC-753

HO2S2 HTR (B2)

P0058

X

X

X*5

EC-753

MAF SEN/CIRCUIT

P0101

—

—

X

EC-761

MAF SEN/CIRCUIT

P0102*3

—

—

—

EC-761

MAF SEN/CIRCUIT

P0103*3

—

—

—

EC-761

IAT SEN/CIRCUIT

P0112

—

—

—

EC-770

IAT SEN/CIRCUIT

P0113

—

—

—

EC-770

ECT SEN/CIRCUIT

P0117*3

—

—

—

EC-775

ECT SEN/CIRCUIT

P0118*3

—

—

—

EC-775

TP SEN/CIRCUIT

P0121

—

—

X

EC-780

TP SEN/CIRCUIT

P0122*3

—

—

—

EC-780

TP SEN/CIRCUIT

P0123*3

—

—

—

EC-780

ECT SENSOR

P0125

—

—

X

EC-793

IAT SENSOR

P0127

—

—

X

EC-770

THERMSTAT FNCTN

P0128

—

—

X

EC-798

HO2S1 (B1)

P0132

X

X

X*5

EC-800

HO2S1 (B1)

P0133

X

X

X*5

EC-808

HO2S1 (B1)

P0134

X

X

X*5

EC-822

HO2S2 (B1)

P0138

X

X

X*5

EC-833

HO2S2 (B1)

P0139

X

X

X*5

EC-843

HO2S1 (B2)

P0152

X

X

X*5

EC-1056

HO2S1 (B2)

P0153

X

X

X*5

EC-808

HO2S1 (B2)

P0154

X

X

X*5

EC-822

HO2S2 (B2)

P0158

X

X

X*5

EC-833

HO2S2 (B2)

P0159

X

X

X*5

EC-843

FUEL SYS-LEAN-B1

P0171

—

—

X

EC-853

FUEL SYS-RICH-B1

P0172

—

—

X

EC-853

FUEL SYS-LEAN-B2

P0174

—

—

X

EC-862

FUEL SYS-RICH-B2

P0175

—

—

X

EC-862

FTT SENSOR

P0181

—

—

X

EC-870

FTT SEN/CIRCUIT

P0182

—

—

X

EC-870

FTT SEN/CIRCUIT

P0183

—

—

X

EC-870

ENG OVER TEMP

P0217

—

—

X

EC-875

MULTI CYL MISFIRE

P0300

—

—

X

EC-882

CYL1 MISFIRE

P0301

—

—

X

EC-882

EC-671

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d) Items (CONSULT-II screen terms)

SRT code

Test value/ Test limit (GST only)

1st trip DTC*1

Reference page

DTC*1*2 CONSULT-II GST

CYL2 MISFIRE

P0302

—

—

X

EC-882

CYL3 MISFIRE

P0303

—

—

X

EC-882

CYL4 MISFIRE

P0304

—

—

X

EC-882

CYL5 MISFIRE

P0305

—

—

X

EC-882

CYL6 MISFIRE

P0306

—

—

X

EC-882

KNOCK SEN/CIRC-B1

P0327

—

—

—

EC-891

KNOCK SEN/CIRC-B1

P0328

—

—

—

EC-891

CKP SEN/CIRCUIT

P0335

—

—

X

EC-895

CMP SEN/CIRCUIT

P0340

—

—

X

EC-901

TW CATALYST SYS-B1

P0420

X

X

X*5

EC-908

TW CATALYST SYS-B2

P0430

X

X

X*5

EC-908

EVAP PURG FLOW/MON

P0441

X

X

X*5

EC-913

EVAP SMALL LEAK

P0442

X

X

X*5

EC-925

PURG VOLUME CONT/V

P0444

—

—

X

EC-939

PURG VOLUME CONT/V

P0445

—

—

X

EC-939

VENT CONTROL VALVE

P0447

—

—

X

EC-946

EVAP SYS PRES SEN

P0452

—

—

X

EC-952

EVAP SYS PRES SEN

P0453

—

—

X

EC-952

EVAP GROSS LEAK

P0455

X

X

X*5

EC-963

EVAP VERY SML LEAK

P0456

X*4

X

X*5

EC-976

FUEL LEV SEN SLOSH

P0460

—

—

X

EC-990

FUEL LEVEL SENSOR

P0461

—

—

X

EC-995

FUEL LEVL SEN/CIRC

P0462

—

—

X

EC-997

FUEL LEVL SEN/CIRC

P0463

—

—

X

EC-997

VEH SPEED SEN/CIRC

P0500*5

—

—

X

EC-1002

ISC SYSTEM/CIRC

P0505

—

—

X

EC-1006

CLOSED TP SW/CIRC

P0510

—

—

X

EC-1012

P0600*4

—

—

—

EC-1019

ECM

P0605

—

—

X

EC-1024

PNP SW/CIRC

P0705

—

—

X

AT-104

ATF TEMP SEN/CIRC

P0710

—

—

X

AT-110

VEH SPD SEN/CIR AT

P0720

—

—

X

AT-116

ENGINE SPEED SIG

P0725

—

—

X

AT-121

A/T 1ST GR FNCTN

P0731

—

—

X

AT-125

A/T 2ND GR FNCTN

P0732

—

—

X

AT-131

A/T 3RD GR FNCTN

P0733

—

—

X

AT-137

A/T 4TH GR FNCTN

P0734

—

—

X

AT-143

A/T COMM LINE

EC-672

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d) Items (CONSULT-II screen terms)

SRT code

Test value/ Test limit (GST only)

1st trip DTC*1

DTC*1*2 CONSULT-II GST

Reference page

TCC SOLENOID/CIRC

P0740

—

—

X

AT-152

A/T TCC S/V FNCTN

P0744

—

—

X

AT-157

L/PRESS SOL/CIRC

P0745

—

—

X

AT-167

SFT SOL A/CIRC

P0750*3

—

—

X

AT-169

SFT SOL B/CIRC

P0755*3

—

—

X

AT-174

HO2S1 (B1)

P1143

X

X

X*5

EC-1026

HO2S1 (B1)

P1144

X

X

X*5

EC-1035

HO2S1 (B1)

P1146

X

X

X*5

EC-1044

HO2S2 (B1)

P1147

X

X

X*5

EC-1054

CLOSED LOOP-B1

P1148

—

—

X*5

EC-1064

HO2S1 (B2)

P1163

X

X

X*5

EC-1026

HO2S1 (B2)

P1164

X

X

X*5

EC-1035

HO2S2 (B2)

P1166

X

X

X*5

EC-1044

HO2S2 (B2)

P1167

X

X

X*5

EC-1054

CLOSED LOOP-B2

P1168

—

—

X

EC-1064

ENG OVER TEMP

P1217

—

—

X

EC-1066

CKP SENSOR (COG)

P1336

—

—

X

EC-1071

EVAP SMALL LEAK

P1442

X

X

X*5

EC-1078

PURG VOLUME CONT/V

P1444

—

—

X

EC-1080

VENT CONTROL VALVE

P1446

—

—

X

EC-1092

VENT CONTROL VALVE

P1448

—

—

X

EC-1099

EVAP VERY SML LEAK

P1456

X*4

X

X*5

EC-976

FUEL LEVEL SEN/CIRK

P1464

—

—

X

EC-1107

VC/V BYPASS/V

P1490

—

—

X

EC-1111

VC CUT/V BYPASS/V

P1491

—

—

X

EC-1117

A/T DIAG COMM LINE

P1605

—

—

X

EC-1126

P1705*5

—

—

X

AT-179

P-N POS SW/CIRCUIT

P1706

—

—

X

EC-1129

O/R CLTCH SOL/CIRC

P1760

—

—

X

AT-188

TP SEN/CIRC A/T

*1: 1st trip DTC No. 1 is the same as DTC No. *2: These numbers are prescribed by SAE J2012. *3: When the fail-safe operation occurs, the MIL illuminates. *4: SRT code will not be set if the self-diagnostic result is NG. *5: These are not displayed with GST. NOTE: Regarding D22 models, “B1” indicates bank 1, “B2” indicates bank 2.

HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC ( With CONSULT-II) NOTE: If the DTC is not for A/T related items (see EC-601), skip steps 2 through 4.

EC-673

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC

NGEC0552S06 NGEC0552S0601

EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d)

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 “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.) 쐌 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).

SEF823YA

The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFDIAG RESULTS” mode with CONSULT-II.

How to Erase DTC (

With GST)

NGEC0552S0602

NOTE: If the DTC is not for A/T related items (see EC-601), skip step 2. 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 “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 in the ECM can be erased by selecting Mode 4 with GST.

EC-674

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Emission-related Diagnostic Information (Cont’d)

쐌

If the battery is disconnected, the emission-related diagnostic information will be lost after approx. 24 hours. 쐌 Erasing the emission-related diagnostic information using CONSULT-II or GST is easier and quicker than switching the mode selector on the ECM. 쐌 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) 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 Lamp (MIL) DESCRIPTION

GI MA EM LC

FE NGEC0553

CL MT AT TF SEF217U

The MIL is located on the instrument panel. 1. The MIL will light up when the ignition switch is turned ON without the engine running. This is a bulb check. 쐌 If the MIL does not light up, refer to EL section (“WARNING LAMPS”) or see EC-1171. 2. When the engine is started, the MIL should go OFF. If the MIL remains on, the on board diagnostic system has detected an engine system malfunction.

PD AX SU BR ST RS BT HA SC EL

EC-675

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Malfunction Indicator Lamp (MIL) (Cont’d)

On Board Diagnostic System Function

=NGEC0553S01

The on board diagnostic system has the following two functions. Diagnostic Test Mode

KEY and ENG. Status

Function

Explanation of Function

Mode I

Ignition switch in ON position

BULB CHECK

This function checks the MIL bulb for damage (blown, open circuit, etc.). If the MIL does not come on, check MIL circuit. (See EC-1171.)

MALFUNCTION WARNING

This is a usual driving condition. When a malfunction is detected twice in two consecutive driving cycles (two trip detection logic), the MIL will light up to inform the driver that a malfunction has been detected. The following malfunctions will light up or blink the MIL in the 1st trip. 쐌 Coolant overtemperature enrichment protection 쐌 “Misfire (Possible three way catalyst damage)” 쐌 “Closed loop control” 쐌 Fail-safe mode

Engine stopped

Engine running

Diagnostic Test Mode I — Bulb Check

NGEC0553S03

In this mode, the MIL on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to “WARNING LAMPS”, EL-94 or see EC-1171.

Diagnostic Test Mode I — Malfunction Warning MIL

NGEC0553S04

Condition

ON

When the malfunction is detected or the ECM’s CPU is malfunctioning.

OFF

No malfunction.

OBD System Operation Chart

NGEC0554

RELATIONSHIP BETWEEN MIL, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS 쐌 쐌 쐌 쐌

쐌

NGEC0554S01

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 MIL will come on. For details, refer to “Two Trip Detection Logic” on EC-660. The MIL 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 MIL (goes off) DTC, Freeze Frame Data (no display)

NGEC0554S02

Fuel Injection System

Misfire

Other

3 (pattern B)

3 (pattern B)

3 (pattern B)

80 (pattern C)

80 (pattern C)

40 (pattern A)

EC-676

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

OBD System Operation Chart (Cont’d) Items 1st Trip DTC (clear) 1st Trip Freeze Frame Data (clear)

Fuel Injection System

Misfire

Other

1 (pattern C), *1

1 (pattern C), *1

1 (pattern B)

*1, *2

*1, *2

1 (pattern B)

GI MA

For details about patterns “B” and “C” under “Fuel Injection System” and “Misfire”, see EC-679. For details about patterns “A” and “B” under “Other”, see EC-681. *1: Clear timing is at the moment OK is detected. *2: Clear timing is when the same malfunction is detected in the 2nd trip.

EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-677

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

OBD System Operation Chart (Cont’d)

RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE” , “FUEL INJECTION SYSTEM”

=NGEC0554S03

SEF392S

*1: When the same malfunction is detected in two consecutive trips, MIL will light up. *2: MIL 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-678

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

VG33E

OBD System Operation Chart (Cont’d)

EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”

NGEC0554S04

Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. 쐌 The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. 쐌 The B counter will be counted up when driving pattern B is satisfied without any malfunction. 쐌 The MIL will go off when the B counter reaches 3. (*2 in “OBD SYSTEM OPERATION CHART”)



GI

NGEC0554S0401

NGEC0554S0402

Driving pattern C means the vehicle operation as follows: 1) The following conditions should be satisfied at the same time: Engine speed: (Engine speed in the freeze frame data) ±375 rpm Calculated load value: (Calculated load value in the freeze frame data) x (1±0.1) [%] Engine coolant temperature (T) condition: 쐌 When the freeze frame data shows lower than 70°C (158°F), “T” should be lower than 70°C (158°F). 쐌 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) 쐌 The C counter will be cleared when the malfunction is detected regardless of (1). 쐌 The C counter will be counted up when (1) is satisfied without the same malfunction. 쐌 The DTC will not be displayed after C counter reaches 80. 쐌 The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC is stored in ECM.

MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-679

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

OBD System Operation Chart (Cont’d)

RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”NGEC0554S05

SEF393S

*1: When the same malfunction is detected in two consecutive trips, MIL will light up. *2: MIL 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-680

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

VG33E

OBD System Operation Chart (Cont’d)

EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” NGEC0554S06 GI NGEC0554S0601

MA EM LC

FE CL AEC574

쐌 쐌 쐌

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.



MT AT TF

NGEC0554S0602

Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. 쐌 The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. 쐌 The B counter will be counted up when driving pattern B is satisfied without any malfunctions. 쐌 The MIL will go off when the B counter reaches 3 (*2 in “OBD SYSTEM OPERATION CHART”).

PD AX SU BR ST RS BT HA SC EL

EC-681

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

CONSULT-II

CONSULT-II CONSULT-II INSPECTION PROCEDURE

=NGEC0555 NGEC0555S01

1. 2.

Turn ignition switch OFF. Connect “CONSULT-II” to data link connector which is located under LH dash panel near the fuse box cover.

3. 4.

Turn ignition switch ON. Touch “START”.

5.

Touch “ENGINE”.

SEF163X

PBR455D

SEF948Y

6.

Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual.

SEF949Y

EC-682

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E CONSULT-II (Cont’d)

ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION NGEC0555S02

GI

DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS

INPUT

ENGINE CONTROL COMPONENT PARTS

Item

WORK SUPPORT

DATA MONITOR

DATA MONITOR (SPEC)

X

X

X

X

X

X

DTC & SRT CONFIRMATION ACTIVE TEST

DTC*1

Camshaft position sensor

X

X

Mass air flow sensor

X

Engine coolant temperature sensor

X

Heated oxygen sensor 1

X

X

X

X

X

Heated oxygen sensor 2

X

X

X

X

X

Vehicle speed sensor

X

X

X

Throttle position sensor

X

X

X

Fuel tank temperature sensor

X

X

X

EVAP control system pressure sensor

X

X

X

Intake air temperature sensor

X

X

X

Crankshaft position sensor (OBD)

X

X

Knock sensor

X

X

X

X

Ignition switch (start signal)

X

X

X

X

Closed throttle position switch (throttle position sensor signal)

X

X

Air conditioner switch

X

X

X

X

Closed throttle position switch

Park/neutral position (PNP) switch

X

X

SRT STATUS

DTC WORK SUPPORT

FREEZE FRAME DATA*2

MA EM LC

X

FE CL

X

MT AT TF PD AX SU BR

Power steering oil pressure switch

X

X

Battery voltage

X

X

Ambient air temperature switch

X

X

ST RS BT HA SC EL

EC-683

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

CONSULT-II (Cont’d) DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS DATA MONITOR

DATA MONITOR (SPEC)

ACTIVE TEST

Injectors

X

X

X

Power transistor (Ignition timing)

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

Item

IACV-AAC valve

WORK SUPPORT

X

EVAP canister purge volume control solenoid valve OUTPUT

ENGINE CONTROL COMPONENT PARTS

DTC & SRT CONFIRMATION

DTC*1

FREEZE FRAME DATA*2

Air conditioner relay Fuel pump relay

X

SRT STATUS

X

Cooling fan

X

X

X

Heated oxygen sensor 1 heater

X

X

X

X

Heated oxygen sensor 2 heater

X

X

X

X

EVAP canister vent control valve

X

X

X

X

Vacuum cut valve bypass valve

X

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-661.

EC-684

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E CONSULT-II (Cont’d)

FUNCTION Diagnostic test mode

=NGEC0555S03

Function

GI

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.

EM

Data monitor (SPEC)

Input/Output specification of the basic fuel schedule, AFM, A/F feedback control value and the other data monitor items can be read.

LC

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 number can be read.

FE

*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) Others

CL MT AT

WORK SUPPORT MODE WORK ITEM

CONDITION

MA

NGEC0555S04

USAGE

TP SW/TP SEN IDLE POSI ADJ

쐌 FOLLOW THE BASIC INSPECTION INSTRUCTION IN When adjusting the idle throttle THE SERVICE MANUAL. position

TARGET IGNITION TIMING ADJ

쐌 IDLE CONDITION

When adjusting target ignition timing After adjustment, confirm target ignition timing with a timing light by turning the distributor.

FUEL PRESSURE RELEASE

쐌 FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure from fuel line

SELF-LEARNING CONT

쐌 THE COEFFICIENT OF SELF-LEARNING CONTROL MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT.

When clean the coefficient of selflearning control valve

TF PD AX SU BR ST RS BT HA SC EL

EC-685

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

CONSULT-II (Cont’d) WORK ITEM

CONDITION

USAGE

EVAP SYSTEM CLOSE

OPEN THE VACUUM CUT VALVE BYPASS VALVE AND CLOSE THE EVAP CANISTER VENT CONTROL VALVE IN ORDER TO MAKE EVAP SYSTEM CLOSE UNDER THE FOLLOWING CONDITIONS. 쐌 IGN SW ON 쐌 ENGINE NOT RUNNING 쐌 AMBIENT TEMPERATURE IS ABOVE 0°C (32°F). 쐌 NO VACUUM AND NO HIGH PRESSURE IN EVAP SYSTEM 쐌 FUEL TANK TEMP. IS MORE THAN 0°C (32°F). 쐌 WITHIN 10 MINUTES AFTER STARTING “EVAP SYSTEM CLOSE” 쐌 WHEN TRYING TO EXECUTE “EVAP SYSTEM CLOSE” UNDER THE CONDITION EXCEPT ABOVE, CONSULT-II WILL DISCONTINUE IT AND DISPLAY APPROPRIATE INSTRUCTION. NOTE: WHEN STARTING ENGINE, CONSULT-II MAY DISPLAY “BATTERY VOLTAGE IS LOW. CHARGE BATTERY”, EVEN IN USING CHARGED BATTERY.

When detecting EVAP vapor leak point of EVAP system

TARGET IDLE RPM ADJ

SET ENGINE SPEED AT THE SPECIFIED VALUE UNDER THE FOLLOWING CONDITIONS. 쐌 ENGINE WARMED UP 쐌 NO-LOAD

When adjusting initial ignition timing and idle speed

SELF-DIAGNOSTIC MODE DTC and 1st Trip DTC

NGEC0555S05 NGEC0555S0501

Regarding items of “DTC and 1st trip DTC”, refer to “TROUBLE DIAGNOSIS — INDEX” (See EC-601.)

Freeze Frame Data and 1st Trip Freeze Frame Data NGEC0555S0502 Freeze frame data item *1 DIAG TROUBLE CODE [PXXXX] FUEL SYS-B1 *2

FUEL SYS-B2 *2

Description 쐌 The engine control component part/control system has a trouble code, it is displayed as “PXXXX”. (Refer to “TROUBLE DIAGNOSIS — INDEX”, EC-601.) 쐌 “Fuel injection system status” at the moment a malfunction is detected is displayed. 쐌 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 [%]

쐌 The calculated load value at the moment a malfunction is detected is displayed.

COOLANT TEMP [°C] or [°F]

쐌 The engine coolant temperature at the moment a malfunction is detected is displayed.

S-FUEL TRIM-B1 [%]

쐌 “Short-term fuel trim” at the moment a malfunction is detected is displayed. 쐌 The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule.

S-FUEL TRIM-B2 [%]

L-FUEL TRIM-B2 [%]

쐌 “Long-term fuel trim” at the moment a malfunction is detected is displayed. 쐌 The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim.

ENGINE SPEED [rpm]

쐌 The engine speed at the moment a malfunction is detected is displayed.

L-FUEL TRIM-B1 [%]

VHCL SPEED [km/h] or 쐌 The vehicle speed at the moment a malfunction is detected is displayed. [mph]

EC-686

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E CONSULT-II (Cont’d)

Freeze frame data item *1 ABSOL PRESS [kPa] or [kg/cm2] or [psi]

Description

GI 쐌 The absolute pressure at the moment a malfunction is detected is displayed.

B/FUEL SCHDL [msec] 쐌 The base fuel schedule at the moment a malfunction is detected is displayed. INT/A TEMP SE [°C] or 쐌 The intake air temperature at the moment a malfunction is detected is displayed. [°F] *1: The items are the same as those of 1st trip freeze frame data. *2: Regarding D22 model, “-B1” indicates right bank and “-B2” indicates left bank.

MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-687

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

CONSULT-II (Cont’d)

DATA MONITOR MODE Monitored item [Unit]

ECM input signals

ENG SPEED [rpm]

쎻

MAS AIR/FL SE [V]

쎻

Main signals

쎻

쐌 The signal voltage of the mass air flow sensor is displayed.

쐌 When the engine is stopped, a certain value is indicated.

쐌 The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed.

쐌 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.

쎻

쎻

HO2S1 (B1) [V]

쎻

쎻

HO2S1 (B2) [V]

쎻

쎻

HO2S2 (B1) [V]

쎻

쎻

HO2S2 (B2) [V]

쎻

쎻

쎻

HO2S1 MNTR (B2) [RICH/LEAN]

쎻

HO2S2 MNTR (B1) [RICH/LEAN]

쎻

쐌 The signal voltage of the heated oxygen sensor 1 is displayed. 쐌 The signal voltage of the heated oxygen sensor 2 is displayed. 쐌 Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control: RICH ... means the mixture became “rich”, and control is being affected toward a leaner mixture. LEAN ... means the mixture became “lean”, and control is being affected toward a rich mixture.

쐌 After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. 쐌 When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously.

쐌 Display of heated oxygen sensor 2 signal: RICH ... means the amount of oxygen after three way catalyst is relatively small. LEAN ... means the amount of oxygen after three way catalyst is relatively large.

쐌 When the engine is stopped, a certain value is indicated.

HO2S2 MNTR (B2) [RICH/LEAN]

쎻

VHCL SPEED SE [km/h] or [mph]

쎻

쎻

쐌 The vehicle speed computed from the vehicle speed sensor signal is displayed.

BATTERY VOLT [V]

쎻

쎻

쐌 The power supply voltage of ECM is displayed.

THRTL POS SEN [V]

쎻

쎻

쐌 The throttle position sensor signal voltage is displayed.

TANK F/TMP SE [°C] or [°F]

쎻

쐌 The fuel temperature judged from the fuel tank temperature sensor signal voltage is displayed.

INT/A TEMP SE [°C] or [°F]

쎻

쐌 The intake air temperature determined by the signal voltage of the intake air temperature sensor is indicated. 쐌 The signal voltage of EVAP control system pressure sensor is displayed.

EVAP SYS PRES [V] FUEL LEVEL SE [V]

쎻

Remarks

쐌 Indicates the engine speed computed from the REF signal (120° signal) of the camshaft position sensor.

COOLAN TEMP/S [°C] or [°F]

HO2S1 MNTR (B1) [RICH/LEAN]

Description

=NGEC0555S06

쐌 The signal voltage of the fuel level sensor is displayed.

EC-688

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E CONSULT-II (Cont’d)

ECM input signals

Main signals

START SIGNAL [ON/OFF]

쎻

쎻

쐌 Indicates [ON/OFF] condition from the starter signal.

CLSD THL POS [ON/OFF]

쎻

쎻

쐌 Indicates idle position [ON/OFF] computed by ECM according to the throttle position sensor signal.

Monitored item [Unit]

P/N POSI SW [ON/OFF]

Remarks 쐌 After starting the engine, [OFF] is displayed regardless of the starter signal.

쎻

쎻

쎻

쐌 Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal.

쎻

쐌 Indicates [ON/OFF] condition from the park/neutral position (PNP) switch signal.

GI MA EM

쐌 Indicates mechanical contact [ON/OFF] condition of the closed throttle position switch.

CLSD THL/P SW [ON/OFF] AIR COND SIG [ON/OFF]

Description

LC

FE CL

PW/ST SIGNAL [ON/OFF]

쎻

쎻

쐌 [ON/OFF] condition of the power steering oil pressure switch determined by the power steering oil pressure signal is indicated.

AMB TEMP SW [ON/OFF]

쎻

쎻

쐌 Indicates [ON/OFF] condition from the ambient air temperature switch signal.

AT

IGNITION SW [ON/OFF]

쎻

쐌 Indicates [ON/OFF] condition from ignition switch.

TF

INJ PULSE-B2 [msec]

쎻

INJ PULSE-B1 [msec]

쐌 Indicates the actual fuel injection pulse width compensated by ECM according to the input signals.

MT

쐌 When the engine is stopped, a certain computed value is indicated.

PD

B/FUEL SCHDL [msec]

쎻

쐌 “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction.

IGN TIMING [BTDC]

쎻

쐌 Indicates the ignition timing computed by ECM according to the input signals.

IACV-AAC/V [%]

쎻

쐌 Indicates the IACV-AAC valve control value computed by ECM according to the input signals.

BR ST

쎻

쐌 Indicates the EVAP canister purge volume control solenoid valve control value computed by the ECM according to the input signals. 쐌 The opening becomes larger as the value increases.

PURG VOL C/V [%]

A/F ALPHA-B2 [%] A/F ALPHA-B1 [%]

쐌 The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.

AX 쐌 When the engine is stopped, a certain value is indicated.

SU

RS 쐌 When the engine is stopped, a certain value is indicated. 쐌 This data also includes the data for the air-fuel ratio learning control.

BT HA

AIR COND RLY [ON/OFF]

쐌 The air conditioner relay control condition (determined by ECM according to the input signal) is indicated.

SC

FUEL PUMP RLY [ON/OFF]

쐌 Indicates the fuel pump relay control condition determined by ECM according to the input signals.

EL

EC-689

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

CONSULT-II (Cont’d)

Monitored item [Unit]

ECM input signals

Main signals

Description

COOLING FAN [ON/OFF]

쐌 Indicates the control condition of the cooling fan (determined by ECM according to the input signal). ON ... Operation OFF ... Stop

VENT CONT/V [ON/OFF]

쐌 The control condition of the EVAP canister vent control valve (determined by ECM according to the input signal) is indicated. 쐌 ON ... Closed OFF ... Open

HO2S1 HTR (B1) [ON/OFF] HO2S1 HTR (B1) [ON/OFF] HO2S2 HTR (B1) [ON/OFF] HO2S2 HTR (B2) [ON/OFF]

쐌 Indicates [ON/OFF] condition of front heated oxygen sensor heater determined by ECM according to the input signals. 쐌 Indicates [ON/OFF] condition of rear heated oxygen sensor heater determined by ECM according to the input signals.

VC/V BYPASS/V [ON/OFF]

쐌 The control condition of the vacuum cut valve bypass valve (determined by ECM according to the input signal) is indicated. 쐌 ON ... Open OFF ... Closed

CAL/LD VALUE [%]

쐌 “Calculated load value” indicates the value of the current airflow divided by peak airflow.

ABSOL TH·P/S [%]

쐌 “Absolute throttle position sensor” indicates the throttle opening computed by ECM according to the signal voltage of the throttle position sensor.

MASS AIRFLOW [g·m/s]

쐌 Indicates the mass airflow computed by ECM according to the signal voltage of the mass airflow sensor.

VOLTAGE [V]

쐌 Voltage measured by the voltage probe.

FREQUENCY [msec] or [Hz] or [%]

Remarks

쐌 Pulse width, frequency or duty cycle measured by the pulse probe.

쐌 Only “#” is displayed if item is unable to be measured. 쐌 Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured.

NOTE: 쐌 Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. 쐌 Regarding D22 model, “-B1” indicates right bank and “-B2” indicates left bank.

EC-690

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E CONSULT-II (Cont’d)

DATA MONITOR (SPEC) MODE Monitored item [Unit]

MAS A/F SE-B1 [V]

ECM input signals

Main signals

쎻

쎻

B/FUEL SCHDL [msec] A/F ALPHA-B1 [%]

쎻

A/F ALPHA-B2 [%]

쎻

Description

NGEC0555S11

GI

Remarks

쐌 The signal voltage of the mass air flow sen- 쐌 When the engine is running, specifisor specification is displayed. cation range is indicated.

MA

쐌 “Base fuel schedule” indicates the fuel injec쐌 When the engine is running, specifition pulse width programmed into ECM, cation range is indicated. prior to any learned on board correction.

EM

쐌 When the engine is running, specifi쐌 Indicates the mean value of the air-fuel ratio cation range is indicated. feedback correction factor per cycle. 쐌 This data also includes the data for the air-fuel ratio learning control.

LC

NOTE: 쐌 Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. 쐌 Regarding D22 model, “B1” indicates bank 1 and “B2” indicates bank 2.

ACTIVE TEST MODE TEST ITEM

CONDITION

FE NGEC0555S07

JUDGEMENT

CHECK ITEM (REMEDY)

쐌 Engine: Return to the original 쐌 Harness and connector trouble condition If trouble symptom disappears, see FUEL INJECTION 쐌 Fuel injectors 쐌 Change the amount of fuel injec- CHECK ITEM. 쐌 Front heated oxygen sensor tion using CONSULT-II. 쐌 Engine: Return to the original trouble condition IGNITION TIMING 쐌 Timing light: Set 쐌 Retard the ignition timing using CONSULT-II.

IACV-AAC/V OPENING

쐌 Engine: After warming up, idle the engine. 쐌 Change the IACV-AAC valve opening percent using CONSULT-II.

If trouble symptom disappears, see 쐌 Adjust initial ignition timing CHECK ITEM.

CL MT AT TF PD

Engine speed changes according to the opening percent.

쐌 Harness and connector 쐌 IACV-AAC valve

POWER BALANCE

쐌 Engine: After warming up, idle the engine. 쐌 A/C switch “OFF” 쐌 Shift lever “N” 쐌 Cut off each injector signal one at a time using CONSULT-II.

Engine runs rough or dies.

쐌 쐌 쐌 쐌 쐌 쐌

ENG COOLANT TEMP

쐌 Engine: Return to the original trouble condition 쐌 Change the engine coolant temperature using CONSULT-II.

쐌 Harness and connector If trouble symptom disappears, see 쐌 Engine coolant temperature senCHECK ITEM. sor 쐌 Fuel injectors

COOLING FAN

쐌 Ignition switch: ON 쐌 Turn the cooling fan “ON” and “OFF” using CONSULT-II.

Cooling fan moves and stops.

FUEL PUMP RELAY

쐌 Ignition switch: ON (Engine stopped) 쐌 Turn the fuel pump relay “ON” and “OFF” using CONSULT-II and listen to operating sound.

Fuel pump relay makes the operat- 쐌 Harness and connector ing sound. 쐌 Fuel pump relay

Harness and connector Compression Injectors Power transistor Spark plugs Ignition coils

쐌 Harness and connector 쐌 Cooling fan motor 쐌 Cooling fan relay

AX SU BR ST RS BT HA SC EL

EC-691

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

CONSULT-II (Cont’d) TEST ITEM

CONDITION

JUDGEMENT

CHECK ITEM (REMEDY)

PURG VOL CONT/V

쐌 Engine: After warming up, run engine at 1,500 rpm. 쐌 Change the EVAP canister purge Engine speed changes according volume control solenoid valve to the opening percent. opening percent using CONSULT-II.

FUEL/T TEMP SEN

쐌 Change the fuel tank temperature using CONSULT-II.

VENT CONTROL/V

쐌 Ignition switch: ON (Engine stopped) 쐌 Turn solenoid valve “ON” and “OFF” with the CONSULT-II and listen to operating sound.

Solenoid valve makes an operating 쐌 Harness and connector sound. 쐌 Solenoid valve

VC/V BYPASS/V

쐌 Ignition switch: ON (Engine stopped) 쐌 Turn solenoid valve “ON” and “OFF” with the CONSULT-II and listen to operating sound.

Solenoid valve makes an operating 쐌 Harness and connector sound. 쐌 Solenoid valve

DTC CONFIRMATION MODE SRT STATUS Mode

쐌 Harness and connector 쐌 Solenoid valve

NGEC0555S08 NGEC0555S0801

For details, refer to “SYSTEM READINESS TEST (SRT) CODE”, EC-662.

SRT WORK SUPPORT Mode

NGEC0555S0803

SRT status and some of the data monitor item can be read.

EC-692

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E CONSULT-II (Cont’d)

DTC Work Support Mode Test mode

Test item

Condition

NGEC0555S0802

Reference page

EVAP SML LEAK P0442/P1442

EC-925

EVAP VERY SML LEAK P0456/1456

EC-976

EVAPORATIVE SYSTEM PURG VOL CN/V P1444

GI MA

EC-1080

PURGE FLOW P0441

EC-913

VC CUT/V BP/V P1491

EC-1117

HO2S1 (B1) P0134

EC-822

HO2S1 (B1) P1143

EC-1026

HO2S1 (B1) P1144

EC-1035

HO2S1 (B1) P0133

Refer to corresponding trouble diagnosis for DTC.

HO2S1 HO2S1 (B2) P0154 HO2S1 (B2) P1163

EM LC

EC-808 EC-822 EC-1026

HO2S1 (B2) P1164

EC-1035

HO2S1 (B2) P0153

EC-808

HO2S2 (B1) P1146

EC-1044

HO2S2 (B1) P1147

EC-1054

HO2S2 (B1) P0139

EC-843

HO2S2 (B2) P1166

EC-1044

HO2S2 (B2) P1167

EC-1054

HO2S2 (B2) P0159

EC-843

FE CL MT AT

HO2S2

TF PD AX

REAL TIME DIAGNOSIS IN DATA MONITOR MODE SU (RECORDING VEHICLE DATA) NGEC0555S09

SEF705Y

CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1) “AUTO TRIG” (Automatic trigger): 쐌 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%”, “REAL-TIME DIAG” screen is also displayed. The recording time after the malfunction detection and the recording speed can be changed by “TRIGGER POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL. 2) “MANU TRIG” (Manual trigger): 쐌 DTC/1st trip DTC and malfunction item will not be displayed

BR ST RS BT HA SC EL

SEF707X

EC-693

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

CONSULT-II (Cont’d)

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” 쐌 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. 쐌 While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO TRIG)” mode, especially in case the incident is intermittent. When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the “DTC Confirmation Procedure”, the moment a malfunction is found the DTC/1st trip DTC will be displayed. (Refer to “Incident Simulation Tests” in “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”, GI-23. 2) “MANU TRIG” 쐌 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-694

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Generic Scan Tool (GST)

Generic Scan Tool (GST) DESCRIPTION

=NGEC0556 NGEC0556S01

Generic Scan Tool (OBDII scan tool) complying with SAE J1978 has 7 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.

GI MA EM LC

SEF139P

GST INSPECTION PROCEDURE 1. 2.

NGEC0556S02

Turn ignition switch OFF. Connect “GST” to data link connector for GST which is located under LH dash panel near the fuse box cover.

FE CL MT

SEF163X

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.)

AT TF PD AX

AEC059B

5.

Perform each diagnostic mode according to each service procedure. For further information, see the GST Operation Manual of the tool maker.

SU BR ST RS

AEC060B

BT HA SC EL

EC-695

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33E

Generic Scan Tool (GST) (Cont’d)

FUNCTION Diagnostic test mode

NGEC0556S03

Function

MODE 1

READINESS TESTS

This mode gains access to current emission-related data values, including analog inputs and outputs, digital inputs and outputs, 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-686).]

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: 쐌 Clear number of diagnostic trouble codes (MODE 1) 쐌 Clear diagnostic trouble codes (MODE 3) 쐌 Clear trouble code for freeze frame data (MODE 1) 쐌 Clear freeze frame data (MODE 2) 쐌 Reset status of system monitoring test (MODE 1) 쐌 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 can close EVAP system in ignition switch “ON” position (Engine stopped). When this mode is performed, the following parts can be opened or closed. 쐌 EVAP canister vent control valve open 쐌 Vacuum cut valve bypass valve closed In the following conditions, this mode cannot function. 쐌 Low ambient temperature 쐌 Low battery voltage 쐌 Engine running 쐌 Ignition switch OFF 쐌 Low fuel temperature 쐌 Too much pressure is applied to EVAP system This mode is to enable the off-board to request vehicle specific vehicle information such as Vehicle Identification Number (VIN) and calibration IDs.

EC-696

TROUBLE DIAGNOSIS — INTRODUCTION

VG33E Introduction

Introduction

MEF036D

SEF233G

NGEC0557

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-699. 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.

GI MA EM LC

FE CL MT AT TF PD AX

SEF234G

DIAGNOSTIC WORKSHEET

SEF907L

NGEC0557S01

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 MIL to come on steady or blink and DTC to be detected. Examples: 쐌 Vehicle ran out of fuel, which caused the engine to misfire. 쐌 Fuel filler cap was left off or incorrectly screwed on, allowing fuel to evaporate into the atmosphere [for the models with EVAP (SMALL LEAK) diagnosis].

SU BR ST RS BT HA SC EL

EC-697

IDX

TROUBLE DIAGNOSIS — INTRODUCTION

VG33E

Introduction (Cont’d)

Worksheet Sample

NGEC0557S0101

MTBL0017

EC-698

TROUBLE DIAGNOSIS — INTRODUCTION

VG33E Work Flow

Work Flow

NGEC0558

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST SEF510ZF

*1 *2

*3

EC-716 If time data of “SELF-DIAG RESULTS” is other than “0” or “[1t]”, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739.

*4

*5

If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to “TROUBLE DIAGNOSIS FOR POWER SUPPLY”, EC-740. If malfunctioning part cannot be

*6 *7

detected, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. EC-667 EC-735

RS BT HA SC EL

EC-699

IDX

TROUBLE DIAGNOSIS — INTRODUCTION

VG33E

Work Flow (Cont’d)

DESCRIPTION FOR WORK FLOW STEP

NGEC0558S01

DESCRIPTION

STEP I

Get detailed information about the conditions and the environment when the incident/symptom occurred using the “DIAGNOSTIC WORK SHEET”, EC-698.

STEP II

Before confirming the concern, check and write down (print out using CONSULT-II or GST) the (1st trip) DTC and the (1st trip) freeze frame data, then erase the DTC and the data. (Refer to EC-673.) The (1st trip) DTC and the (1st trip) freeze frame data can be used when duplicating the incident at STEP III & IV. If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 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-717.) 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 “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. If the malfunction code is detected, skip STEP IV and perform STEP V.

STEP IV

Try to detect the (1st trip) DTC by driving in (or performing) the “DTC Confirmation Procedure”. Check and read the (1st trip) DTC and (1st trip) freeze frame data by using CONSULT-II or GST. 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 “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. In case the “DTC 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-701.) If CONSULT-II is available, perform “DATA MONITOR (SPEC)” mode with CONSULT-II and proceed to the “TROUBLE DIAGNOSIS — SPECIFICATION VALUE”, EC-735. (If malfunction is detected, proceed to “REPAIR REPLACE”.) Then perform inspections according to the Symptom Matrix Chart. (Refer to EC-717.)

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-721, EC-726. 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 “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”, “Circuit Inspection”, GI-25. Repair or replace the malfunction parts. If malfunctioning part cannot be detected, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739.

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 “DTC Confirmation Procedure” and confirm the normal code [DTC No. P0000 or 0505] 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 and TCM (Transmission control module). (Refer to EC-673.)

EC-700

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E Basic Inspection

Basic Inspection

NGEC0559

Precaution: Perform Basic Inspection without electrical or mechanical loads applied; 쐌 Headlamp switch is OFF, 쐌 Air conditioner switch is OFF, 쐌 Rear window defogger switch is OFF, 쐌 Steering wheel is in the straight-ahead position, etc. 1

GI MA EM

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: 쐌 Harness connectors for improper connections 쐌 Vacuum hoses for splits, kinks, or improper connections 쐌 Wiring for improper connections, pinches, or cuts

LC

FE CL MT

SEF983U

Models with CONSULT-II

䊳

GO TO 2.

Models with GST

䊳

GO TO 2.

Models with No Tools

䊳

GO TO 16.

2

AT TF PD AX

CONNECT CONSULT-II OR GST TO THE VEHICLE

With CONSULT-II Connect “CONSULT-II” to the data link connector for CONSULT-II and select “ENGINE” from the menu. Refer to EC-682.

SU BR

With GST Connect “GST” to the data link connector for GST. Refer to EC-695. Models with CONSULT-II

䊳

GO TO 3.

ST

Models with GST

䊳

GO TO 15.

RS BT HA SC EL

EC-701

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E

Basic Inspection (Cont’d)

3

CHECK FI CAM FUNCTION

With CONSULT-II 1. Turn ignition switch ON. 2. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. 3. Start engine and warm it up.

SEF013Y

4. When engine coolant temperature is 75 to 85°C (167 to 185°F), check the following. 쐌 The center of mark A is aligned with mark C. 쐌 The cam follower lever’s roller is not touching the fast idle cam.

SEF971R

OK or NG OK

䊳

GO TO 4.

NG

䊳

1. Check FI cam. Refer to “Fast Idle Cam (FIC)”, EC-646. 2. GO TO 4.

EC-702

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E Basic Inspection (Cont’d)

4

CHECK IGNITION TIMING

With CONSULT-II 1. Warm up engine to normal operating temperature. 2. Select “TARGET IDLE RPM ADJ” in “WORK SUPPORT” mode and touch “START”.

GI MA EM LC

SEC019C

3. Check ignition timing at idle using a timing light.

FE CL MT AT SEF984U

Ignition timing: 10°±2° BTDC

TF

OK or NG OK

䊳

GO TO 5.

NG

䊳

1. Adjust ignition timing by turning distributor. Refer to “Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment”, EC-648. 2. GO TO 5.

5

PD AX

CHECK BASE IDLE SPEED

SU

With CONSULT-II 1. Select “TARGET IDLE RPM ADJ” in “WORK SUPPORT” mode and touch “START”.

BR ST RS BT SEC019C

2. Check idle speed. 700±50 rpm (in “P” or “N” position)

HA OK or NG

OK

䊳

GO TO 6.

SC

NG

䊳

1. Adjust engine speed by turning idle speed adjusting screw. Refer to “Idle Speed/ Ignition Timing/Idle Mixture Ratio Adjustment”, EC-648. 2. GO TO 6.

EL

EC-703

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E

Basic Inspection (Cont’d)

6

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION-I

With CONSULT-II NOTE: Always check ignition timing and base idle speed before performing the following. 1. Warm up engine to normal operating temperature. 2. Check FI cam, refer to procedure 3. 3. Stop engine. 䊳

7

GO TO 7.

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION-II

1. Turn ignition switch ON. 2. Select ”CLSD THL/P SW” in “DATA MONITOR” mode. 3. Read “CLSD THL/P SW” signal under the following conditions. 쐌 Insert a 0.3 mm (0.012 in) and 0.4 mm (0.016 in) feeler gauge alternately between the throttle adjust screw (TAS) and throttle drum as shown in the figure and check the signal.

LEC517

SEF173Y

“CLSD THL/P SW” signal should remain “ON” while inserting 0.3 mm (0.012 in) feeler gauge. “CLSD THL/P SW” signal should remain “OFF” while inserting 0.4 mm (0.016 in) feeler gauge. OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 8.

8

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION

With CONSULT-II NOTE: 쐌 Never adjust throttle adjust screw (TAS). 쐌 Do not touch throttle drum when checking “CLSD THL/P SW” signal, doing so may cause an incorrect adjustment. 1. Warm up engine to normal operating temperature. 2. Check FI cam. Refer to procedure 3. 3. Stop engine. 4. Loosen throttle position sensor fixing bolts. 䊳

GO TO 9.

EC-704

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E Basic Inspection (Cont’d)

9

ADJUSTMENT CLOSED THROTTLE POSITION SWITCH IDLE POSITION-II

1. Turn ignition switch ON. 2. Select “CLSD THL/P SW” in “DATA MONITOR” mode. 3. Insert 0.35 mm (0.0138 in) feeler gauge between throttle adjust screw and throttle drum as shown in the figure.

GI MA EM LC

LEC517

4. Open throttle valve and then close. 5. Check “CLSD THL/P SW” signal.

FE CL MT AT TF SEF305Y

“CLSD THL/P SW” signal should remain “OFF” when the throttle valve is closed.

PD

OK or NG OK

䊳

GO TO 10.

NG

䊳

GO TO 8.

10

AX

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION-III

SU

With CONSULT-II Turn throttle position sensor body clockwise until “CLSD THL/P SW” signal switches to “OFF”.

BR ST RS BT SEF689W

䊳

HA

GO TO 11.

SC EL

EC-705

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E

Basic Inspection (Cont’d)

11

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION-IV

With CONSULT-II 1. Remove 0.35 mm (0.0138 in) feeler gauge then insert 0.3 mm (0.012 in) feeler gauge. 2. Temporarily tighten sensor body fixing bolts as follows. 쐌 Gradually move the sensor body counterclockwise and stop it when “CLSD THL/P SW” signal switches from “OFF” to “ON”, then temporarily tighten sensor body fixing bolts.

SEF689W

3. 4. 5. 6. 7.

Make sure two or three times that the signal is “ON” when the throttle valve is closed and “OFF” when it is opened. Remove 0.3 mm (0.012 in) feeler gauge then insert 0.4 mm (0.016 in) feeler gauge. Make sure two or three times that the signal remains “OFF” when the throttle valve is closed. Tighten throttle position sensor. Check the “CLSD THL/P SW” signal again. The signal remains “OFF” while closing throttle valve. OK or NG

OK

䊳

GO TO 12.

NG

䊳

GO TO 8.

EC-706

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E Basic Inspection (Cont’d)

12

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. Remove feeler gauge. 2. Start engine. 3. Warm up engine to normal operating temperature. 4. Select “CLSD THL POS” in “DATA MONITOR” mode. 5. Stop engine. (Turn ignition switch OFF.) 6. Turn ignition switch ON and wait at least 5 seconds.

GI MA EM LC

FE CL SEF864V

7. Turn ignition switch OFF and wait at least 5 seconds. 8. Repeat steps 5 and 6 until “CLSD THL POS” signal changes to “ON”.

MT AT TF PD AX

SEF197Y

SU 䊳

13

GO TO 13.

BR

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. 3. Check idle speed. 750±50 rpm (in “P” or “N” position)

ST RS

OK or NG

BT

OK

䊳

INSPECTION END

NG

䊳

Adjust idle speed. Refer to “Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment”, EC-648.

HA SC EL

EC-707

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E

Basic Inspection (Cont’d)

14

CHECK FI CAM FUNCTION

With GST 1. Turn ignition switch ON. 2. Select “MODE 1” with GST. 3. Start engine and warm it up. 4. When engine coolant temperature is 75 to 85°C (167 to 185°F), check the following. 쐌 The center of mark A is aligned with mark C. 쐌 The cam follower lever’s roller is not touching the fast idle cam.

SEF971R

OK or NG OK

䊳

GO TO 16.

NG

䊳

1. Check FI cam. Refer to “Fast Idle Cam (FIC)”, EC-646. 2. GO TO 16.

EC-708

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E Basic Inspection (Cont’d)

15

CHECK FI CAM FUNCTION

No Tools 1. Set the voltmeter between ECM terminal 59 (Engine coolant temperature sensor signal) and ground. 2. Start engine and warm it up.

GI MA EM LC SEF119W

3. When the voltage is between 1.10 to 1.36V, check the following. 쐌 The center of mark A is aligned with mark C. 쐌 The cam follower lever’s roller is not touching the fast idle cam.

FE CL MT AT SEF971R

TF

OK or NG

PD

OK

䊳

GO TO 16.

NG

䊳

1. Check FI cam. Refer to “Fast Idle Cam (FIC)”, EC-646. 2. GO TO 16.

AX SU BR ST RS BT HA SC EL

EC-709

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E

Basic Inspection (Cont’d)

16

CHECK IGNITION TIMING

Without CONSULT-II 1. Warm up engine to normal operating temperature. 2. Stop engine and disconnect throttle position sensor harness connector.

SEF975R

3. Start engine. 4. Check ignition timing at idle using a timing light.

SEF984U

Ignition timing: 10°±2° BTDC OK or NG OK

䊳

GO TO 17.

NG

䊳

1. Adjust ignition timing by turning distributor. Refer to “Idle Speed/Ignition Timing/ Idle Mixture Ratio Adjustment”, EC-648. 2. GO TO 17.

17

CHECK BASE IDLE SPEED

Without CONSULT-II Does engine speed fall to the following speed? 700±50 rpm (in “P” or “N” position) OK or NG OK

䊳

GO TO 18.

NG

䊳

1. Adjust engine speed by turning idle speed adjusting screw. Refer to “Idle Speed/ Ignition Timing/ Idle Mixture Ratio Adjustment”, EC-648. 2. GO TO 18.

18

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION

Without CONSULT-II NOTE: Always check ignition timing and base idle speed before performing the following. 1. Warm up engine to normal operating temperature. 2. Check FI cam, refer to procedure 12 or 13. 3. Stop engine. 䊳

GO TO 19.

EC-710

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E Basic Inspection (Cont’d)

19

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION-I

1. Disconnect closed throttle position switch harness connector. 2. Check continuity between closed throttle position switch terminals 5 and 6 under the following conditions.

GI MA EM LC SEF862V

쐌 Insert the 0.3 mm (0.012 in) and 0.4 mm (0.016 in) feeler gauge alternately between the throttle adjust screw (TAS) and throttle drum as shown in the figure.

FE CL MT AT

LEC517

“Continuity should exist” while inserting 0.3 mm (0.012 in) feeler gauge. “Continuity should not exist” while inserting 0.4 mm (0.016 in) feeler gauge. OK or NG OK

䊳

GO TO 24.

NG

䊳

GO TO 20.

20

PD AX

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION

Without CONSULT-II NOTE: 쐌 Never adjust throttle adjust screw (TAS). 쐌 Do not touch throttle drum when checking “continuity”, doing so may cause an incorrect adjustment. 1. Warm up engine to normal operating temperature. 2. Check FI cam. Refer to procedure 12 or 13. 3. Stop engine. 4. Loosen throttle position sensor fixing bolts. 䊳

TF

SU BR ST RS

GO TO 21.

BT HA SC EL

EC-711

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E

Basic Inspection (Cont’d)

21

ADJUSTMENT CLOSED THROTTLE POSITION SWITCH IDLE POSITION-II

1. Disconnect closed throttle position switch harness connector. 2. Insert 0.35 mm (0.0138 in) feeler gauge between the throttle adjust screw and throttle drum as shown in the figure.

LEC517

3. Open throttle valve then close. 4. Check continuity between closed throttle position switch terminals 5 and 6.

SEF862V

Continuity should not exist while closing the throttle position sensor. OK or NG OK

䊳

GO TO 23.

NG

䊳

GO TO 22.

22

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION-III

Without CONSULT-II Turn throttle position sensor body clockwise until continuity does not exist.

SEF689W

䊳

GO TO 23.

EC-712

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E Basic Inspection (Cont’d)

23

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION-IV

Without CONSULT-II 1. Remove 0.35 mm (0.0138 in) feeler gauge then insert 0.3 mm (0.012 in) feeler gauge. 2. Temporarily tighten sensor body fixing bolts as follows. 쐌 Gradually move the sensor body counterclockwise and stop it when the continuity comes to exist, then temporarily tighten sensor body fixing bolts.

GI MA EM LC

SEF689W

3. Make sure two or three times that the continuity exists when the throttle valve is closed and continuity does not exist when it is opened. 4. Remove 0.3 mm (0.012 in) feeler gauge then insert 0.4 mm (0.016 in) feeler gauge. 5. Make sure two or three times that the continuity does not exist when the throttle valve is closed. 6. Tighten throttle position sensor. 7. Check the continuity again. Continuity does not exist while closing the throttle valve. OK or NG OK

䊳

GO TO 24.

NG

䊳

GO TO 20.

24

FE CL MT AT TF

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. Remove feeler gauge. 2. Start engine. 3. Warm up engine to normal operating temperature. 4. Stop engine. (Turn ignition switch OFF.) 5. Turn ignition switch ON and wait at least 5 seconds.

PD AX SU BR ST RS BT

SEF864V

6. Turn ignition switch OFF and wait at least 5 seconds. 7. Repeat steps 4 and 5, 20 times. 䊳

HA SC

GO TO 25.

EL

EC-713

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33E

Basic Inspection (Cont’d)

25

REINSTALLATION

Without CONSULT-II 1. Reconnect throttle position sensor harness connector and closed throttle position switch harness connector. 2. Start engine and rev it (2,000 to 3,000 rpm) two or three times under no-load and then run engine at idle speed. 䊳

26

GO TO 26.

CHECK TARGET IDLE SPEED

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm (in “P” or “N” position) OK or NG OK

䊳

GO TO 27.

NG

䊳

1. Adjust idle speed. Refer to “Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment”, EC-648. 2. GO TO 27.

27

ERASE UNNECESSARY DTC

After this inspection, unnecessary DTC No. might be displayed. Erase the stored memory in ECM and TCM (Transmission control module). Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-673 and “HOW TO ERASE DTC”, AT-35. 䊳

INSPECTION END

EC-714

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

DTC Inspection Priority Chart

DTC Inspection Priority Chart

NGEC0560

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. Priority 1

2

3

GI

Detected items (DTC) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

P0101, P0102, P0103 Mass air flow sensor P0112, P0113, P0127 Intake air temperature sensor P0117, P0118, P0125 Engine coolant temperature sensor P0121, P0122, P0123 Throttle position sensor P0181, P0182, P0183 Fuel tank temperature sensor P0327, P0328 Knock sensor P0335 P1336 Crankshaft position sensor (OBD) P0340 Camshaft position sensor P0460 P0461 P1464 Fuel level sensor P0500 Vehicle speed sensor P0600 A/T communication line P0605 ECM P1605 A/T diagnosis communication line P1706 Park/Neutral position (PNP) switch

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

P0132-P0134, P1143, P1144/P0152-P0154, P1163, P1164 Heated oxygen sensor 1 P0031, P0032/P0051, P0052 Heated oxygen sensor 1 heater P0138, P0139, P1146, P1147/P0158, P0159, P1166, P1167 Heated oxygen sensor 2 P0037, P0038/P0057, P0058 Heated oxygen sensor 2 heater P0217 Engine coolant overtemperature enrichment protection P0444, P0445, P1444 EVAP canister purge volume control solenoid valve P0447 P1446 P1448 EVAP canister vent control valve P0452, P0453 EVAP control system pressure sensor P0510 Closed throttle position switch P0705-P0755 P1705 P1760 A/T related sensors, solenoid valves and switches P0456, P1456 EVAP control system (VERY SMALL LEAK) P1447 EVAP control system purge flow monitoring P1490 P1491 Vacuum cut valve bypass valve

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

P0171 P0172 P0174 P0175 Fuel injection system function P0306 - P0300 Misfire P0420 P0430 Three way catalyst function P0442/P1442 EVAP control system (SMALL LEAK) P0455 EVAP control system (GROSS LEAK) P0505 IACV-AAC valve P0731-P0734 P0744 A/T function P1148 P1168 Closed loop control

MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-715

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

Fail-safe Chart

Fail-safe Chart

=NGEC0561

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 MIL illuminates. DTC No. Detected items

CONSULT-II GST

Engine operating condition in fail-safe mode

P0101 P0102 P0103

Mass air flow sensor circuit Engine speed will not rise more than 2,400 rpm due to the fuel cut.

P0117 P0118

Engine coolant temperature sensor circuit

Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON or START. CONSULT-II displays the engine coolant temperature decided by ECM. Condition 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 P0121 P0122 P0123

Throttle position sensor circuit

Engine coolant temperature decided (CONSULT-II display)

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

Driving condition

When engine is idling When accelerating Unable to ECM access ECM

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 MIL 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 will not rise more than 3,000 rpm

Engine speed Fuel injection

Simultaneous multiport fuel injection system

Ignition timing

Ignition timing is fixed at the preset value Fuel pump relay is “ON” when engine is running and “OFF” when engine stalls

Fuel pump IACV-AAC valve

Replace ECM, if ECM fail-safe condition is confirmed.

EC-716

Full open

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

Symptom Matrix Chart

Symptom Matrix Chart

NGEC0562

SYSTEM — BASIC ENGINE CONTROL SYSTEM

NGEC0562S01

GI

BATTERY DEAD (UNDER CHARGE)

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEATS/WATER TEMPERATURE HIGH

SLOW/NO RETURN TO IDLE

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

AH

AJ AK AL AM HA

2

3

HIGH IDLE/LOW IDLE

AA AB AC AD AE AF AG

ENGINE STALL

IDLING VIBRATION

Fuel

MA

ROUGH IDLE/HUNTING

Warranty symptom code

HESITATION/SURGING/FLAT SPOT

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Fuel pump circuit

3 1

1

2

3

2

Injector circuit

1

2

Air

4

4

4

4

4

4

4

3

3

CL EC-1153

3

3

1

1

1

2

2

3

3

2 IACV-FICD solenoid valve circuit

3

3

3

2

1

1

EC-642

1

EC-648 1

2

2

3 EC-1166

3

3

1

1

1

1

1

1

EC-648

Ignition circuit

1

1

2

2

2

2

2

2

EC-1138

2

3

3

3

3

2

Air conditioner circuit

1

1

2

3

1 - 6: The numbers refer to the order of inspection. (continued on next page)

TF PD AX SU

EC-740 3

2

AT

EC-1006

Incorrect ignition timing adjustment

Main power supply and ground circuit

MT

EC-626

4 1

IACV-AAC valve circuit

Ignition

FE

EC-645

Positive crankcase ventilation system Incorrect idle speed adjustment

LC Reference page

EC-1145

Fuel pressure regulator system Evaporative emission system

EM

1 HA-26

BR ST RS BT HA SC EL

EC-717

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

Symptom Matrix Chart (Cont’d)

BATTERY DEAD (UNDER CHARGE)

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

2

OVERHEATS/WATER TEMPERATURE HIGH

2

Camshaft position sensor circuit

SLOW/NO RETURN TO IDLE

AH

HIGH IDLE/LOW IDLE

IDLING VIBRATION

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

AA AB AC AD AE AF AG

ENGINE STALL

ROUGH IDLE/HUNTING

Warranty symptom code

HESITATION/SURGING/FLAT SPOT

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Reference page

AJ AK AL AM HA EC-901

1 Mass air flow sensor circuit

1

2

Heated oxygen sensor 1 (front) circuit Engine coolant temperature sensor circuit

2

2 3

1

2

3

EC-822

2 3

EC-761

3

3

EC-775, 793

2

EC-780

1

EC-701

2 Throttle position sensor circuit

1

2

2

2

Incorrect throttle position sensor adjustment

3

1

1

1

Vehicle speed sensor circuit

2

Knock sensor circuit ECM Start signal circuit

1

1

EC-1002 3

3

3

3 2

2

3

3

2

2

EC-891 EC-1024, 716

1

1

EC-1150

Park/neutral position (PNP) switch circuit

3

3

3 3

Power steering oil pressure switch circuit

1

2

EC-1129

2 EC-1161

1 - 6: The numbers refer to the order of inspection. (continued on next page)

EC-718

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

Symptom Matrix Chart (Cont’d)

SYSTEM — ENGINE MECHANICAL & OTHER

NGEC0562S02

Fuel

BATTERY DEAD (UNDER CHARGE)

EXCESSIVE OIL CONSUMPTION

MA EXCESSIVE FUEL CONSUMPTION

OVERHEATS/WATER TEMPERATURE HIGH

GI

SLOW/NO RETURN TO IDLE

AH

HIGH IDLE/LOW IDLE

IDLING VIBRATION

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

AA AB AC AD AE AF AG

ENGINE STALL

ROUGH IDLE/HUNTING

Warranty symptom code

HESITATION/SURGING/FLAT SPOT

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

EM Reference section

FE CL

AJ AK AL AM HA

Fuel tank

FE-4 5

Fuel piping

5

Vapor lock

5

5

5

4

MT

5

5

AT

Valve deposit Poor fuel (Heavy weight gasoline, Low octane) Air

5

5

5

5

5

4

5 —

TF

Air duct

PD

Air cleaner Air leakage from air duct (Mass air flow sensor — throttle body) Throttle body, Throttle wire

5

5

5

5

5

5

4

5

AX

5 4

FE-3

SU

Air leakage from intake manifold/ Collector/Gasket Cranking

LC

5

—

BR

Battery 1

1

1

Generator circuit

1

1

1

1 SC-10

1

ST

Starter circuit Park/neutral position (PNP) switch Drive plate/Flywheel

AT-104 6

EM-124

1 - 6: The numbers refer to the order of inspection. (continued on next page)

RS BT HA SC EL

EC-719

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

Symptom Matrix Chart (Cont’d)

Engine

BATTERY DEAD (UNDER CHARGE)

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEATS/WATER TEMPERATURE HIGH

SLOW/NO RETURN TO IDLE

AH

HIGH IDLE/LOW IDLE

IDLING VIBRATION

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

AA AB AC AD AE AF AG

ENGINE STALL

ROUGH IDLE/HUNTING

Warranty symptom code

HESITATION/SURGING/FLAT SPOT

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Reference section

AJ AK AL AM HA

Cylinder head 5

5

5

5

5

5

5

5

Cylinder head gasket

2

2

Cylinder block Piston

3

Piston ring 6

6

6

6

6

6

6

6

Connecting rod EM-92, EM-82 and EM-115

Bearing Crankshaft Valve Timing chain mechanism Camshaft 6 Intake valve

6

6

6

6

6

6

6 2

Exhaust valve Hydraulic lash adjuster Exhaust

Exhaust manifold/Tube/Muffler/ Gasket

6

6

6

6

6

6

6

6

FE-9

6

MA-32, EM-79 and LC-20

Three way catalyst Lubrication

Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery

6

6

6

6

6

6

6

Oil level (Low/Filthy) oil Cooling

2

MA-32

Radiator/Hose/Radiator filler cap Thermostat

5

5

Water pump Water gallery

LC-27 6

6

6

6

6

Cooling fan

6 5

Coolant level (low)/Contaminated coolant

6

2

6

5 MA-28

1 - 6: The numbers refer to the order of inspection.

EC-720

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NGEC0563

Remarks: 쐌 Specification data are reference values. 쐌 Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data in spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the ECM according to the signals input from the camshaft position sensor and other ignition timing related sensors. 쐌 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

쐌 Tachometer: Connect 쐌 Run engine and compare tachometer indication with the CONSULT-II value.

MAS AIR/FL SE

쐌 쐌 쐌 쐌

COOLAN TEMP/S

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

1.0 - 1.7V

2,500 rpm

1.7 - 2.3V

쐌 Engine: After warming up

HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2)

쐌 Engine: After warming up

쐌 Engine: After warming up

Maintaining engine speed at 2,000 rpm

Maintaining engine speed at 2,000 rpm

AT

0 - 0.3V +, Approx. 0.6 1.0V

TF

LEAN +, RICH

PD

쐌 Ignition switch: ON (Engine stopped)

11 - 14V

쐌 Engine: After warming up, idle the engine

Throttle valve: fully closed (a)

0.15 - 0.85V

Throttle valve: Partially open

Between (a) and (b)

Throttle valve: fully opened (b)

3.5 - 4.7V

쐌 Ignition switch: ON , START , ON 쐌 Engine: After warming up, idle the engine

AIR COND SIG

쐌 Engine: After warming up, idle the engine

P/N POSI SW

PW/ST SIGNAL

쐌 Ignition switch: ON

쐌 Engine: After warming up, idle the engine

CL

LEAN +, RICH Changes more than 5 times during 10 seconds.

BATTERY VOLT

CLSD THL POS CLSD THL/P SW

FE

MT

Almost the same speed as the CONSULT-II value

START SIGNAL

LC

0 - 0.3V +, Approx. 0.6 1.0V

쐌 Turn drive wheels and compare speedometer indication with the CONSULT-II value

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

EM

More than 70°C (158°F)

VHCL SPEED SE

THRTL POS SEN

MA

Almost the same speed as the CONSULT-II value.

Idle

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

SPECIFICATION

GI

OFF , ON , OFF

Throttle valve: Idle position

ON

Throttle valve: Slightly open

OFF

Air conditioner switch: OFF

OFF

Air conditioner 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 turned

ON

EC-721

AX SU BR ST RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM AMB TEMP SW

CONDITION 쐌 Ignition switch: ON 쐌 Compare ambient air temperature with the following:

SPECIFICATION

Below 19°C (66°F)

OFF

Above 25°C (77°F)

ON

IGNITION SW

쐌 Ignition switch: ON , OFF , ON

INJ PULSE-B2 INJ PULSE-B1

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

2.4 - 3.7 msec

2,000 rpm

1.9 - 3.3 msec

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

1.0 - 1.6 msec

B/FUEL SCHDL

쐌 쐌 쐌 쐌

2,000 rpm

0.7 - 1.4 msec

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

15° BTDC

2,000 rpm

More than 25° BTDC

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

10 - 20%

2,000 rpm

—

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

0%

2,000 rpm

—

Maintaining engine speed at 2,000 rpm

54 - 155%

IGN TIMING

IACV-AAC/V

PURG VOL C/V

ON , OFF , ON

A/F ALPHA-B2 A/F ALPHA-B1

쐌 Engine: After warming up

EVAP SYS PRES

쐌 Ignition switch: ON

Approx. 1.8 - 4.8V

AIR COND RLY

쐌 Air conditioner switch: OFF , ON

OFF , ON

쐌 Ignition switch is turned to ON (Operates for 5 seconds) 쐌 Engine running and cranking

ON

FUEL PUMP RLY

Except as shown above

OFF

COOLING FAN

쐌 After warming up engine, idle the engine. 쐌 Air conditioner switch: OFF

Engine coolant temperature is 94°C (201°F) or less

OFF

Engine coolant temperature is 95°C (203°F) or more

ON

쐌 Ignition switch: ON

OFF

쐌 Engine speed: Below 3,200 rpm

ON

쐌 Engine speed: Above 3,200 rpm

OFF

쐌 Ignition switch: ON (Engine stopped) 쐌 Engine speed: Above 3,200 rpm

OFF

쐌 Engine speed: Below 3,200 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]

ON

VC/V BYPASS/V

Ignition switch: ON

OFF

CAL/LD VALUE

쐌 쐌 쐌 쐌

VENT CONT/V HO2S1 HTR (B1) HO2S1 HTR (B2)

HO2S2 HTR (B1) HO2S2 HTR (B2)

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

18.5 - 26.0%

2,500 rpm

18.0 - 21.0%

EC-722

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM

ABSOL TH·P/S

MASS AIRFLOW

CONDITION

SPECIFICATION

쐌 Engine: After warming up 쐌 Ignition switch: ON

Throttle valve: fully closed

0.0%

GI

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

Throttle valve: fully open

Approx. 80%

MA

Idle

3.3 - 4.8 g·m/s

EM

2,500 rpm

12.0 - 14.9 g·m/s

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

LC

Major Sensor Reference Graph in Data Monitor Mode

NGEC0564

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

FE NGEC0564S01

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”.

CL MT AT TF PD

SEF306Y

AX

ENG SPEED, MAS AIR/FL SE, THRTL POS SEN, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1 NGEC0564S02 Below is the data for “ENG SPEED”, “MAS AIR/FL SE”, “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 sufficiently. Each value is for reference, the exact value may vary.

SU BR ST RS BT HA SC EL

EC-723

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

Major Sensor Reference Graph in Data Monitor Mode (Cont’d)

SEF241Y

EC-724

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

Major Sensor Reference Graph in Data Monitor Mode (Cont’d)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEF242YD

EL

EC-725

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

ECM Terminals and Reference Value

ECM Terminals and Reference Value PREPARATION 1.

NGEC0565 NGEC0565S01

쐌

ECM is located behind the instrument lower cover. For this inspection: Remove instrument lower cover.

2.

Remove ECM harness protector.

3.

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.

SEF324V

AEC913

쐌 쐌 쐌

MEC486B

ECM HARNESS CONNECTOR TERMINAL LAYOUTNGEC0565S02

SEF533P

ECM INSPECTION TABLE

NGEC0565S03

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 the ECM terminals, such as the ground.

EC-726

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

GI

Approximately 0.7V

MA [Engine is running] 쐌 Idle speed

EM SEF988U

1

PU/W

LC

Ignition signal 1.1 - 1.5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

FE SEF989U

CL

1 - 2V

MT [Engine is running] 쐌 Warm-up condition 쐌 Idle speed

AT SEF992U

3

R/L

TF

Tachometer 3 - 5V

PD [Engine is running] 쐌 Engine speed is 2,000 rpm

AX SEF993U

4

OR/B

ECM relay (Self shutoff)

[Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

0 - 1.5V

[Ignition switch OFF] 쐌 A few seconds passed after turning ignition switch OFF

BATTERY VOLTAGE (11 - 14V)

SU BR ST RS BT HA SC EL

EC-727

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed

5

R/Y

EVAP canister purge volume control solenoid valve

SEF994U

BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Engine speed is 2,000 rpm (More than 100 seconds after starting engine)

SEF995U

7

9

10

11

12

Y/G

B/Y

B/R

W/R

P

A/T check signal

Ambient air temperature switch

ECM ground

[Ignition switch ON] [Engine is running]

0 - 3.0V

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is above 25°C (77°F) 쐌 Air conditioner is operating

0V

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is below 19°C (66°F) 쐌 Air conditioner is operating

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is below 19°C (66°F) 쐌 Air conditioner is not operating

Approximately 5V

[Engine is running] 쐌 Idle speed

Engine ground

[Ignition switch ON] 쐌 For 5 seconds after turning ignition switch ON [Engine is running]

0 - 1V

[Ignition switch ON] 쐌 More than 5 seconds after turning ignition switch ON

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Both A/C switch and blower switch are ON*

0 - 1V

[Engine is running] 쐌 A/C switch is OFF

BATTERY VOLTAGE (11 - 14V)

[Ignition switch ON]

0 - 1V

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed

Engine ground

Fuel pump relay

Air conditioner relay

18

R/W

Malfunction indicator lamp

19

B/R

ECM ground

EC-728

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

ECM Terminals and Reference Value (Cont’d) TERMINAL NO. 20

21

22

23

24

25

WIRE COLOR

L/OR

G/R

L/B

L

W/L

B/Y

ITEM

CONDITION

Air conditioner switch

Park/neutral position (PNP) switch

Approximately 0V

[Ignition switch START]

9 - 12V

MA

[Engine is running] 쐌 Both A/C switch and blower switch are ON (Compressor operates)*

Approximately 0V

EM

[Engine is running] 쐌 A/C switch is OFF

BATTERY VOLTAGE (11 - 14V)

LC

[Ignition switch ON] 쐌 Gear position is “N” or “P”

Approximately 0V

[Ignition switch ON] 쐌 Except the above gear position

Approximately 5V

FE

[Engine is running] 쐌 Warm-up condition 쐌 More than -40.0 kpa (-300 mmHg, -11.81 inHg) 0.15 - 0.85V of vacuum is applied to the throttle opener with a Throttle position sensor hand vacuum pump. 쐌 Accelerator pedal fully released [Ignition switch ON] 쐌 Accelerator pedal fully depressed

3.5 - 4.7V

[Ignition switch OFF]

0V

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

6 - 8V

6 - 8V

Ignition switch

26

PU/W

A/T signal No. 1

27

P/B

A/T signal No. 2

[Ignition switch ON] [Engine is running] 쐌 Idle speed

BR/W

GI

[Ignition switch ON] Start signal

[Ignition switch ON] [Engine is running] 쐌 Idle speed

28

DATA (DC Voltage)

CL MT AT TF PD AX SU

[Engine is running] 쐌 Warm-up condition 쐌 More than -40.0 kpa (-300 mmHg, -11.81 inHg) BATTERY VOLTAGE of vacuum is applied to the throttle opener with a (11 - 14V) Throttle position switch hand vacuum pump. (Closed position) 쐌 Accelerator pedal fully released [Ignition switch ON] 쐌 Accelerator pedal depressed

BR ST RS

Approximately 0V 2 - 3V

BT 29

G/B

Vehicle speed sensor

[Engine is running] 쐌 Lift up the vehicle. 쐌 In 2nd gear position 쐌 Vehicle speed is 40 km/h (25 MPH)

HA SEF996U

32

B/Y

ECM ground

[Engine is running] 쐌 Idle speed

EC-729

Engine ground (Probe this terminal with (−) tester probe when measuring)

SC EL IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

ECM Terminals and Reference Value (Cont’d) TERMINAL NO. 35

39

WIRE COLOR G/R

GY/R

ITEM A/T signal No. 3

Power steering oil pressure switch

CONDITION

DATA (DC Voltage)

[Ignition switch ON]

0V

[Engine is running] 쐌 Steering wheel is being turned

Approximately 0V

[Engine is running] 쐌 Steering wheel is not being turned

Approximately 5V

42

B/W

Sensors’ power supply

[Ignition switch ON]

Approximately 5V

43

BR

Sensors’ ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V 0.3 - 0.5V

[Engine is running] 쐌 Idle speed

44

PU

SEF997U

Camshaft position sensor (Reference signal)

0.3 - 0.5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

SEF998U

46

OR/B

Fuel level sensor

[Ignition switch ON]

Approximately 0 - 4.8V Output voltage varies with fuel level. 1 - 2V (AC range)

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

47

L

SEF690W

Crankshaft position sensor (OBD)

3 - 4V (AC range)

[Engine is running] 쐌 Engine speed is 2,000 rpm

SEF691W

EC-730

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

GI

Approximately 2.5V

MA [Engine is running] 쐌 Warm-up condition 쐌 Idle speed

49

LG

EM SEF999U

Camshaft position sensor (Position signal)

LC

Approximately 2.5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

FE SEF001V

CL

0 - Approximately 1.0V

MT 50

B

Heated oxygen sensor 1 (bank 1)

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

AT SEF002V

TF

0 - Approximately 1.0V

PD 51

G

Heated oxygen sensor 1 (bank 2)

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

AX SEF002V

54

R

Mass air flow sensor

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

1.0 - 1.7V

BR

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm

1.7 - 2.3V

ST RS

55

G

Mass air flow sensor ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

56

OR

Heated oxygen sensor 2 (bank 1)

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

0 - Approximately 1.0V

Y

Heated oxygen sensor 2 (bank 2)

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

0 - Approximately 1.0V

Engine coolant temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with engine coolant temperature

57

59

LG/R

SU

EC-731

BT HA SC EL IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

60

Y/B

Fuel tank temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with fuel temperature

61

PU/R

Intake air temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with intake air temperature.

62

Y

EVAP control system pressure sensor

[Ignition switch ON]

Approximately 1.8 - 4.8V

64

W

Knock sensor

[Engine is running] 쐌 Idle speed

Approximately 2.5V

66

B

Fuel level sensor ground

[Engine is running] 쐌 Idle speed

Approximately 0V

67

B/P

Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

69

LG/R

Data link connector for GST

[Engine is running] 쐌 Idle speed (GST is disconnected)

6 - 10V

72

B/P

Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

75

Y/R

76

GY/L

Data link connector for CONSULT-II

0 - 4V [Engine is running] 쐌 Idle speed (Connect CONSULT-II and turned on.) 3 - 9V

80

SB

Power supply (Backup)

[Ignition switch OFF]

BATTERY VOLTAGE (11 - 14V) 8 - 11V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

SEF005V

101

OR/L

IACV-AAC valve 7 - 10V

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 3,000 rpm

SEF692W

EC-732

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

MA

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed 102 104 106 109 111 113

W/B W/R W/G W/L W/PU W

Injector Injector Injector Injector Injector Injector

No. No. No. No. No. No.

1 3 5 2 4 6

GI

EM LC SEF007V

BATTERY VOLTAGE (11 - 14V)

FE

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

CL SEF008V

MT

108

R/G

EVAP canister vent control valve

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

116

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

117

B/P

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

TF PD

BR/Y

[Engine is running] 쐌 Engine speed is below 3,200 rpm

Approximately 0.4V

Heated oxygen sensor 1 heater (bank 1)

[Engine is running] 쐌 Engine speed is above 3,200 rpm

BATTERY VOLTAGE (11 - 14V)

AX

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 3,200 rpm

Approximately 0.4V

[Engine is running] 쐌 Engine speed is above 3,200 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 3,200 rpm 쐌 After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more.

Approximately 0.4V

[Ignition switch ON] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 3,200 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 3,200 rpm 쐌 After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more.

Approximately 0.4V

[Ignition switch ON] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 3,200 rpm

BATTERY VOLTAGE (11 - 14V)

119

120

121

122

123

P/B

BR

R/B

R/Y

Vacuum cut valve bypass valve

Heated oxygen sensor 1 heater (bank 2)

Heated oxygen sensor 2 heater (bank 1)

Heated oxygen sensor 2 heater (bank 2)

EC-733

AT

SU BR ST RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33E

ECM Terminals and Reference Value (Cont’d) TERMINAL NO. 124

WIRE COLOR B/R

ITEM

ECM ground

CONDITION [Engine is running] 쐌 Idle speed

*: Any mode except OFF, ambient air temperature is above 25°C (77°F).

EC-734

DATA (DC Voltage)

Engine ground

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

VG33E Description

Description

NGEC0958

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: 쐌 B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction) 쐌 A/F ALPHA-B1/B2 (The mean value of air-fuel ratio feedback correction factor per cycle) 쐌 MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)

Testing Condition

GI MA EM LC

NGEC0959

쐌 Vehicle driven distance: More than 5,000 km (3,100 miles) 쐌 Barometric pressure: 101.3 kPa (760.0 mmHg, 29.92 inHg)±3 kPa (22.5 mmHg, 0.89 inHg) 쐌 Atmospheric temperature: 20 - 30°C (68 - 86°F) 쐌 Engine coolant temperature: 75 - 95°C (167 - 203°F) 쐌 Transmission: Warmed-up*1 쐌 Electrical load: Not applied*2 쐌 Engine speed: Idle *1: For A/T models, after the engine is warmed up to normal operating temperature, drive vehicle until “FLUID TEMP SE” (A/T fluid temperature sensor signal) indicates less than 0.9V. For M/T models, drive vehicle for 5 minutes after the engine is warmed up to normal operating temperature. *2: Rear window defogger switch, air conditioner switch, lighting switch are “OFF”. Cooling fans are not operating. Steering wheel is straight ahead.

FE CL MT AT TF PD AX

Inspection Procedure

SEF601Z

NGEC0960

NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform “Basic Inspection”, EC-701. 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1”, “A/F ALPHA-B2” 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-736.

SU BR ST RS BT HA SC EL

EC-735

IDX

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

VG33E

Diagnostic Procedure

Diagnostic Procedure

NGEC0961

SEF613ZB

EC-736

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

VG33E

Diagnostic Procedure (Cont’d)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEF768Z

EL

EC-737

IDX

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

VG33E

Diagnostic Procedure (Cont’d)

SEC653C

EC-738

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT

VG33E Description

Description

NGEC0566

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 (1st trip) DTC 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

NGEC0566S01

STEP in Work Flow

GI MA EM

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 does not appear during the DTC Confirmation Procedure.

VI

The Diagnostic Procedure for PXXXX does not indicate the problem area.

LC

FE CL MT

Diagnostic Procedure 1

INSPECTION START

Erase (1st trip) DTCs. Refer to “HOW TO ERASE EMISSION — RELATED INFORMATION”, EC-673. 䊳

2

GO TO 2.

NGEC0567

AT TF PD

CHECK GROUND TERMINALS

Check ground terminals for corroding or loose connection. Refer to “Circuit Inspection”, “GROUND INSPECTION”, GI-28.

AX

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace.

SU BR

3

SEARCH FOR ELECTRICAL INCIDENT

Perform “Incident Simulation Tests”, GI-23. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace.

4

ST RS BT

CHECK CONNECTOR TERMINALS

Refer to “How to Check Enlarged Contact Spring of Terminal”, GI-20. OK or NG OK

䊳

INSPECTION END

NG

䊳

Repair or replace connector.

HA SC EL

EC-739

IDX

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33E

Main Power Supply and Ground Circuit

Main Power Supply and Ground Circuit WIRING DIAGRAM

NGEC0568

WEC163A

EC-740

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33E

Main Power Supply and Ground Circuit (Cont’d)

ECM TERMINALS AND REFERENCE VALUE

NGEC0569

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

4

OR/B

ITEM

CONDITION

GI MA

DATA (DC Voltage)

EM

ECM relay (Self-shutoff)

[Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

LC

0 - 1.5V

[Ignition switch OFF] BATTERY VOLTAGE 쐌 A few seconds passed after turning ignition switch (11 - 14V) OFF

FE

10

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

19

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

[Ignition switch OFF]

0V

24

W/L

Ignition switch [Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground (Probe this terminal with (−) tester probe when measuring)

25

32

67

B/Y

B/Y

B/P

72

B/P

80

SB

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

Power supply (Back-up)

[Ignition switch OFF]

BATTERY VOLTAGE (11 - 14V) Engine ground

116

B/R

ECM ground

[Engine is running] 쐌 Idle speed

117

B/P

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

124

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

1

MT AT

Power supply for ECM

DIAGNOSTIC PROCEDURE

CL

TF PD AX SU BR ST

NGEC0570

RS

INSPECTION START

BT

Start engine. Is engine running? Yes or No Yes

䊳

GO TO 6.

No

䊳

GO TO 2.

HA SC EL

EC-741

IDX

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33E

Main Power Supply and Ground Circuit (Cont’d)

2

CHECK ECM POWER SUPPLY CIRCUIT-I

1. Turn ignition switch OFF and then ON. 2. Check voltage between ECM terminal 24 and ground with CONSULT-II or tester.

SEF674U

Voltage: Battery voltage OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M58, F28 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between ECM and fuse 䊳

4

Repair harness or connectors.

CHECK ECM GROUND CIRCUIT-I FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 10, 19, 25, 32, 116, 124 and engine ground. Refer to WIRING DIAGRAM. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 15.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-2 (if equipped) 쐌 Harness for open between ECM and engine ground 䊳

Repair open circuit or short to power in harness or connectors.

EC-742

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33E

Main Power Supply and Ground Circuit (Cont’d)

6

CHECK ECM POWER SUPPLY CIRCUIT-II

1. Stop engine. 2. Check voltage between ECM terminal 80 and ground with CONSULT-II or tester.

GI MA EM LC SEF678U

Voltage: Battery voltage OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

FE CL

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M59, F27 쐌 Fuse block (J/B) connector M27 쐌 10A fuse 쐌 Harness for open or short between ECM and fuse 䊳

MT AT

Repair harness or connectors.

TF 8

CHECK ECM POWER SUPPLY CIRCUIT-III

PD

1. Turn ignition switch ON and then OFF. 2. Check voltage between ECM terminals 67, 72, 117 and ground with CONSULT-II or tester.

AX SU BR SEF679U

Voltage: After turning ignition switch OFF, battery voltage will exist for a few seconds, then drop to approximately 0V. OK or NG

ST RS

OK

䊳

GO TO 14.

NG (Battery voltage does not exist.)

䊳

GO TO 9.

BT

NG (Battery voltage exists for more than a few seconds.)

䊳

GO TO 13.

HA SC EL

EC-743

IDX

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33E

Main Power Supply and Ground Circuit (Cont’d)

9

CHECK ECM POWER SUPPLY CIRCUIT-IV

1. Disconnect ECM relay.

AEC927A

2. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.

SEF625W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

10

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between ECM relay and harness connector F27 䊳

11

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK ECM OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 4 and ECM 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

䊳

GO TO 12.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

12

CHECK HARNESS CONTINUITY BETWEEN ECM RELAY AND ECM FOR OPEN AND SHORT

1. Check harness continuity between ECM terminals 67, 72, 117 and ECM relay terminal 3. Refer to WIRING DIAGRAM. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 13.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-744

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33E

Main Power Supply and Ground Circuit (Cont’d)

13

CHECK ECM RELAY

1. Apply 12V direct current between relay terminals 1 and 2. 2. Check continuity between relay terminals 3 and 5.

GI MA EM LC SEF039W

12V (1 - 2) applied: Continuity exists. No voltage applied: No continuity OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace ECM relay.

14

CL

CHECK ECM GROUND CIRCUIT-II FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 10, 19, 25, 32, 116, 124 and engine ground. Refer to WIRING DIAGRAM. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 15.

NG

䊳

GO TO 5.

15

FE

MT AT TF PD AX

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

SU

INSPECTION END

BR ST RS BT HA SC EL

EC-745

IDX

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33E

Description

Description

NGEC0644

SYSTEM DESCRIPTION

NGEC0644S01

Sensor

ECM function

Input Signal to ECM

Camshaft position sensor

Actuator

Heated oxygen Heated oxygen sensor 1 heatsensor 1 ers heater control

Engine speed

The ECM performs ON/OFF control of the heated oxygen sensor 1 heaters corresponding to the engine speed.

OPERATION

NGEC0644S02

Engine speed

rpm

Heated oxygen sensor 1 heaters

Above 3,200

OFF

Below 3,200

ON

CONSULT-II Reference Value in Data Monitor Mode

NGEC0645

Specification data are reference values. MONITOR ITEM HO2S1 HTR (B1) HO2S1 HTR (B2)

CONDITION

SPECIFICATION

쐌 Engine speed: Below 3,200 rpm

ON

쐌 Engine speed: Above 3,200 rpm

OFF

ECM Terminals and Reference Value

NGEC0646

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 the ECM terminals, such as the ground. TERMINAL NO.

119

121

WIRE COLOR

BR/Y

BR

ITEM

Heated oxygen sensor 1 heater (bank 1)

Heated oxygen sensor 1 heater (bank 2)

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Engine speed is above 3,200 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 3,200 rpm

Approximately 0.4V

[Engine is running] 쐌 Engine speed is above 3,200 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 3,200 rpm

Approximately 0.4V

On Board Diagnosis Logic

NGEC0647

Malfunction is detected when the current amperage in the heated oxygen sensor 1 heater circuit is out of the normal range. [An excessively low (P0031) (B1)/(P0051) (B2) or high (P0032) (B1)/(P0052) (B2) voltage signal is sent to ECM through the heated oxygen sensor 1 heater.]

POSSIBLE CAUSE 쐌 쐌

NGEC0647S01

Harness or connectors [The heated oxygen sensor 1 heater circuit is open or shorted.] Heated oxygen sensor 1 heater

EC-746

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF058Y

NGEC0648

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is 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 run it for at least 6 seconds at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-750. With GST 1) Start engine and run it for at least 6 seconds at idle speed. 2) Turn ignition switch OFF, wait at least 5 seconds and then turn ON. 3) Start engine and run it for at 6 seconds at idle speed. 4) Select “MODE 3” with GST. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-750. 쐌 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.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-747

IDX

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33E

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0649 NGEC0649S01

WEC164A

EC-748

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33E

Wiring Diagram (Cont’d)

LEFT BANK

NGEC0649S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC165A

EC-749

EL IDX

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0650

CHECK HO2S1 POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Check heated oxygen sensor 1 harness protector.

SEF505YB

3. Disconnect corresponding heated oxygen sensor 1 harness connector.

WEC545

4. Turn ignition switch ON. 5. Check voltage between HO2S1 terminal 1 and ground with CONSULT-II or tester.

SEF633W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M59, F27 쐌 Fuse block (J/B) connector M26 쐌 10A fuse 쐌 Harness for open or short between heated oxygen sensor 1 and fuse 䊳

Repair harness or connectors.

EC-750

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK HO2S1 HEATER OUTPUT CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

GI MA EM LC

SEC658C

Continuity should exist. 4. Also check harness for short to ground and short to power.

CL

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

4

FE

MT

CHECK HEATED OXYGEN SENSOR 1 HEATER

AT

Check resistance between HO2S1 terminals 3 and 1.

TF PD AX SU AEC158A

Resistance: 2.3 - 4.3Ω at 25°C (77°F) Check continuity between HO2S1 terminals 2 and 1, 3 and 2. Continuity should not exist. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BR ST RS

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

BT HA SC EL

EC-751

IDX

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33E

Diagnostic Procedure (Cont’d)

5

REPLACE HEATED OXYGEN SENSOR 1

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

6

Replace malfunctioning heated oxygen sensor 1.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-752

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33E Description

Description

NGEC0683

SYSTEM DESCRIPTION

NGEC0683S01

Sensor

ECM function

Input Signal to ECM

Camshaft position sensor

Actuator

Heated oxygen Heated oxygen sensor 2 heatsensor 2 ers heater control

Engine speed

GI

The ECM performs ON/OFF control of the heated oxygen sensor 2 heaters corresponding to the engine speed.

OPERATION

MA EM LC

NGEC0683S02

Engine speed rpm

Heated oxygen sensor 2 heaters

Above 3,200

OFF

Below 3,200

ON

FE

CONSULT-II Reference Value in Data Monitor Mode

CL

NGEC0684

Specification data are reference values. MONITOR ITEM

HO2S2 HTR (B1) HO2S2 HTR (B2)

MT CONDITION

SPECIFICATION

쐌 Ignition switch: ON (Engine stopped) 쐌 Engine is running above 3,200 rpm.

OFF

쐌 Engine is running below 3,200 rpm after driving for 2 minutes at a speed of 70 km/h (43 MPH) or more.

ON

AT TF

ECM Terminals and Reference Value

NGEC0685

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 the ECM terminals, such as the ground. TERMINAL NO.

122

123

WIRE COLOR

R/B

R/Y

PD AX SU

ITEM

Heated oxygen sensor 2 heater (bank 1)

Heated oxygen sensor 2 heater (bank 2)

CONDITION

DATA (DC Voltage)

BR

[Ignition switch “ON”] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 3,200 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 3,200 rpm 쐌 After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more

Approximately 0.4V

[Ignition switch “ON”] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 3,200 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 3,200 rpm 쐌 After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more

Approximately 0.4V

ST RS BT HA SC EL

EC-753

IDX

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0686

Malfunction is detected when the current amperage in the heated oxygen sensor 2 heater circuit is out of the normal range. [An excessively low (P0037) (B1)/(P0057) (B2) or high (P0038) (B1)/(P0058) (B2) voltage signal is sent to ECM through the heated oxygen sensor 2 heater.]

POSSIBLE CAUSE 쐌 쐌

DTC Confirmation Procedure

SEF058Y

NGEC0686S01

Harness or connectors (The heated oxygen sensor 2 heater circuit is open or shorted.) Heated oxygen sensor 2 heater NGEC0687

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is 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. 3) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 4) Stop vehicle and let engine idle for at least 6 seconds. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-757. With GST Follow the procedure “With CONSULT-II”.

EC-754

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33E Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0688 NGEC0688S01

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC166A

EC-755

IDX

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33E

Wiring Diagram (Cont’d)

LEFT BANK

NGEC0688S02

WEC167A

EC-756

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0689

CHECK HO2S2 POWER SUPPLY CIRCUIT

GI

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 2 harness protector color.

MA EM LC

SEF372ZA

FE

3. Disconnect corresponding heated oxygen sensor 2 harness connector.

CL MT AT WEC546

4. Turn ignition switch ON. 5. Check voltage between HO2S2 terminal 3 and ground.

TF PD AX SU

SEF637W

BR

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

RS

DETECT MALFUNCTIONING PART

BT

Check the following. 쐌 Harness connectors M59, F27 쐌 Fuse block (J/B) connector M26 쐌 10A fuse 쐌 Harness for open or short between heated oxygen sensor 2 and fuse 䊳

ST

Repair harness or connectors.

HA SC EL

EC-757

IDX

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK HO2S2 HEATER OUTPUT CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram.

SEC665C

Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-3 (if equipped) 쐌 Harness for open or short between heated oxygen sensor 2 and engine ground. 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-758

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33E

Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 2 HEATER

Check the following. 1. Check resistance between HO2S2 terminals 2 and 3.

GI MA EM LC

FE CL MT AT SEF716W

Resistance: 2.3 - 4.3Ω at 25°C (77°F) 2. Check continuity.

TF PD MTBL0233

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.

AX SU

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

BR ST RS BT HA SC EL

EC-759

IDX

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33E

Diagnostic Procedure (Cont’d)

6

REPLACE HEATED OXYGEN SENSOR 2

Check heated oxygen sensor 2 (rear) harness protector color.

SEF372ZA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

7

Replace malfunctioning heated oxygen sensor 2.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-760

DTC P0101, P0102, P0103 MAF SENSOR

VG33E Component Description

Component Description

NGEC0571

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.

SEF030T

GI MA EM LC

CONSULT-II Reference Value in Data Monitor Mode

NGEC0572

Specification data are reference values. MONITOR ITEM

MAS AIR/FL SE

CAL/LD VALUE

MASS AIRFLOW

CONDITION 쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

SPECIFICATION

Idle

1.0 - 1.7V

2,500 rpm

1.7 - 2.3V

Idle

18.5 - 26.0%

2,500 rpm

18.0 - 21.0%

Idle

3.3 - 4.8 g·m/s

2,500 rpm

12.0 - 14.9 g·m/s

FE CL MT

ditto

AT

ditto

ECM Terminals and Reference Value

TF NGEC0573

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

54

55

R

G

ITEM

CONDITION

PD AX

DATA (DC Voltage)

SU

Mass air flow sensor

Mass air flow sensor ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

1.0 - 1.7V

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm

1.7 - 2.3V

ST

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

RS

On Board Diagnosis Logic

BR

NGEC0574

Malfunction is detected when (Malfunction A, P0103) an excessively high voltage from the sensor is sent to ECM when engine is not running, (Malfunction B, P0102) an excessively low voltage from the sensor is sent to ECM when engine is running, (Malfunction C, P0101) a high voltage from the sensor is sent to ECM under light load driving condition, (Malfunction D, P0101) a low voltage from the sensor is sent to ECM under heavy load driving condition.

EC-761

BT HA SC EL IDX

DTC P0101, P0102, P0103 MAF SENSOR

VG33E

On Board Diagnosis Logic (Cont’d)

POSSIBLE CAUSE Malfunction A or C 쐌

NGEC0574S01 NGEC0574S0101

Harness or connectors (The sensor circuit is open or shorted.) Mass air flow sensor

쐌

Malfunction B or D 쐌

NGEC0574S0102

Harness or connectors (The sensor circuit is open or shorted.) Intake air leaks Mass air flow sensor

쐌 쐌

FAIL-SAFE MODE

NGEC0574S02

When the malfunction B is detected, the ECM enters fail-safe mode and the MIL lights up. 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

NGEC0575

Perform “PROCEDURE FOR MALFUNCTION A” first. If the 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. If there is no problem on “PROCEDURE FOR MALFUNCTION B”, perform “PROCEDURE FOR MALFUNCTION C”. If there is no problem on ”PROCEDURE FOR MALFUNCTION C”, perform “PROCEDURE FOR MALFUNCTION D”. 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.

PROCEDURE FOR MALFUNCTION A 1) 2) 3) 4)

SEF058Y

5) 6)

NGEC0575S01

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 6 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-766. If 1st trip DTC is not detected, go to next step. Start engine and let it idle for at least 6 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-766.

EC-762

DTC P0101, P0102, P0103 MAF SENSOR

VG33E

DTC Confirmation Procedure (Cont’d)

With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC PROCEDURE FOR MALFUNCTION B

NGEC0575S02

With CONSULT-II 1) Turn ignition switch ON. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and wait 5 seconds at most. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-766. With GST Follow the procedure “With CONSULT-II”.

CL MT

SEF058Y

PROCEDURE FOR MALFUNCTION C

SEF174Y

FE

NGEC0575S03

NOTE: If engine will not start or stops soon, wait at least 10 seconds with engine stopped (Ignition switch ON) instead of running engine at idle speed. 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) Run engine for at least 10 seconds at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-766. With GST Follow the procedure “With CONSULT-II”.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-763

IDX

DTC P0101, P0102, P0103 MAF SENSOR

VG33E

DTC Confirmation Procedure (Cont’d)

PROCEDURE FOR MALFUNCTION D

NGEC0575S04

CAUTION: Always drive vehicle at a safe speed. With CONSULT-II 1) Turn ignition switch “ON”. 2) Start engine and warm it up to normal operating temperature. If engine cannot be started, go to “Diagnostic Procedure”, EC-766. 3) Select “DATA MONITOR” mode with CONSULT-II. 4) Check the voltage of MAS AIR/FL SE with “DATA MONITOR”. 5) Increases engine speed to about 4,000 rpm. 6) Monitor the linear voltage rise in response to engine speed increases. If NG, go to “Diagnostic Procedure”, EC-766. If OK, go to following step. 7) Maintain the following conditions for at least 10 consecutive seconds. ENG SPEED

More than 2,000 rpm

THRTL POS SEN

More than 3V

Selector lever

Suitable position

Driving location

Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test.

SEF998NA

8)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-766.

SEF175Y

Overall Function Check PROCEDURE FOR MALFUNCTION D

SEF534P

NGEC0576 NGEC0576S01

Use this procedure to check the overall function of the mass air flow sensor circuit. During this check, a 1st trip DTC might not be confirmed. With GST 1) Start engine and warm it up to normal operating temperature. 2) Select “MODE 1” with GST. 3) Check the mass air flow sensor signal with “MODE 1”. 4) Check for linear mass air flow sensor signal value rise in response to increases to about 4,000 rpm in engine speed. 5) If NG, go to “Diagnostic Procedure”, EC-766.

EC-764

DTC P0101, P0102, P0103 MAF SENSOR

VG33E Wiring Diagram

Wiring Diagram

NGEC0577

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC168A

EC-765

EL IDX

DTC P0101, P0102, P0103 MAF SENSOR

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0578

INSPECTION START

Which malfunction (A, B, C or D) is duplicated?

MTBL0063

Type I or Type II Type I

䊳

GO TO 3.

Type II

䊳

GO TO 2.

2

CHECK INTAKE SYSTEM

Check the following for connection. 쐌 Air duct 쐌 Vacuum hoses 쐌 Intake air passage between air duct to intake manifold collector OK or NG OK

䊳

GO TO 3.

NG

䊳

Reconnect the parts.

3

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC518

䊳

GO TO 4.

EC-766

DTC P0101, P0102, P0103 MAF SENSOR

VG33E Diagnostic Procedure (Cont’d)

4

CHECK MAFS POWER SUPPLY CIRCUIT

1. Disconnect mass air flow sensor harness connector.

GI MA EM LC AEC641A

2. Turn ignition switch ON. 3. Check voltage between terminal 2 and ground with CONSULT-II or tester.

FE CL MT SEF627W

AT

Voltage: Battery voltage OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

PD

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between ECM relay and mass air flow sensor 쐌 Harness for open or short between mass air flow sensor and ECM 䊳

6

TF

AX SU

Repair harness or connectors.

CHECK MAFS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between MAFS terminal 3 and ECM terminal 55. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to power in harness or connectors.

BR ST RS BT HA SC EL

EC-767

IDX

DTC P0101, P0102, P0103 MAF SENSOR

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK MAFS INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between MAFS terminal 4 and ECM terminal 54. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

8

CHECK MASS AIR FLOW SENSOR

1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 54 (Mass air flow sensor signal) and ground.

SEF747U

LEC102A

4. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Then repeat above check. 5. If NG, remove mass air flow sensor from air duct. Check hot wire for damage or dust.

SEF030T

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace mass air flow sensor.

EC-768

DTC P0101, P0102, P0103 MAF SENSOR

VG33E Diagnostic Procedure (Cont’d)

9

CHECK MAFS SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector-2. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground Refer to Wiring Diagram. 쐌 Joint connector (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-2.

GI MA EM LC

OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

FE

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

CL

INSPECTION END

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-769

IDX

DTC P0112, P0113, P0127 IAT SENSOR

VG33E

Component Description

Component Description

NGEC0585

The intake air temperature sensor is mounted to the air duct housing. 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. Intake air temperature °C (°F)

Voltage*

(V)

Resistance

kΩ

LEC519

20 (68)

3.5

2.1 - 2.9

80 (176)

1.23

0.27 - 0.38

*: These data are reference values and are measured between ECM terminal 61 (Intake air temperature sensor) and ground.

CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than the ECM terminals, such as the ground. SEF012P

On Board Diagnosis Logic

NGEC0586

Malfunction is detected when (Malfunction A) an excessively low (P0112) or high (P0113) voltage from the sensor is sent to ECM, (Malfunction B, P0127) rationally incorrect voltage from the sensor is sent to ECM, compared with the voltage signal from engine coolant temperature sensor.

POSSIBLE CAUSE 쐌 쐌

NGEC0586S01

Harness or connectors (The sensor circuit is open or shorted.) Intake air temperature sensor

DTC Confirmation Procedure

NGEC0587

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 5 seconds before conducting the next test.

EC-770

DTC P0112, P0113, P0127 IAT SENSOR

VG33E

DTC Confirmation Procedure (Cont’d)

PROCEDURE FOR MALFUNCTION A

NGEC0587S01

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”, EC-773. With GST Follow the procedure “With CONSULT-II”.

MA EM LC

SEF058Y

PROCEDURE FOR MALFUNCTION B

SEF176Y

GI

NGEC0587S02

CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: 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. With CONSULT-II 1) Wait until engine coolant temperature is less than 90°C (194°F). a) Turn ignition switch ON. b) Select “DATA MONITOR” mode with CONSULT-II. c) Check the engine coolant temperature. d) If the engine coolant temperature is not less than 90°C (194°F), turn ignition switch OFF and cool down engine. 쐌 Perform the following steps before engine coolant temperature is above 90°C (194°F). 2) Turn ignition switch ON. 3) Select “DATA MONITOR” mode with CONSULT-II. 4) Start engine. 5) Hold vehicle speed at more than 70 km/h (43 MPH) for 100 consecutive seconds. 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-773. With GST Follow the procedure “With CONSULT-II”.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-771

IDX

DTC P0112, P0113, P0127 IAT SENSOR

VG33E

Wiring Diagram

Wiring Diagram

NGEC0588

WEC169A

EC-772

DTC P0112, P0113, P0127 IAT SENSOR

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0589

CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT

GI

1. Turn ignition switch OFF. 2. Disconnect intake air temperature sensor harness connector.

MA EM LC

LEC519

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground.

FE CL MT AT

SEF203W

Voltage: Approximately 5V

TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

PD AX

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and intake air temperature sensor 䊳

SU BR

Repair harness or connectors.

ST 3

CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between sensor terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power.

RS BT

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

HA SC EL

EC-773

IDX

DTC P0112, P0113, P0127 IAT SENSOR

VG33E

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M81, F36 쐌 Joint connector-4 (if equipped) 쐌 Harness for open or short between ECM and intake air temperature sensor 䊳

5

Repair open circuit or short to power in harness or connectors.

CHECK INTAKE AIR TEMPERATURE SENSOR

Check resistance as shown in the figure.

SEF947Q



MTBL0228

SEF012P

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace intake air temperature sensor.

6

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-774

DTC P0117, P0118 ECT SENSOR

VG33E Component Description

Component Description

NGEC0590

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.

GI MA EM LC

SEF594K

Engine coolant temperature °C (°F)

SEF012P

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

FE CL

*: These data are reference values and are measured between ECM terminal 59 (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 the ECM terminals, such as the ground.

MT AT TF PD AX

On Board Diagnosis Logic

NGEC0591

Malfunction is detected when an excessively high (P0118) or low (P0117) voltage from the sensor is sent to ECM.

POSSIBLE CAUSE 쐌 쐌

BR NGEC0591S01

Harness or connectors (The sensor circuit is open or shorted.) Engine coolant temperature sensor

FAIL-SAFE MODE

SU

ST NGEC0591S02

When this malfunction is detected, the ECM enters fail-safe mode and the MIL lights up.

RS BT HA SC EL

EC-775

IDX

DTC P0117, P0118 ECT SENSOR

VG33E

On Board Diagnosis Logic (Cont’d) 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

DTC Confirmation Procedure

SEF058Y

NGEC0592

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. 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”, EC-778. With GST Follow the procedure “With CONSULT-II”.

EC-776

DTC P0117, P0118 ECT SENSOR

VG33E Wiring Diagram

Wiring Diagram

NGEC0593

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC170A

EC-777

EL IDX

DTC P0117, P0118 ECT SENSOR

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0594

CHECK ECTS POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect engine coolant temperature sensor harness connector.

AEC643A

3. Turn ignition switch ON. 4. Check voltage between ECTS terminal 1 and ground with CONSULT-II or tester.

SEF206W

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

2

CHECK ECTS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between ECTS terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-4 (if equipped) 쐌 Harness for open between ECM and engine coolant temperature sensor 䊳

Repair open circuit or short to power in harness or connectors.

EC-778

DTC P0117, P0118 ECT SENSOR

VG33E Diagnostic Procedure (Cont’d)

4

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

GI MA EM LC SEF152P



FE CL MTBL0229

MT AT TF PD SEF012P

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace engine coolant temperature sensor.

5

AX SU BR

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

ST

INSPECTION END

RS BT HA SC EL

EC-779

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33E

Description

Description

NGEC0595

NOTE: If DTC P0121, P0122, P0123 is displayed with DTC P0510, first perform the trouble diagnosis for DTC P0510. Refer to EC-1012.

COMPONENT DESCRIPTION

NGEC0595S01

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.

SEF349X

CONSULT-II Reference Value in Data Monitor Mode

NGEC0596

Specification data are reference values. MONITOR ITEM

CONDITION 쐌 Engine: After warming up, idle the engine

THRTL POS SEN

ABSOL TH·P/S

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

SPECIFICATION

Throttle valve: fully closed (a)

0.15 - 0.85V

Throttle valve: Partially open

Between (a) and (b)

Throttle valve: fully open (b)

3.5 - 4.7V

쐌 Engine: After warming up 쐌 Ignition switch: ON 쐌 More than -40.0 kpa (-300 Throttle valve: fully closed mmHg, -11.81 inHg) of vacuum is applied to the throttle opener with a hand vacuum pump.

0.0%

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

Approx. 80%

Throttle valve: fully open

EC-780

DTC P0121, P0122, P0123 TP SENSOR

VG33E

ECM Terminals and Reference Value

ECM Terminals and Reference Value

=NGEC0597

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 the ECM terminals, such as the ground. TERMINAL NO.

23

WIRE COLOR

L

ITEM

Throttle position sensor

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Warm-up condition 쐌 Accelerator pedal fully released

0.15 - 0.85V

[Ignition switch ON] 쐌 Accelerator pedal fully depressed

3.5 - 4.7V

GI MA EM LC

42

B/W

Sensors’ power supply

[Ignition switch ON]

Approximately 5V

43

BR

Sensors’ ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

FE CL MT

On Board Diagnosis Logic

NGEC0598

Malfunction is detected when (Malfunction A) an excessively low (P0122) or high (P0123) voltage from the sensor is sent to ECM, (Malfunction B, P0121) a high voltage from the sensor is sent to ECM under light load driving conditions, (Malfunction C, P0121) a low voltage from the sensor is sent to ECM under heavy load driving conditions.

POSSIBLE CAUSE Malfunction A 쐌 쐌

쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC0598S0102

Harness or connectors (The throttle position sensor circuit is open or shorted.) Throttle position sensor Fuel injector Camshaft position sensor Mass air flow sensor

Malfunction C

NGEC0598S0103

Harness or connectors (The throttle position sensor circuit is open or shorted.) Intake air leaks Throttle position sensor

FAIL-SAFE MODE

TF PD AX

NGEC0598S0101

Harness or connectors (The throttle position sensor circuit is open or shorted.) Throttle position sensor

Malfunction B 쐌

NGEC0598S01

AT

NGEC0598S02

When the malfunction A is detected, the ECM enters fail-safe mode and the MIL lights up.

SU BR ST RS BT HA SC EL

EC-781

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33E

On Board Diagnosis Logic (Cont’d) 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

NGEC0599

NOTE: 쐌 Perform “PROCEDURE FOR MALFUNCTION A” first. If the 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. If there is no problem on “PROCEDURE FOR MALFUNCTION B”, perform “PROCEDURE FOR MALFUNCTION C”. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A

NGEC0599S01

CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: 쐌 Before performing the following procedure, confirm that battery voltage is more than 10V at idle. 쐌 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.

With CONSULT-II 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. 1)

Vehicle speed

More than 5 km/h (3 MPH)

Selector lever

Suitable position except “P” or “N” position

3) SEF065Y

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-786. With GST Follow the procedure “With CONSULT-II”.

EC-782

DTC P0121, P0122, P0123 TP SENSOR

VG33E

DTC Confirmation Procedure (Cont’d)

PROCEDURE FOR MALFUNCTION B

NGEC0599S02

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 10 seconds. If idle speed is over 1,000 rpm, maintain the following conditions for at least 10 seconds to keep engine speed below 1,000 rpm.

SEF058Y

Selector lever

Suitable position except “P” or “N”

Brake pedal

Depressed

Vehicle speed

0 km/h (0 MPH)

GI MA EM LC

4)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-786. With GST Follow the procedure “With CONSULT-II”.

FE CL MT

PROCEDURE FOR MALFUNCTION C

SEF177Y

NGEC0599S03

CAUTION: Always drive vehicle at a safe speed. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode with CONSULT-II. 5) Select “THRTL POS SEN” and “ABSOL TH·P/S” in “DATA MONITOR” mode with CONSULT-II. 6) Press RECORD on CONSULT-II SCREEN at the same time accelerator pedal is depressed. 7) Print out the recorded graph and check the following: 쐌 The voltage rise is linear in response to accelerator pedal depression. 쐌 The voltage when accelerator pedal is fully depressed is approximately 4V. If NG, go to “Diagnostic Procedure”, EC-786. If OK, go to following step.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-783

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33E

DTC Confirmation Procedure (Cont’d)

SEF174Z

8) 9)

SEF805Z

Select “AUTO TRIG” in “DATA MONITOR” mode with CONSULT-II. Maintain the following conditions for at least 10 consecutive seconds.

CMPS·RPM (REF)

More than 2,000 rpm

MAS AIR/FL SE

More than 3V

COOLAN TEMP/S

More than 70°C (158°F)

IACV-AAC/V

Less than 80%

Selector lever

Suitable position

Driving location

Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test.

10) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-786. With GST Follow the procedure “With CONSULT-II”.

EC-784

DTC P0121, P0122, P0123 TP SENSOR

VG33E Wiring Diagram

Wiring Diagram

NGEC0600

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC171A

EC-785

EL IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0601

INSPECTION START

Which malfunction A, B or C is duplicated?

MTBL0066

Type A, B or C Type A or B

䊳

GO TO 4.

Type C

䊳

GO TO 2.

2

ADJUST THROTTLE POSITION SENSOR

Check the following items. Refer to “Basic Inspection”, EC-701.

MTBL0576

䊳

3

GO TO 3.

CHECK INTAKE SYSTEM.

1. Turn ignition switch OFF. 2. Check the following for connection. 쐌 Air duct 쐌 Vacuum hoses 쐌 Intake air passage between air duct to intake manifold collector OK or NG OK

䊳

GO TO 4.

NG

䊳

Reconnect the parts.

EC-786

DTC P0121, P0122, P0123 TP SENSOR

VG33E Diagnostic Procedure (Cont’d)

4

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

GI MA EM LC

LEC518

䊳

5

FE

GO TO 5.

CL

CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT

1. Disconnect throttle position sensor harness connector.

MT AT TF PD AEC638A

2. Turn ignition switch ON. 3. Check voltage between sensor terminal 3 and ground with CONSULT-II or tester.

AX SU BR ST SEF630W

Voltage: Approximately 5V

RS OK or NG

OK

䊳

GO TO 6.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

BT HA SC EL

EC-787

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33E

Diagnostic Procedure (Cont’d)

6

CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

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 power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check harness for open between ECM and throttle position sensor. 䊳

8

Repair open circuit or short to power in harness or connectors.

CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 23 and 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 (With CONSULT-II)

䊳

GO TO 9.

OK (Without CONSULTII)

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

9 1. 2. 3. 4. 5.

CHECK THROTTLE POSITION SENSOR With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine (ignition switch OFF). Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check voltage of “THRTL POS SEN” under the following conditions. Voltage measurement must be made with throttle position sensor installed in vehicle.

SEF062Y

OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 11.

EC-788

DTC P0121, P0122, P0123 TP SENSOR

VG33E Diagnostic Procedure (Cont’d)

10 1. 2. 3. 4.

CHECK 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 23 (Throttle position sensor signal) and ground. Voltage measurement must be made with throttle position sensor installed in vehicle.

GI MA EM LC MTBL0231

OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 11.

11

FE CL

ADJUST CLOSED THROTTLE POSITION SWITCH

Adjust closed throttle position switch. Refer to “Basic Inspection”, EC-701.

MT AT TF MTBL0576

PD

OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace throttle position sensor. To adjust it, perform “Basic Inspection”, EC-701.

AX SU BR ST RS BT HA SC EL

EC-789

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33E

Diagnostic Procedure (Cont’d)

12

CHECK MASS AIR FLOW SENSOR

1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 54 (Mass air flow sensor signal) and ground.

SEF747U

LEC102A

4. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Then repeat above check. 5. If NG, remove mass air flow sensor from air duct. Check hot wire for damage or dust.

SEF030T

OK or NG OK

䊳

GO TO 13.

NG

䊳

Replace mass air flow sensor.

EC-790

DTC P0121, P0122, P0123 TP SENSOR

VG33E Diagnostic Procedure (Cont’d)

13

CHECK CAMSHAFT POSITION SENSOR

1. Install any parts removed. 2. Start engine. 3. Check voltage between ECM terminals 44, 48 and ground, ECM terminal 49 and ground with DC range.

GI MA EM LC

FE CL MT AT TF PD AEC072B

AX

OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace distributor assembly with camshaft position sensor.

14

SU

CHECK FUEL INJECTOR

BR

1. Disconnect injector harness connector. 2. Check resistance between terminals as shown in the figure.

ST RS BT HA SEF625V

Resistance: 10 - 14Ω [at 25°C (77°F)]

SC OK or NG

OK

䊳

GO TO 15.

NG

䊳

Replace fuel injector.

EL

EC-791

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33E

Diagnostic Procedure (Cont’d)

15

CHECK THROTTLE POSITION SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector-2. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-2. OK or NG OK

䊳

GO TO 16.

NG

䊳

Repair open circuit or short to power in harness or connectors.

16

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-792

DTC P0125 ECT SENSOR

VG33E Description

Description

NGEC0602

NOTE: If DTC P0125 is displayed with P0117, P0118, first perform the trouble diagnosis for DTC P0117, P0118. Refer to EC-775.

GI MA EM LC

COMPONENT DESCRIPTION

NGEC0602S01

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.

FE CL MT

SEF594K

Engine coolant temperature °C (°F)

SEF012P

AT Voltage*

(V)

Resistance

(kΩ)

TF

−10 (14)

4.4

9.2

20 (68)

3.5

2.1 - 2.9

50 (122)

2.2

0.68 - 1.00

90 (194)

0.9

0.236 - 0.260

PD

*: These data are reference values and are measured between ECM terminal 59 (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 the ECM terminals, such as the ground.

AX SU BR ST RS

On Board Diagnosis Logic

NGEC0603

BT

Malfunction is detected when voltage sent to ECM from the sensor is not practical, even when some time has passed after starting the engine, or engine coolant temperature is insufficient for closed loop fuel control.

HA

POSSIBLE CAUSE

SC

쐌 쐌 쐌

Harness or connectors (High resistance in the circuit) Engine coolant temperature sensor Thermostat

EC-793

NGEC0603S01

EL IDX

DTC P0125 ECT SENSOR

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF174Y

=NGEC0604

CAUTION: Be careful not to overheat engine. 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. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Check that “COOLAN TEMP/S” is above 10°C (50°F). If it is above 10°C (50°F), the test result will be OK. If it is below 10°C (50°F), go to following step. 4) Start engine and run it for 65 minutes at idle speed. If “COOLAN TEMP/S” increases to more than 10°C (50°F) within 65 minutes, stop engine because the test result will be OK. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-796. With GST Follow the procedure “With CONSULT-II”.

EC-794

DTC P0125 ECT SENSOR

VG33E Wiring Diagram

Wiring Diagram

NGEC0605

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC170A

EC-795

EL IDX

DTC P0125 ECT SENSOR

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0606

CHECK ECTS POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect engine coolant temperature sensor harness connector.

AEC643A

3. Turn ignition switch ON. 4. Check voltage between ECTS terminal 1 and ground with CONSULT-II or tester.

SEF206W

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

2

CHECK ECTS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between ECTS terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-4 (if equipped) 쐌 Harness for open between ECM and engine coolant temperature sensor 䊳

Repair open circuit or short to power in harness or connectors.

EC-796

DTC P0125 ECT SENSOR

VG33E Diagnostic Procedure (Cont’d)

4

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

GI MA EM LC SEF152P



FE CL MTBL0229

MT AT TF PD SEF012P

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace engine coolant temperature sensor.

5

AX SU BR

CHECK THERMOSTAT OPERATION

When the engine is cold [lower than 70°C (158°F)] condition, grasp lower radiator hose and confirm the engine coolant does not flow.

ST

OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair or replace thermostat. Refer to “Thermostat”, “ ENGINE COOLING SYSTEM”, LC-13.

RS BT

6

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

HA

INSPECTION END

SC EL

EC-797

IDX

DTC P0128 THERMOSTAT FUNCTION

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0986

Engine coolant temperature has not risen enough to open the thermostat even though the engine has run long enough. This is due to a leak in the seal or the thermostat open stuck. Malfunction is detected when the engine coolant temperature does not reach to specified temperature even though the engine has run long enough.

POSSIBLE CAUSE 쐌 쐌 쐌

NGEC0986S01

Thermostat function Leakage from sealing portion of thermostat Engine coolant temperature sensor

DTC Confirmation Procedure

NGEC0988

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. TESTING CONDITION: 쐌 For best results, perform at ambient temperature of –10°C (14°F) or higher. 쐌 For best results, perform at engine coolant temperature of –10°C (14°F) to 70°C (158°F).

WITH CONSULT-II 1)

2) 3) 4)

5)

NGEC0988S01

Replace thermostat with new one. Refer to LC-13, “Thermostat”. Use only a genuine NISSAN thermostat as a replacement. If an incorrect thermostat is used, the MIL may come on. Turn ignition switch “ON”. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Check that the “COOLAN TEMP/S” is above 70°C (158°F). If it is below 70°C (158°F), go to following step. If it is above 70°C (158°F), stop engine and cool down the engine to less than 70°C (158°F), then retry from step 1. Drive vehicle for 10 consecutive minutes under the following conditions.

VHCL SPEED SE

80 - 120 km/h (50 - 75 MPH)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-601.

WITH GST 1)

Follow the prodedure “WITH CONSULT-II” above.

EC-798

NGEC0988S02

DTC P0128 THERMOSTAT FUNCTION

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0989

CHECK ENGINE COOLANT TEMPERATURE SENSOR

GI

1. Turn ignition switch OFF. 2. Remove engine coolant temperature sensor. 3. Check resistance between engine coolant temperature sensor terminals under the following conditions.

MA EM LC

FE CL MT SEF304X

AT

OK or NG

TF

OK

䊳

INSPECTION END

NG

䊳

Replace engine coolant temperature sensor.

PD AX SU BR ST RS BT HA SC EL

EC-799

IDX

DTC P0132, P0152 HO2S1

VG33E

Component Description

Component Description

NGEC0637

The heated oxygen sensor 1 is placed into the front tube. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NGEC0638

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 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

NGEC0639

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1 (Bank 1) [Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

51

G

Heated oxygen sensor 1 (Bank 2) SEF002V

EC-800

DTC P0132, P0152 HO2S1

VG33E On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0640

To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high. Malfunction is detected when an excessively high voltage from the sensor is sent to ECM.

POSSIBLE CAUSE 쐌 쐌

MA

NGEC0640S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 1

EM LC

SEF301UA

DTC Confirmation Procedure

SEF174Y

GI

NGEC0641

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) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Restart engine and let it idle for 25 seconds. 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-804. With GST Follow the procedure “With CONSULT-II”. 쐌 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.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-801

IDX

DTC P0132, P0152 HO2S1

VG33E

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0642 NGEC0642S01

WEC172A

EC-802

DTC P0132, P0152 HO2S1

VG33E Wiring Diagram (Cont’d)

LEFT BANK

NGEC0642S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC173A

EC-803

EL IDX

DTC P0132, P0152 HO2S1

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0643

INSPECTION START

1. Turn ignition switch OFF. 2. Check heated oxygen sensor 1 harness protector.

SEF505YB

3. Disconnect corresponding heated oxygen sensor 1 harness connector.

WEC545

䊳

2

GO TO 2.

RETIGHTEN HEATED OXYGEN SENSOR 1

1. Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

GO TO 3.

EC-804

DTC P0132, P0152 HO2S1

VG33E Diagnostic Procedure (Cont’d)

3

CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

GI MA EM LC

SEC656C

Continuity should exist. 3. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram.

FE CL MT AT TF SEC657C

Continuity should not exist. 4. Also check harness for short to power.

PD OK or NG

AX

OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

SU 4

CHECK FRONT HO2S1 CONNECTOR FOR WATER

1. Disconnect heated oxygen sensor 1 harness connector. 2. Check connectors for water. Water should not exist. OK or NG OK (With CONSULT-II)

䊳

GO TO 5.

OK (Without CONSULTII)

䊳

GO TO 6.

NG

䊳

Repair or replace harness or connectors.

BR ST RS BT HA SC EL

EC-805

IDX

DTC P0132, P0152 HO2S1

VG33E

Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 1

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 with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown left:

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

EC-806

DTC P0132, P0152 HO2S1

VG33E Diagnostic Procedure (Cont’d)

6

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

GI MA EM LC

SEF796Z

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.

FE CL

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

MT

REPLACE HEATED OXYGEN SENSOR 1

AT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

TF

7

PD AX SU SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

BR ST

Replace malfunctioning heated oxygen sensor 1.

RS 8

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

BT

INSPECTION END

HA SC EL

EC-807

IDX

DTC P0133, P0153 HO2S1

VG33E

Component Description

Component Description

NGEC0629

The heated oxygen sensor 1 is placed into the front tube. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NGEC0630

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 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

NGEC0631

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1 (Bank 1) [Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

51

G

Heated oxygen sensor 1 (Bank 2) SEF002V

EC-808

DTC P0133, P0153 HO2S1

VG33E On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0632

To judge the malfunction of heated oxygen sensor 1, this diagnosis measures response time of heated oxygen sensor 1 signal. The time is compensated by engine operating (speed and load), fuel feedback control constant, and heated oxygen sensor 1 temperature index. Judgment is based on whether the compensated time (heated oxygen sensor 1 cycling time index) is inordinately long or not. Malfunction is detected when the response of the voltage signal from the sensor takes more than the specified time. SEF010V

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC0632S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 1 Heated oxygen sensor 1 heater Fuel pressure Injectors Intake air leaks Exhaust gas leaks PCV valve Mass air flow sensor

DTC Confirmation Procedure

GI MA EM LC

FE CL MT NGEC0633

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-809

IDX

DTC P0133, P0153 HO2S1

VG33E

DTC Confirmation Procedure (Cont’d)

SEF338Z

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 5 seconds. 3) Turn ignition switch ON and select “HO2S1 (B1)/(B2) P0133/ P0153” 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 40 to 50 seconds.) ENG SPEED

1,800 - 3,300 rpm

Vehicle speed

More than 80 km/h (50 MPH)

B/FUEL SCHDL

2.8 - 13 msec

Selector lever

Suitable position

SEF339Z

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-813.

SEF658Y

Overall Function Check

SEF919UA

NGEC0634

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 4) If NG, go to “Diagnostic Procedure”, EC-813.

EC-810

DTC P0133, P0153 HO2S1

VG33E Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0635 NGEC0635S01

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC172A

EC-811

IDX

DTC P0133, P0153 HO2S1

VG33E

Wiring Diagram (Cont’d)

LEFT BANK

NGEC0635S02

WEC173A

EC-812

DTC P0133, P0153 HO2S1

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0636

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

LEC518

䊳

FE

GO TO 2.

CL 2

RETIGHTEN HEATED OXYGEN SENSOR 1

MT

Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb)

AT 䊳

GO TO 3.

TF 3

CHECK FOR EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.

PD AX SU BR ST SEF099P

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace.

4

RS BT

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor.

HA

OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair or replace.

SC EL

EC-813

IDX

DTC P0133, P0153 HO2S1

VG33E

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 “CLEAR”.

SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0100 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-673. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6.

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171, P0174 or P0172, P0175. Refer to EC-853, 862.

No

䊳

GO TO 6.

EC-814

DTC P0133, P0153 HO2S1

VG33E Diagnostic Procedure (Cont’d)

6

CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check heated oxygen sensor 1 harness protector.

GI MA EM LC SEF505YB

3. Disconnect corresponding heated oxygen sensor 1 harness connector.

FE CL MT AT WEC545

4. Disconnect ECM harness connector. 5. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

TF PD AX MTBL0587

Continuity should exist. 6. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram.

SU BR ST

MTBL0588

RS

Continuity should not exist. 7. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

BT HA SC EL

EC-815

IDX

DTC P0133, P0153 HO2S1

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK HEATED OXYGEN SENSOR 1 HEATER

Check resistance between HO2S1 terminals 3 and 1.

AEC158A

Resistance: 2.3 - 4.3Ω at 25°C (77°F) Check continuity between HO2S1 terminals 2 and 1, 3 and 2. Continuity should not exist. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 12.

EC-816

DTC P0133, P0153 HO2S1

VG33E Diagnostic Procedure (Cont’d)

8

CHECK MASS AIR FLOW SENSOR

1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 54 (Mass air flow sensor signal) and ground.

GI MA EM LC

SEF747U

FE CL MT MTBL0227

4. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Then repeat above check. 5. If NG, remove mass air flow sensor from air duct. Check hot wire for damage or dust.

AT TF PD AX SU SEF030T

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace mass air flow sensor.

BR ST RS BT HA SC EL

EC-817

IDX

DTC P0133, P0153 HO2S1

VG33E

Diagnostic Procedure (Cont’d)

9

CHECK PCV VALVE

With engine running at idle, remove PCV valve ventilation hose from PCV valve; make sure that 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.

SEC137A

OK or NG OK (With CONSULT-II)

䊳

GO TO 10.

OK (Without CONSULTII)

䊳

GO TO 11.

NG

䊳

Replace PCV valve.

EC-818

DTC P0133, P0153 HO2S1

VG33E Diagnostic Procedure (Cont’d)

10

CHECK HEATED OXYGEN SENSOR 1

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 with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

GI MA EM LC

FE SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below.

CL MT AT TF PD

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

AX SU BR ST RS SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BT HA

OK or NG

SC

OK

䊳

GO TO 12.

NG

䊳

Replace malfunctioning heated oxygen sensor 1.

EL

EC-819

IDX

DTC P0133, P0153 HO2S1

VG33E

Diagnostic Procedure (Cont’d)

11

CHECK FRONT HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

SEF796Z

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. OK or NG OK

䊳

GO TO 13.

NG

䊳

GO TO 12.

12

REPLACE HEATED OXYGEN SENSOR 1

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 1.

EC-820

DTC P0133, P0153 HO2S1

VG33E Diagnostic Procedure (Cont’d)

13

CHECK HO2S1 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 14.

NG

䊳

Repair open circuit or short to power in harness or connectors.

14

CHECK INTERMITTENT INCIDENT

GI MA EM LC

FE

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-821

IDX

DTC P0134, P0154 HO2S1

VG33E

Component Description

Component Description

NGEC0607

The heated oxygen sensor 1 is placed into the front tube. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NGEC0608

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 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

NGEC0609

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1 (bank 1) [Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

51

G

Heated oxygen sensor 1 (bank 2) SEF002V

EC-822

DTC P0134, P0154 HO2S1

VG33E On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0610

Under the condition in which the heated oxygen sensor 1 signal is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output voltage is within 200 to 400 mV range is monitored, and the diagnosis checks that this time is not inordinately long. Malfunction is detected when the voltage from the sensor is constantly approx. 0.3V.

POSSIBLE CAUSE SEF237U

쐌 쐌

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 1

GI MA EM

NGEC0610S01

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-823

IDX

DTC P0134, P0154 HO2S1

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

SEC701C

SEC702C

SEC703C

=NGEC0611

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 5 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “HO2S1 (B1)/(B2) P0134/P0154” 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

1,800 - 3,100 rpm

Vehicle speed

More than 65 km/h (40 MPH)

B/FUEL SCHDL

2.8 - 13 msec

Selector lever

Suitable position

6)

If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-828. During this test, P1148 and P1168 may be stored in ECM.

EC-824

DTC P0134, P0154 HO2S1

VG33E Overall Function Check

Overall Function Check

SEF919UA

=NGEC0612

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage does not remain in the range of 0.2 - 0.4V. 4) If NG, go to “Diagnostic Procedure”, EC-828.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-825

IDX

DTC P0134, P0154 HO2S1

VG33E

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0613 NGEC0613S01

WEC172A

EC-826

DTC P0134, P0154 HO2S1

VG33E Wiring Diagram (Cont’d)

LEFT BANK

NGEC0613S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC173A

EC-827

EL IDX

DTC P0134, P0154 HO2S1

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0614

INSPECTION START

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC518

3. Make sure HO2S 1 harness protector color, and disconnect corresponding heated oxygen sensor 1 harness connector.

SEF505YB

WEC545

䊳

GO TO 2.

EC-828

DTC P0134, P0154 HO2S1

VG33E Diagnostic Procedure (Cont’d)

2

CHECK HO2S 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

GI MA EM LC

SEC654C

Continuity should exist. 3. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram.

FE CL MT AT TF SEC655C

Continuity should not exist. 4. Also check harness for short to power.

PD OK or NG

AX

OK (With CONSULT-II)

䊳

GO TO 3.

OK (Without CONSULTII)

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

SU BR ST RS BT HA SC EL

EC-829

IDX

DTC P0134, P0154 HO2S1

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK HEATED OXYGEN SENSOR 1

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 with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below.

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace malfunctioning heated oxygen sensor 1.

EC-830

DTC P0134, P0154 HO2S1

VG33E Diagnostic Procedure (Cont’d)

4

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

GI MA EM LC

SEF796Z

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.

FE CL

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

MT

REPLACE HEATED OXYGEN SENSOR 1

AT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

TF

5

PD AX SU SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

BR ST

Replace malfunctioning heated oxygen sensor 1.

RS BT HA SC EL

EC-831

IDX

DTC P0134, P0154 HO2S1 Diagnostic Procedure (Cont’d)

6

CHECK HO2S 1 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector-2. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-2. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to power in harness or connectors.

7

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-832

VG33E

DTC P0138, P0158 HO2S2

VG33E Component Description

Component Description

SEF327R

NGEC0675

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

GI MA EM LC

CONSULT-II Reference Value in Data Monitor Mode

NGEC0676

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2)

FE

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up

CL

Revving engine from idle up to 2,000 rpm LEAN +, RICH

ECM Terminals and Reference Value

MT NGEC0677

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 the ECM terminals, such as the ground. TERMINAL NO. 56 57

WIRE COLOR

AT TF PD

ITEM

CONDITION

OR

Heated oxygen sensor 2 (bank 1)

Y

Heated oxygen sensor 2 (bank 2)

DATA (DC Voltage)

AX [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 2,000 rpm

0 - Approximately 1.0V

SU BR ST RS

On Board Diagnosis Logic

NGEC0678

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the voltage is unusually high during the various driving condition such as fuel-cut. Malfunction is detected when an excessively high voltage from the sensor is sent to ECM.

BT HA SC EL

SEF305UA

EC-833

IDX

DTC P0138, P0158 HO2S2

VG33E

On Board Diagnosis Logic (Cont’d)

POSSIBLE CAUSE 쐌 쐌

=NGEC0678S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 2

DTC Confirmation Procedure

SEF189Y

ENG SPEED

Less than 3,600 rpm

COOLAN TEMP/S

More than 70°C (158°F)

Selector lever

Suitable position

6)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-838.

Overall Function Check

SEF922UA

NGEC0679

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 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 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.

NGEC0680

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 terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. 4) Check the voltage when racing up to 4,000 rpm under no load

EC-834

DTC P0138, P0158 HO2S2

VG33E Overall Function Check (Cont’d)

5)

at least 10 times. (depress and release accelerator pedal as soon as possible) The voltage should be below 1.4V during this procedure. If NG, go to “Diagnostic Procedure”, EC-838.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-835

IDX

DTC P0138, P0158 HO2S2

VG33E

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0681 NGEC0681S01

WEC174A

EC-836

DTC P0138, P0158 HO2S2

VG33E Wiring Diagram (Cont’d)

LEFT BANK

NGEC0681S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC175A

EC-837

EL IDX

DTC P0138, P0158 HO2S2

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0682

INSPECTION START

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC518

3. Check heated oxygen sensor 2 harness protector color.

SEF372ZA

4. Disconnect corresponding heated oxygen sensor 2 harness connector. 5. Disconnect ECM harness connector. 䊳

GO TO 2.

EC-838

DTC P0138, P0158 HO2S2

VG33E Diagnostic Procedure (Cont’d)

2

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram.

GI MA EM LC SEC663C

Continuity should exist. 2. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram.

FE CL MT AT SEC664C

Continuity should not exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

3

CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

PD AX SU BR ST RS

DETECT MALFUNCTIONING PART

BT

Check the following. 쐌 Joint connector-3 (if equipped) 쐌 Harness for open between heated oxygen sensor 2 and engine ground. 䊳

TF

HA

Repair open circuit or short to power in harness or connectors.

SC EL

EC-839

IDX

DTC P0138, P0158 HO2S2

VG33E

Diagnostic Procedure (Cont’d)

5

CHECK HO2S2 CONNECTORS FOR WATER

Check heated oxygen sensor 2 connector and harness connector for water. Water should not exist. OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

Repair or replace harness or connectors.

6

CHECK HEATED OXYGEN SENSOR 2

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)/(B2)” as the monitor item with CONSULTII. 4. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

SEF989RD

“HO2S2 (B1)/(B2)” should be above 0.62V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

EC-840

DTC P0138, P0158 HO2S2

VG33E Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without 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. Set voltmeter probes between ECM terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (depress and release accelerator pedal as soon as possible)

GI MA EM LC

FE SEF797ZB

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 “O/D” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

CL MT AT TF

REPLACE HEATED OXYGEN SENSOR 2

PD

1. Stop vehicle and turn ignitioin switch OFF. 2. Check heated oxygen sensor 2 (rear) harness protector color.

AX SU BR ST SEF372ZA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

RS BT

Replace malfunctioning heated oxygen sensor 2.

HA SC EL

EC-841

IDX

DTC P0138, P0158 HO2S2 Diagnostic Procedure (Cont’d)

9

CHECK HO2S2 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-842

VG33E

DTC P0139, P0159 HO2S2

VG33E Component Description

Component Description

SEF327R

NGEC0667

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

GI MA EM LC

CONSULT-II Reference Value in Data Monitor Mode

NGEC0668

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2)

FE

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up

CL

Revving engine from idle up to 2,000 rpm LEAN +, RICH

ECM Terminals and Reference Value

MT NGEC0669

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 the ECM terminals, such as the ground. TERMINAL NO. 56 57

WIRE COLOR OR Y

AT TF PD

ITEM

CONDITION

Heated oxygen sensor 2 (bank 1) Heated oxygen sensor 2 (bank 2)

DATA (DC Voltage)

AX [Engine is running] 쐌 Revving engine from idle up to 2,000 rpm

0 - Approximately 1.0V

SU BR ST RS

On Board Diagnosis Logic

NGEC0670

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the switching response of the sensor’s voltage is faster than specified during the various driving condition such as fuel-cut. Malfunction is detected when it takes more time for the sensor to respond between rich and lean than the specified time.

BT HA SC EL

SEF302U

EC-843

IDX

DTC P0139, P0159 HO2S2

VG33E

On Board Diagnosis Logic (Cont’d)

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌

DTC Confirmation Procedure

SEF666Y

SEF667Y

NGEC0670S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 2 Fuel pressure Injectors Intake air leaks

NGEC0671

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. TESTING CONDITION: Open engine hood before conducting following procedure With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that “COOLANT TEMP/S” is more than 70°C (158°F). 6) Select “HO2S2 (B1)/(B2) P0139/P0159” of “HO2S2” in DTC WORK SUPPORT” mode with CONSULT-II. 7) Start engine and follow the instructions of CONSULT-II. 8) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If NG is displayed, refer to “DIAGNOSTIC PROCEDURE”, EC-848. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. a) Stop engine and cool down “COOLANT TEMP/SE” to less than 70°C (158°F). b) Turn ignition switch ON. c) Select “DATA MONITOR” mode with CONSULT-II. d) Start engine. e) Perform from step 6) again when the “COOLANT TEMP/S” reaches to 70°C (158°F)

SEF668Y

EC-844

DTC P0139, P0159 HO2S2

VG33E Overall Function Check

Overall Function Check

SEF922UA

=NGEC0672

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. 4) Check the voltage when racing 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 “O/D” OFF (A/T). The voltage should change at more than 0.06V for 1 second during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-848.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-845

IDX

DTC P0139, P0159 HO2S2

VG33E

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0673 NGEC0673S01

WEC174A

EC-846

DTC P0139, P0159 HO2S2

VG33E Wiring Diagram (Cont’d)

LEFT BANK

NGEC0673S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC175A

EC-847

EL IDX

DTC P0139, P0159 HO2S2

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0674

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC518

䊳

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-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.

SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-673. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6.

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171, P0174 or P0172, P0175. Refer to EC-853, 862.

No

䊳

GO TO 3.

EC-848

DTC P0139, P0159 HO2S2

VG33E Diagnostic Procedure (Cont’d)

3

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 2 harness protector color.

GI MA EM LC SEF372ZA

3. Disconnect corresponding heated oxygen sensor 2 harness connector.

FE CL MT AT WEC546

TF

4. Disconnect ECM harness connector. 5. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram.

PD AX MTBL0591

Continuity should exist. 6. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram.

SU BR ST

MTBL0592

RS

Continuity should not exist. 7. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

BT HA SC EL

EC-849

IDX

DTC P0139, P0159 HO2S2

VG33E

Diagnostic Procedure (Cont’d)

4

CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-3 (if equipped) 쐌 Harness for open between heated oxygen sensor 2 and engine ground. 䊳

6

Repair open circuit or short to power in harness or connectors.

CHECK HEATED OXYGEN SENSOR 2

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)/(B2)” as the monitor item with CONSULTII. 4. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

SEF989RD

“HO2S2 (B1)/(B2)” should be above 0.62V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

EC-850

DTC P0139, P0159 HO2S2

VG33E Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without 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. Set voltmeter probes between ECM terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (depress and release accelerator pedal as soon as possible)

GI MA EM LC

FE SEF797ZB

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 “O/D” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

CL MT AT TF

REPLACE HEATED OXYGEN SENSOR 2

PD

1. Stop vehicle and turn ignitioin switch OFF. 2. Check heated oxygen sensor 2 (rear) harness protector color.

AX SU BR ST SEF372ZA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

RS BT

Replace malfunctioning heated oxygen sensor 2.

HA SC EL

EC-851

IDX

DTC P0139, P0159 HO2S2 Diagnostic Procedure (Cont’d)

9

CHECK HO2S2 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to “HARNESS LAYOUT”, EL-250 .) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-852

VG33E

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0690

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the ECM judges the condition as the fuel injection system malfunction and light up the MIL (2 trip detection logic). Sensor Heated oxygen sensors 1

Input Signal to ECM Density of oxygen in exhaust gas (Mixture ratio feedback signal)

ECM function Fuel injection control

GI MA EM LC

Actuator Injectors

Malfunction is detected when fuel injection system does not operate properly, the amount of mixture ratio compensation is too large. (The mixture ratio is too lean.)

FE

POSSIBLE CAUSE

CL

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

Intake air leaks Heated oxygen sensor 1 Injectors Exhaust gas leaks Incorrect fuel pressure Lack of fuel Mass air flow sensor PCV system (Loose or disconnected rubber tube)

NGEC0690S01

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-853

IDX

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF968Y

=NGEC0691

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) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 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 or P0174 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-857. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-857. If engine does not start, check exhaust and intake air leak visually. With GST Follow the procedure “With CONSULT-II”.

EC-854

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33E Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0692 NGEC0692S01

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC176A

EC-855

IDX

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33E

Wiring Diagram (Cont’d)

LEFT BANK

NGEC0692S02

WEC177A

EC-856

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0693

CHECK EXHAUST AIR LEAK

GI

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.

MA EM LC

SEF099P

FE

OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair or replace.

2

CL MT

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace.

3

AT TF PD

CHECK FOR PCV HOSE

Check PCV hose for loose connection or disconnection. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace.

AX SU BR ST RS BT HA SC EL

EC-857

IDX

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33E

Diagnostic Procedure (Cont’d)

4 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT Turn ignition switch OFF. Disconnect corresponding heated oxygen sensor 1 harness connector. Disconnect ECM harness connector. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

SEF831Z

Continuity should exist. 5. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram.

SEF832Z

Continuity should not exist. 6. Also check harness for short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

5

CHECK FUEL PRESSURE

1. Release fuel pressure to zero. Refer to EC-644. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (3.0 kg/cm2, 43 psi) OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

EC-858

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33E

Diagnostic Procedure (Cont’d)

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuel pump and circuit (Refer to EC-1153.) 쐌 Fuel pressure regulator (Refer to EC-645.) 쐌 Fuel lines (Refer to “ENGINE MAINTENANCE”, MA-26.) 쐌 Fuel filter for clogging 䊳

7

Repair or replace.

GI MA EM

CHECK MASS AIR FLOW SENSOR

With CONSULT-II 1. Install all parts removed. 2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm With GST 1. Install all parts removed. 2. Check mass air flow sensor signal in MODE 1 with GST. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm OK or NG OK

䊳

GO TO 8.

NG

䊳

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-761.

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-859

IDX

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33E

Diagnostic Procedure (Cont’d)

8

CHECK FUNCTION OF INJECTORS

With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

SEF981Z

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

䊳

GO TO 9.

NG

䊳

Perform trouble diagnosis for “INJECTORS”, EC-1145.

EC-860

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33E

Diagnostic Procedure (Cont’d)

9

CHECK INJECTOR

1. 2. 3. 4.

Confirm that the engine is cooled down and there are no fire hazards near the vehicle. Turn ignition switch OFF. Disconnect injector harness connectors on left bank (for DTC P0171), right bank (for DTC P0174). Remove injector gallery assembly. Refer to EC-645. Keep fuel hose and all injectors connected to injector gallery. The injector harness connectors on right bank (for DTC P0171), left bank (for DTC P0174) should remain connected. 5. Disconnect all ignition coil harness connectors. 6. Prepare pans or saucers under each injector. 7. Crank engine for about 3 seconds. Make sure that fuel sprays out from injectors.

GI MA EM LC

FE CL SEF595Q

Fuel should be sprayed evenly for each injector.

MT

OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace injectors from which fuel does not spray out. Always replace O-ring with new ones.

10

AT TF

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

PD

INSPECTION END

AX SU BR ST RS BT HA SC EL

EC-861

IDX

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0694

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the ECM judges the condition as the fuel injection system malfunction and light up the MIL (2 trip detection logic). Sensor Heated oxygen sensors 1

Input Signal to ECM Density of oxygen in exhaust gas (Mixture ratio feedback signal)

ECM function Fuel injection control

Actuator Injectors

Malfunction is detected when fuel injection system does not operate properly, the amount of mixture ratio compensation is too large. (The mixture ratio is too rich.)

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌

Heated oxygen sensor 1 Injectors Exhaust gas leaks Incorrect fuel pressure Mass air flow sensor

EC-862

NGEC0694S01

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF968Y

=NGEC0695

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) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 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, P0175 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-866. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-866. If engine does not start, remove ignition plugs and check for fouling, etc. With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-863

IDX

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33E

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0696 NGEC0696S01

WEC176A

EC-864

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33E

Wiring Diagram (Cont’d)

LEFT BANK

NGEC0696S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC177A

EC-865

EL IDX

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0697

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

䊳

GO TO 2.

NG

䊳

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

䊳

GO TO 3.

NG

䊳

Repair or replace.

EC-866

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33E

Diagnostic Procedure (Cont’d)

3 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT Turn ignition switch OFF. Disconnect corresponding heated oxygen sensor 1 harness connector. Disconnect ECM harness connector. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

GI MA EM LC

SEF833Z

Continuity should exist. 5. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram.

FE CL MT AT TF

SEF834Z

PD

Continuity should not exist. 6. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

4

1. Release fuel pressure to zero. Refer to EC-644. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (3.0 kg/cm2, 43 psi) OK or NG 䊳

GO TO 6.

NG

䊳

GO TO 5.

SU BR

CHECK FUEL PRESSURE

OK

AX

ST RS BT HA SC EL

EC-867

IDX

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33E

Diagnostic Procedure (Cont’d)

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuel pump and circuit (Refer to EC-1153.) 쐌 Fuel pressure regulator (Refer to EC-645.) 䊳

6

Repair or replace.

CHECK MASS AIR FLOW SENSOR

With CONSULT-II 1. Install all parts removed. 2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm With GST 1. Install all parts removed. 2. Check mass air flow sensor signal in MODE 1 with GST. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm OK or NG OK

䊳

GO TO 7.

NG

䊳

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-761.

EC-868

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK FUNCTION OF INJECTORS

With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

GI MA EM LC

SEF981Z

3. Make sure that each circuit produces a momentary engine speed drop.

FE

Without CONSULT-II 1. Start engine. 2. Listen to each injector operating sound.

CL MT AT TF MEC703B

PD

Clicking noise should be heard. OK or NG OK

䊳

GO TO 8.

NG

䊳

Perform trouble diagnosis for “INJECTORS”, EC-1145.

8

CHECK INJECTOR

1. Remove injector assembly. Refer to EC-645. Keep fuel hose and all injectors connected to injector gallery. 2. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 3. Disconnect injector harness connectors left bank (for DTC P0172), right bank (for P0175). The injector harness connectors on right bank (for P0172), left bank (for P0175) should remain connected. 4. Disconnect all ignition coil harness connectors. 5. Prepare pans or saucers under each injectors. 6. Crank engine for about 3 seconds. Make sure fuel does not drip from injector.

AX SU BR ST RS BT

OK or NG OK (Does not drip)

䊳

GO TO 9.

NG (Drips)

䊳

Replace the injectors from which fuel is dripping. Always replace O-ring with new one.

9

HA SC

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-869

EL IDX

DTC P0181, P0182, P0183 FTT SENSOR

VG33E

Component Description

Component Description

NGEC0698

The fuel tank temperature sensor is used to detect the fuel temperature inside the fuel tank. 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.

AEC933A

Fluid temperature °C (°F)

Voltage*

(V)

Resistance

(kΩ)

20 (68)

3.5

2.3 - 2.7

50 (122)

2.2

0.79 - 0.90

*: These data are reference values and are measured between ECM terminal 60 (Fuel tank 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 the ECM terminals, such as the ground.

On Board Diagnosis Logic

NGEC0699

Malfunction is detected when an excessively high (P0183) or low (P0182) voltage is sent to ECM, rationally incorrect voltage (P0181) from the sensor is sent to ECM, compared with the voltage signals from engine coolant temperature sensor and intake air temperature sensor.

POSSIBLE CAUSE 쐌 쐌

Harness or connectors (The sensor circuit is open or shorted.) Fuel tank temperature sensor

EC-870

NGEC0699S01

DTC P0181, P0182, P0183 FTT SENSOR

VG33E DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC0700

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.

GI MA EM LC

1) 2) 3)

4)

SEF174Y

5) 6) 7)

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 10 seconds. If the result is NG, go to “Diagnostic Procedure”, EC-873. If the result is OK, go to following step. Check “COOLAN TEMP/S” value. If “COOLAN TEMP/S” is less than 60°C (140°F), the result will be OK. If “COOLAN TEMP/S” is above 60°C (140°F), go to the following step. Cool engine down until “COOLAN TEMP/S” is less than 60°C (140°F). Wait at least 10 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-873.

FE CL MT AT TF PD AX

With GST Follow the procedure “With CONSULT-II”.

SU BR ST RS BT HA SC EL

EC-871

IDX

DTC P0181, P0182, P0183 FTT SENSOR

VG33E

Wiring Diagram

Wiring Diagram

NGEC0701

LEC503

EC-872

DTC P0181, P0182, P0183 FTT SENSOR

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0702

CHECK FUEL TANK TEMPERATURE SENSOR POWER SUPPLY CIRCUIT

GI

1. Turn ignition switch OFF. 2. Disconnect fuel tank gauge unit harness connector.

MA EM LC

AEC933A

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

FE CL MT AT

SEF639W

Voltage: Approximately 5V

TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

PD AX

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors B101, M67 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuel tank temperature sensor 䊳

SU BR

Repair harness or connector.

ST 3

CHECK FUEL TANK TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between sensor terminal 4 and body ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power.

RS BT

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

HA SC

DETECT MALFUNCTIONING PART

Check harness for open between fuel tank temperature sensor and body ground. 䊳

Repair open circuit or short to power in harness or connectors.

EC-873

EL IDX

DTC P0181, P0182, P0183 FTT SENSOR

VG33E

Diagnostic Procedure (Cont’d)

5

CHECK FUEL TANK TEMPERATURE SENSOR

Check resistance by heating with hot water or heat gun as shown in the figure.

AEC052B

MTBL0234

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace fuel tank temperature sensor.

6

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-874

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0965

This diagnosis checks whether the engine coolant temperature is extraordinary high, even when the load is not heavy. When malfunction is detected, the malfunction indicator lamp (MIL) will light up even in the first trip. Malfunction is detected when engine coolant temperature is excessively high under normal engine speed.

GI MA EM LC

Possible Cause 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC0966

Cooling fan (crankshaft driven) Thermostat Improper ignition timing Engine coolant temperature sensor Blocked radiator Blocked front end (Improper fitting of nose mask) Crushed vehicle frontal area (Vehicle frontal is collided but not repaired) 쐌 Blocked air passage by improper installation of front fog lamp or fog lamps. 쐌 Improper mixture ratio of coolant 쐌 Damaged bumper For more information, refer to “MAIN 12 CAUSES OF OVERHEATING”, EC-881.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-875

IDX

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33E

Overall Function Check

Overall Function Check

=NGEC0704

Use this procedure to check the overall function of the engine coolant over temperature enrichment protection 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.

WITH CONSULT-II 1.

쐌 쐌 SEF621W

a)

b)

2.

3.

4.

5.

6.

NGEC0704S01

Check the coolant level and mixture ratio (Using coolant tester) in the reservoir tank and radiator. Allow engine to cool before checking coolant level and mixture ratio. If the coolant level in the reservoir and/or the radiator is below the proper range, skip following steps and go to “Diagnostic Procedure”, EC-878. If the coolant mixture ratio is out of range between 45 to 55%, replace the coolant. Refer to “Changing Engine Coolant”, MA-28. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pouring coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to “Anti-freeze Coolant Mixture Ratio”, MA-15. After refilling coolant, run engine to ensure that no water-flow noise is emitted. After checking or replacing coolant, go to step 3) below. Confirm whether customer filled the engine coolant or not. If customer filled the engine coolant, skip following steps and go to “Diagnostic Procedure”, EC-878. Start engine and make sure that cooling fan (crankshaft driven) operates. If NG, go to “Diagnostic Procedure”, EC-878. After repair, go to next step. Check for blocked coolant passage. Warm up engine to normal operating temperature, then grasp upper and lower radiator hoses and make sure that coolant flows. If NG, go to step 4 of “Diagnostic Procedure”, EC-878. After repair, go to next step. Be extremely careful not to touch any moving or adjacent parts. Check radiator for blocked air passage Check for blocked condenser or radiator (condenser or radiator fins damaged, condenser or radiator clogged), after market fog lamps ...etc. Check for condenser or radiator fin damage, shroud damage, vehicle front end for clogging of debris or insects ...etc. Check for improper fitting of front end cover, damaged radiator grille or bumper, vehicle frontal area damaged by collision but not repaired. If NG, take appropriate action and then go to next step. Check ECT sensor for proper operation. Refer to step 5 of “Diagnostic Procedure”, EC-878. If NG, replace ECT sensor and go to next step.

EC-876

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33E

Overall Function Check (Cont’d)

7.

Check ignition timing. Refer to “Basic Inspection”, EC-701. Make sure that ignition timing is 10° ± 2° at 700 ± 50 rpm. If NG, adjust ignition timing and then recheck.

GI MA EM LC

SEF927Z

WITHOUT CONSULT-II 1.

쐌 쐌 SEF621W

a)

b)

2.

3.

4.

5.

6.

NGEC0704S02

Check the coolant level and mixture ratio (Using coolant tester) in the reservoir tank and radiator. Allow engine to cool before checking coolant level and mixture ratio. If the coolant level in the reservoir and/or radiator is below the proper range, skip the following steps and go to “Diagnostic Procedure”, EC-878. If the coolant mixture ratio is out of range between 45 to 55%, replace the coolant. Refer to “Changing Engine Coolant”, MA-28. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pouring coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to “Anti-freeze Coolant Mixture Ratio”, MA-13. After refilling coolant, run engine to ensure that no water-flow noise is emitted. After checking or replacing coolant, go to step 3) below. Confirm whether customer filled the engine coolant or not. If customer filled engine coolant, skip following steps and go to “Diagnostic Procedure”, EC-878. Start engine and make sure that cooling fan (crankshaft driven) operates. Be careful not to overheat engine. If NG, go to step 1 of “Diagnostic Procedure”, EC-878. After repair, go to next step. Check for blocked coolant passage. Warm up engine to normal operating temperature, then grasp upper and lower radiator hoses and make sure that coolant flows. If NG, go to step 4 of “Diagnostic Procedure”, EC-878. After repair, go to next step. Be extremely careful not to touch any moving or adjacent parts. Check radiator for blocked air passage Check for blocked condenser or radiator (condenser or radiator fins damaged, condenser or radiator clogged), after market fog lamps,...etc. Check for condenser or radiator fin damage, shroud damage, vehicle front end for clogging of debris or insects ...etc. Check for improper fitting of front end cover, damaged radiator grille or bumper, vehicle frontal area damaged by collision but not repaired. If NG, take appropriate action and then go to next step. Check ECT sensor for proper operation. Refer to step 5 of “Diagnostic Procedure”, EC-878. If NG, replace ECT sensor and go to next step.

EC-877

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33E

Overall Function Check (Cont’d)

7.

Check ignition timing. Refer to “Basic Inspection”, EC-701. Make sure that ignition timing is 10° ± 2° at 700 ± 50 rpm. If NG, adjust ignition timing and then recheck.

SEF927Z

Diagnostic Procedure 1

NGEC0706

CHECK COOLING FAN (CRANKSHAFT DRIVEN) OPERATION

Start engine and make sure that cooling fan (crankshaft driven) operates. OK or NG OK

䊳

GO TO 2.

NG

䊳

Check cooling fan (crankshaft driven). Refer to LC-34, “Cooling Fan”.

2

CHECK COOLING SYSTEM FOR LEAK

Apply pressure to the cooling system with a tester, and check if the pressure drops. CAUTION: Higher than the specified pressure may cause radiator damage. Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi)

SLC754A

Pressure should not drop. OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following for leak: 쐌 Hose 쐌 Radiator 쐌 Water pump Refer to “Water Pump”, LC-29.

EC-878

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK RADIATOR CAP

Apply pressure to cap with a tester and check radiator cap relief pressure.

GI MA EM LC SLC755A

Radiator cap relief pressure: 59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi)

FE

OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace radiator cap.

4

CL MT

CHECK THERMOSTAT

1. Check valve seating condition at normal room temperatures. It should seat tightly. 2. Check valve opening temperature and valve lift.

AT TF PD AX

SLC343

Valve opening temperature: 82°C (180°F) [standard] Valve lift: More than 10 mm/95°C (0.31 in/203°F) 3. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to “Thermostat”, LC-31.

SU BR ST

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace thermostat.

RS BT HA SC EL

EC-879

IDX

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33E

Diagnostic Procedure (Cont’d)

5

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

SEF152P



MTBL0229

SEF012P

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace engine coolant temperature sensor.

6

CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-881. 䊳

INSPECTION END

EC-880

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33E

Main 12 Causes of Overheating

Main 12 Causes of Overheating Engine

Step

OFF

1

Inspection item 쐌 쐌 쐌 쐌

Blocked Blocked Blocked Blocked

radiator condenser radiator grille bumper

Equipment 쐌 Visual

Standard No blocking

NGEC0707

Reference page —

MA

2

쐌 Coolant mixture

쐌 Coolant tester

50 - 50% coolant mixture See “RECOMMENDED FLUIDS AND LUBRICANTS” in MA-13.

3

쐌 Coolant level

쐌 Visual

Coolant up to MAX level in reservoir tank and radiator filler neck

See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA-28.

4

쐌 Radiator cap

쐌 Pressure tester

59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi) (Limit)

See “System Check”, “ENGINE COOLING SYSTEM” in LC-28.

FE CL

ON*1

5

쐌 Coolant leaks

쐌 Visual

No leaks

See “System Check”, “ENGINE COOLING SYSTEM” in LC-29.

ON*1

6

쐌 Thermostat

쐌 Touch the upper and lower radiator hoses

Both hoses should be hot

See “Thermostat” and “Radiator”, “ENGINE COOLING SYSTEM” in LC-31, LC-32.

ON*1

7

쐌 Cooling fan (Crankshaft driven)

쐌 Visual

Operating

See LC-34, “Cooling Fan”.

OFF

8

쐌 Combustion gas leak

쐌 Color checker chemical tester 4 Gas analyzer

Negative

—

ON*2

9

쐌 Coolant temperature gauge

쐌 Visual

Gauge less than 3/4 when driving

—

쐌 Coolant overflow to reservoir tank

쐌 Visual

No overflow during driving and idling

OFF*3

OFF

GI

See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA-28.

Should be initial level in reservoir tank

See “ENGINE MAINTENANCE” in MA-26.

11

쐌 Cylinder head

0.1 mm (0.004 in) Maximum distortion (warping)

See “Inspection”, “CYLINDER HEAD” in EM-96.

12

쐌 Cylinder block and pis- 쐌 Visual tons

No scuffing on cylinder walls or piston

See “Inspection”, “CYLINDER BLOCK” in EM-117.

쐌 Straight gauge feeler gauge

*1: Engine running at 3,000 rpm for 10 minutes. *2: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *3: After 60 minutes of cool down time. For more information, refer to “OVERHEATING CAUSE ANALYSIS”, LC-35.

LC

MT AT TF PD

쐌 Coolant return from 쐌 Visual reservoir tank to radiator

10

EM

AX SU BR ST RS BT HA SC EL

EC-881

IDX

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33E On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0708

When a misfire occurs, engine speed will fluctuate. If the engine speed fluctuates enough to cause the CKP sensor signal to vary, ECM can determine that a misfire is occurring. Sensor Crankshaft position sensor (OBD)

Input Signal to ECM Engine speed

ECM function On board diagnosis of misfire

The misfire detection logic consists of the following two conditions. 1. One Trip Detection Logic (Three Way Catalyst Damage) On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to overheating, the MIL 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 MIL will turn off. If another misfire condition occurs that can damage the TWC on a second trip, the MIL will blink. When the misfire condition decreases to a level that will not damage the TWC, the MIL will remain on. If another misfire condition occurs that can damage the TWC, the MIL will begin to blink again. 2. Two Trip Detection Logic (Exhaust quality deterioration) For misfire conditions that will not damage the TWC (but will affect vehicle emissions), the MIL 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. Malfunction is detected when multiple cylinders misfire, No. 1 cylinder misfires, No. 2 cylinder misfires, No. 3 cylinder misfires, No. 4 cylinder misfires, No. 5 cylinder misfires and No. 6 cylinder misfires.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

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 Drive plate or flywheel Heated oxygen sensor 1 Incorrect distributor rotor

EC-882

NGEC0708S01

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33E DTC Confirmation Procedure

DTC Confirmation Procedure

SEF213Y

Diagnostic Procedure 1

=NGEC0709

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 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 warm it up to normal operating temperature. 3) Turn ignition switch OFF and wait at least 5 seconds. 4) Start engine again and drive at 1,500 to 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-883. With GST Follow the procedure “With CONSULT-II”.

CHECK FOR INTAKE AIR LEAK

1. Start engine and run it at idle speed. 2. Listen for the sound of the intake air leak.

NGEC0710

GI MA EM LC

FE CL MT AT TF

OK or NG

PD

OK

䊳

GO TO 2.

NG

䊳

Discover air leak location and repair.

AX 2

CHECK FOR EXHAUST SYSTEM CLOGGING

Stop engine and visually check exhaust tube, three way catalyst and muffler for dents.

SU

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace it.

BR ST RS BT HA SC EL

EC-883

IDX

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33E Diagnostic Procedure (Cont’d)

3

PERFORM POWER BALANCE TEST

With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode.

SEF981Z

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?

AEC646A

Yes or No Yes

䊳

GO TO 4.

No

䊳

GO TO 7.

4

CHECK INJECTOR

Does each injector make an operating sound at idle?

MEC703B

Yes or No Yes

䊳

GO TO 5.

No

䊳

Check injector(s) and circuit(s). Refer to EC-1145.

EC-884

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33E Diagnostic Procedure (Cont’d)

5 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.

GI MA EM LC

SEF282G

FE

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

CL MT

6

CHECK IGNITION WIRES

1. Inspect wires for cracks, damage, burned terminals and for improper fit. 2. Measure the resistance of wires to their distributor cap terminal. Move each wire while testing to check for intermittent breaks.

AT TF PD AX SU

SEF174P

Resistance:

BR ST RS

MTBL0235

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.

BT HA

OK or NG OK

䊳

Check the following: 쐌 Distributor rotor head for incorrect parts 쐌 Ignition coil, power transistor and their circuits Refer to EC-1138.

NG

䊳

Replace.

EC-885

SC EL IDX

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33E Diagnostic Procedure (Cont’d)

7

CHECK SPARK PLUGS

Remove the spark plugs and check for fouling, etc.

SEF156I

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to “ENGINE MAINTENANCE”, MA-34.

8

CHECK COMPRESSION PRESSURE

Refer to EM-77. 쐌 Check compression pressure. Standard: 1,196 kPa (12.2 kg/cm2, 173 psi)/300 rpm Minimum: 883 kPa (9.0 kg/cm2, 128 psi)/300 rpm Difference between each cylinder: 98 kPa (1.0 kg/cm2, 14 psi)/300 rpm OK or NG OK

䊳

GO TO 9.

NG

䊳

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-644. 3. Install fuel pressure gauge and check fuel pressure.

AEC064B

At idle: Approx. 235 kPa (2.4 kg/cm2, 34 psi) OK or NG OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

EC-886

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33E Diagnostic Procedure (Cont’d)

10

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuel pump and circuit (Refer to EC-1153.) 쐌 Fuel pressure regulator (Refer to EC-645.) 쐌 Fuel lines (Refer to “ENGINE MAINTENANCE”, MA-31.) 쐌 Fuel filter for clogging 䊳

11

GI MA

Repair or replace.

EM

CHECK IGNITION TIMING

LC

Check the following items. Refer to “Basic Inspection”, EC-701.

FE CL MTBL0576

OK or NG OK (With CONSULT-II)

䊳

GO TO 12.

OK (Without CONSULTII)

䊳

GO TO 13.

NG

䊳

Adjust ignition timing.

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-887

IDX

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33E Diagnostic Procedure (Cont’d)

12

CHECK HEATED OXYGEN SENSOR 1

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 with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown left:

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace heated oxygen sensor 1.

EC-888

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33E Diagnostic Procedure (Cont’d)

13

CHECK FRONT HEATED OXYGEN SENSOR LH/RH

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (right bank sensor signal) or 51 (left bank sensor signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

GI MA EM LC

SEF796Z

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.

FE CL

OK or NG OK

䊳

GO TO 15.

NG

䊳

GO TO 14.

MT AT

14

REPLACE HEATED OXYGEN SENSOR 2

TF

1. Stop vehicle and turn ignitioin switch OFF. 2. Check heated oxygen sensor 2 harness protector color.

PD AX SU

SEF372ZA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 2.

BR ST RS BT HA SC EL

EC-889

IDX

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33E Diagnostic Procedure (Cont’d)

15

CHECK MASS AIR FLOW SENSOR

With CONSULT-II Check mass air flow sensor signal in “DATA MONITOR” mode with CONSULT-II. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm With GST Check mass air flow sensor signal in MODE 1 with GST. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm OK or NG OK

䊳

GO TO 16.

NG

䊳

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-761.

16

CHECK SYMPTOM MATRIX CHART

Check items on the rough idle symptom in “Symptom Matrix Chart”, EC-717. OK or NG OK

䊳

GO TO 17.

NG

䊳

Repair or replace.

17

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-673. 䊳

18

GO TO 18.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-890

DTC P0327, P0328 KS

VG33E Component Description

Component Description

NGEC0711

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 MIL will not light for knock sensor malfunction. The knock sensor has one trip detection logic.

ECM Terminals and Reference Value

W

ITEM

Knock sensor

EM

NGEC0712

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 the ECM terminals, such as the ground.

64

MA

LC

SEF332I

TERMIWIRE NAL COLOR NO.

GI

CONDITION [Engine is running] 쐌 Idle speed

DATA (DC Voltage)

CL

Approximately 2.5V

On Board Diagnosis Logic

FE

MT NGEC0713

Malfunction is detected when an excessively low or high voltage from the knock sensor is sent to ECM.

AT

POSSIBLE CAUSE

TF

쐌 쐌

NGEC0713S01

Harness or connectors (The knock sensor circuit is open or shorted.) Knock sensor

PD AX

DTC Confirmation Procedure

SEF059Y

NGEC0714

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. 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-893. With GST Follow the procedure “With CONSULT-II”.

SU BR ST RS BT HA SC EL

EC-891

IDX

DTC P0327, P0328 KS

VG33E

Wiring Diagram

Wiring Diagram

NGEC0715

WEC178A

EC-892

DTC P0327, P0328 KS

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0716

CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT-I

GI

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check resistance between ECM terminal 64 and engine ground. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. Resistance: Approximately 500 - 620 kΩ [at 25°C (77°F)] 4. Also check harness for short to ground and short to power.

MA EM LC

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 2.

2

FE

CHECK INPUT SIGNAL CIRCUIT-II

1. Disconnect knock sensor harness connector. 2. Check harness continuity between ECM terminal 64 and knock sensor terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

CL MT

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

AT

DETECT MALFUNCTIONING PART

TF

Check the following. 쐌 Harness connector F37, F101 쐌 Harness for open or short between ECM and knock sensor 䊳

PD

Repair open circuit or short to ground or short to power in harness or connectors.

AX 4

CHECK KNOCK SENSOR

쐌 Use an ohmmeter which can measure more than 10 MΩ. 1. Disconnect knock sensor harness connector. 2. Check resistance between terminal 1 and ground.

SU BR ST RS BT SEF799Z

CAUTION: Do not use any knock sensors that have been dropped or physically damaged. Use only new ones.

HA

OK or NG

SC

OK

䊳

GO TO 8.

NG

䊳

Replace knock sensor.

EL

EC-893

IDX

DTC P0327, P0328 KS

VG33E

Diagnostic Procedure (Cont’d)

5

RETIGHTEN GROUND SCREWS

Loose and retighten engine ground screws.

LEC518

䊳

6

GO TO 6.

CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT

1. Disconnect harness connectors F37, F101. 2. Check harness continuity between harness connector F37 terminal 6 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F37, F101 쐌 Joint connector 1 (if equipped) 쐌 Harness for open between harness connector F37 and engine ground 䊳

8

Repair open circuit or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-894

DTC P0335 CKP SENSOR (OBD)

VG33E Component Description

Component Description

SEF804Z

NGEC0717

The crankshaft position sensor (OBD) is located on the transaxle 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.

GI MA EM LC

FE CL MT

WEC549

ECM Terminals and Reference Value

NGEC0718

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (AC Voltage) 1 - 2V (AC range)

AT TF PD AX SU

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

BR SEF690W

47

L

Crankshaft position sensor (OBD)

ST

3 - 4V (AC range)

RS [Engine is running] 쐌 Engine speed is 2,000 rpm

BT SEF691W

HA SC EL

EC-895

IDX

DTC P0335 CKP SENSOR (OBD)

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0719

Malfunction is detected when the proper pulse signal from the crankshaft position sensor (OBD) is not sent to ECM while the engine is running at the specified engine speed.

POSSIBLE CAUSE 쐌 쐌

DTC Confirmation Procedure

SEF058Y

NGEC0719S01

Harness or connectors [The crankshaft position sensor (OBD) circuit is open.] Crankshaft position sensor (OBD)

NGEC0720

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 15 seconds at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-898. With GST Follow the procedure “With CONSULT-II”.

EC-896

DTC P0335 CKP SENSOR (OBD)

VG33E Wiring Diagram

Wiring Diagram

NGEC0721

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC179A

EC-897

EL IDX

DTC P0335 CKP SENSOR (OBD)

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0722

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC518

䊳

2

GO TO 2.

CHECK CKPS (OBD) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.

WEC549

2. Check continuity between ECM terminal 47 and 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

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Harness for open or short between ECM and crankshaft position sensor (OBD) 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-898

DTC P0335 CKP SENSOR (OBD)

VG33E Diagnostic Procedure (Cont’d)

4

CHECK CKPS (OBD) GROUND CIRCUIT FOR OPEN AND SHORT

1. Reconnect ECM harness connector. 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.

GI MA

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

EM LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Joint connector-4 (if equipped) 쐌 Harness for open or short between crankshaft position sensor (OBD) and ECM 䊳

FE

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK CRANKSHAFT POSITION SENSOR (OBD)

CL

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.

MT AT TF PD AX SEF960N

SU

5. Check resistance as shown in the figure.

BR ST RS SEF504V

Resistance: Approximately 512 - 632Ω [at 20°C (68°F)] OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace crankshaft position sensor (OBD).

BT HA SC EL

EC-899

IDX

DTC P0335 CKP SENSOR (OBD)

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK CKPS (OBD) SHIELD CIRCUIT FOR OPEN AND SHORT

1. Disconnect harness connectors F38, F102. 2. Check harness continuity between harness connector F38 terminal 6 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Joint connector-1 (if equipped) 쐌 Harness for open between harness connector F38 and engine ground 䊳

9

Repair open circuit or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-900

DTC P0340 CMP SENSOR

VG33E Component Description

Component Description

SEF928V

NGEC0723

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 ECM 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 6 slits for a 120° (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. NOTE: The rotor screw which secures the distributor rotor head to the distributor shaft must be torqued properly. : 3.6±0.3 N·m (37±3 kg-cm, 32±3 in-lb)

ECM Terminals and Reference Value

NGEC0724

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 the ECM terminals, such as the ground.

4

WIRE COLOR

OR/B

ITEM

ECM relay (Self shutoff)

MA EM LC

FE CL MT

SEF614B

TERMINAL NO.

GI

CONDITION

DATA (DC Voltage)

[Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

0 - 1.5V

[Ignition switch OFF] 쐌 A few seconds passed after turning ignition switch OFF

BATTERY VOLTAGE (11 - 14V)

AT TF PD AX SU BR

0.3 - 0.5V

ST 44

[Engine is running] 쐌 Idle speed

PU

RS SEF997U

Camshaft position sensor (Reference signal)

BT

0.3 - 0.5V

HA 48

PU

[Engine is running] 쐌 Engine speed is 2,000 rpm

SC SEF998U

EC-901

EL IDX

DTC P0340 CMP SENSOR

VG33E

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) Approximately 2.5V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

49

LG

SEF999U

Camshaft position sensor (Position signal)

Approximately 2.5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

SEF001V

67

B/P

72

B/P

117

B/P

Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

On Board Diagnosis Logic

NGEC0725

Malfunction is detected when (Malfunction A) either 1° or 120° signal is not sent to ECM for the first few seconds during engine cranking, (Malfunction B) either 1° or 120° signal is not sent to ECM often enough while the engine speed is higher than the specified engine speed, (Malfunction C) the relation between 1° and 120° signal is not in the normal range during the specified engine speed.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌

NGEC0725S01

Harness or connectors (The camshaft position sensor circuit is open or shorted.) Camshaft position sensor Starter motor (Refer to SC-11.) Starting system circuit (Refer to SC-14.) Dead (Weak) battery

EC-902

DTC P0340 CMP SENSOR

VG33E DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC0726

NOTE: 쐌 Perform “PROCEDURE FOR MALFUNCTION A” first. If DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B AND C”. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle.

PROCEDURE FOR MALFUNCTION A

GI MA EM LC

NGEC0726S01

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”, EC-905. With GST Follow the procedure “With CONSULT-II”.

FE CL MT

SEF013Y

PROCEDURE FOR MALFUNCTION B AND C

NGEC0726S02

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”, EC-905. With GST Follow the procedure “With CONSULT-II”.

AT TF PD AX

SEF058Y

SU BR ST RS BT HA SC EL

EC-903

IDX

DTC P0340 CMP SENSOR

VG33E

Wiring Diagram

Wiring Diagram

NGEC0727

WEC180A

EC-904

DTC P0340 CMP SENSOR

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0728

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

LEC518

䊳

FE

GO TO 2.

CL 2

CHECK CMPS POWER SUPPLY CIRCUIT

MT

1. Disconnect camshaft position sensor harness connector.

AT TF PD AEC647A

AX

2. Turn ignition switch ON. 3. Check voltage between terminal 5 and ground with CONSULT-II or tester.

SU BR ST SEF708U

RS

Voltage: Battery voltage OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

HA

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between camshaft position sensor and ECM relay 쐌 Harness for open or short between camshaft position sensor and ECM 䊳

BT

SC EL

Repair harness or connectors.

EC-905

IDX

DTC P0340 CMP SENSOR

VG33E

Diagnostic Procedure (Cont’d)

4

CHECK CMPS INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between sensor terminal 4 and ECM terminal 49, sensor terminal 3 and ECM terminals 44, 48. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

5

CHECK CMPS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between sensor terminal 6 and engine ground. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-2 (if equipped) 쐌 Harness for open between camshaft position sensor and engine ground 䊳

Repair open circuit or short to power in harness or connector.

EC-906

DTC P0340 CMP SENSOR

VG33E Diagnostic Procedure (Cont’d)

7

CHECK CAMSHAFT POSITION SENSOR

1. Install any parts removed. 2. Start engine. 3. Check voltage between ECM terminals 44, 48 and ground, ECM terminal 49 and ground with DC range.

GI MA EM LC

FE CL MT AT TF PD AEC072B

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace distributor assembly with camshaft position sensor.

8

CHECK CMPS SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector-1. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-1.

AX SU BR ST RS BT

OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair open circuit or short to power in harness or connectors.

9

HA SC

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-907

EL IDX

DTC P0420, P0430 THREE WAY CATALYST FUNCTION

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

SEF484YC

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌

SEF345Z

NGEC0740S01

Warm-up three way catalyst Exhaust tube Intake air leaks Injectors Injector leaks Spark plug Improper ignition timing

DTC Confirmation Procedure

SEF344Z

NGEC0740

The ECM monitors the switching frequency ratio of heated oxygen sensors 1 and 2. A warm-up three way catalyst with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2. As oxygen storage capacity decreases, the heated oxygen sensor 2 switching frequency will increase. When the frequency ratio of heated oxygen sensors 1 and 2 approaches a specified limit value, the warm-up three way catalyst malfunction is diagnosed. Malfunction is detected when warm-up three way catalyst does not operate properly, warm-up three way catalyst does not have enough oxygen storage capacity.

NGEC0741

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 TESTING CONDITION 쐌 Open engine hood before conducting the following procedure. 쐌 Do not hold engine speed for more than the specified minutes below. 1) Turn ignition switch ON. 2) Select “DTC & SRT CONFIRMATION” the SRT WORK SUPPORT” mode with CONSULT-II. 3) Start engine. 4) Rev engine up to 2,500 to 3,500 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 2,000 to 3,000 rpm and maintain it until “INCMP” of “CATALYST” changes to “CMPLT” (It will take maximum of approximately 5 minute.). 7) Select “SELF-DIAG RESULTS” mode with CONSULT-II. If the 1st trip DTC is detected, go to “DIAGNOSTIC PROCEDURE”, EC-910. If not “CMPLT”, stop engine and cool down “COOLANT TEMP/SE” to less than 70°C (158°F) and retest from step 1).

SEF560X

EC-908

DTC P0420, P0430 THREE WAY CATALYST FUNCTION

VG33E

Overall Function Check

Overall Function Check

SEF441V

SEF442V

NGEC0742

Use this procedure to check the overall function of the warm-up three way catalyst. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 50 [heated oxygen sensor 1 (bank 1) signal], 51 [heated oxygen sensor 1 (bank 2) signal] and engine ground, and ECM terminals 56 [heated oxygen sensor 2 (bank 1) signal], 57 [heated oxygen sensor 2 (bank 2) 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 terminals 56 and engine ground, or 57 and engine ground is very less than that of ECM terminals 50 and engine ground, or 51 and engine ground. Switching frequency ratio = A/B A: Heated oxygen sensor 2 voltage switching frequency B: Heated oxygen sensor 1 voltage switching frequency This ratio should be less than 0.75. If the ratio is greater than above, it means warm-up three way catalyst does not operate properly. Go to “Diagnostic Procedure”, EC-910. NOTE: If the voltage at terminal 50 or 51 does not switch periodically more than 5 times within 10 seconds at step 5, perform trouble diagnosis for “DTC P0133, P0153” first. (See EC-808.)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-909

IDX

DTC P0420, P0430 THREE WAY CATALYST FUNCTION

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

=NGEC0743

CHECK EXHAUST SYSTEM

Visually check exhaust tubes and muffler for dent. OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair or replace it.

2

CHECK EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before the warm-up three way catalyst.

SEF099P

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace.

3

CHECK INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace.

4

CHECK IGNITION TIMING

Check the following items. Refer to “Basic Inspection”, EC-701.

MTBL0576

OK or NG OK

䊳

GO TO 5.

NG

䊳

Adjust ignition timing.

EC-910

DTC P0420, P0430 THREE WAY CATALYST FUNCTION

VG33E

Diagnostic Procedure (Cont’d)

5

CHECK INJECTORS

1. Refer to WIRING DIAGRAM for Injectors, EC-1145. 2. Stop engine and then turn ignition switch ON. 3. Check voltage between ECM terminals 102, 104, 106, 109, 111 and 113 and ground with CONSULT-II or tester.

GI MA EM LC SEF711U

Battery voltage should exist. OK or NG OK

䊳

GO TO 6.

NG

䊳

Perform “Diagnostic Procedure”, “INJECTOR”, EC-1146.

6 1. 2. 3. 4. 5.

FE CL

CHECK IGNITION SPARK

MT

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.

AT TF PD AX SU SEF282G

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

BR ST RS BT HA SC EL

EC-911

IDX

DTC P0420, P0430 THREE WAY CATALYST FUNCTION

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK IGNITION WIRES

1. Inspect wires for cracks, damage, burned terminals and for improper fit. 2. Measure the resistance of wires to their distributor cap terminal. Move each wire while testing to check for intermittent breaks.

SEF174P

Resistance:

MTBL0235

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. OK or NG OK

䊳

Check ignition coil, power transistor and their circuits. Refer to EC-1138.

NG

䊳

Replace.

8

CHECK INJECTOR

1. Turn ignition switch OFF. 2. Remove injector assembly. Refer to EC-645. Keep fuel hose and all injectors connected to injector gallery. 3. Disconnect all ignition coil harness connectors. 4. Turn ignition switch ON. Make sure fuel does not drip from injector. OK or NG OK (Does not drip)

䊳

GO TO 9.

NG (Drips)

䊳

Replace the injector(s) from which fuel is dripping.

9

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. Trouble is fixed

䊳

INSPECTION END

Trouble is not fixed

䊳

Replace warm-up three way catalyst.

EC-912

DTC P0441 EVAP CONTROL SYSTEM

VG33E System Description

System Description

NGEC0859

NOTE: If DTC P0441 is displayed with P0510, perform trouble diagnosis for DTC P0510 first. (See EC-1012.)

GI MA EM LC

FE CL SEC666C

In this evaporative emission (EVAP) control system, purge flow occurs during non-closed throttle conditions. Purge volume is related to air intake volume. Under normal purge conditions (non-closed throttle), the EVAP canister purge volume control solenoid valve is open. Purge flow exposes the EVAP control system pressure sensor to intake manifold vacuum.

MT AT TF PD AX

On Board Diagnosis Logic

NGEC0860

Under normal conditions (non-closed throttle), sensor output voltage indicates if pressure drop and purge flow are adequate. If not, a fault is determined. Malfunction is detected when EVAP control system does not operate properly, EVAP control system has a leak between intake manifold and EVAP control system pressure sensor.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

BR ST

NGEC0860S01

EVAP canister purge volume control solenoid valve stuck closed EVAP control system pressure sensor and the circuit Loose, disconnected or improper connection of rubber tube Blocked rubber tube Blocked or bent rubber tube to MAP/BARO switch solenoid valve Cracked EVAP canister EVAP canister purge volume control solenoid valve circuit Closed throttle position switch Blocked purge port EVAP canister vent control valve

EC-913

SU

RS BT HA SC EL IDX

DTC P0441 EVAP CONTROL SYSTEM

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

SEC723C

SEC724C

Selector lever

Suitable position

Vehicle speed

32 - 120 km/h (20 - 75 MPH)

ENG SPEED

500 - 3,400 rpm

B/FUEL SCHDL

1.0 - 10.0 msec

Engine coolant temperature

70 - 100°C (158 - 212°F)

7) SEC725C

NGEC0861

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 5 seconds before conducting the next test. TESTING CONDITION: Always perform test at a temperature of 5°C (41°F) or more. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Start engine and let it idle for at least 70 seconds. 4) Select “PURG FLOW P0441” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. 5) Touch “START”. If “COMPLETED” is displayed, go to step 7. 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 at least 35 seconds.)

If “TESTING” is not changed for a long time, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-916.

EC-914

DTC P0441 EVAP CONTROL SYSTEM

VG33E Overall Function Check

Overall Function Check

SEF906U

=NGEC0862

Use this procedure to check the overall monitoring function of the EVAP control system purge flow monitoring. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Lift up drive wheels. 2) Start engine and warm it up to normal operating temperature. 3) Turn ignition switch OFF, wait at least 5 seconds. 4) Start engine and wait at least 70 seconds. 5) Set voltmeter probes to ECM terminals 62 (EVAP control system pressure sensor signal) and ground. 6) Check EVAP control system pressure sensor value at idle speed and note it. 7) Establish and maintain the following conditions for at least 1 minute. Air conditioner switch

ON

Steering wheel

Fully turned

Headlamp switch

ON

Rear window defogger switch

ON

Engine speed

Approx. 3,000 rpm

Gear position

Any position other than “P”, “N” or “R”

8)

9)

Verify that EVAP control system pressure sensor value stays 0.1V less than the value at idle speed (measured at step 6) for at least 1 second. If NG, go to “Diagnostic Procedure”, EC-916.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-915

IDX

DTC P0441 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

=NGEC0863

CHECK EVAP CANISTER

1. Turn ignition switch OFF. 2. Check EVAP canister for cracks. OK or NG OK (With CONSULT-II)

䊳

GO TO 2.

OK (Without CONSULTII)

䊳

GO TO 3.

NG

䊳

Replace EVAP canister.

2

CHECK PURGE FLOW

With CONSULT-II 1. Disconnect vacuum hose connected to EVAP canister purge volume control solenoid valve at EVAP service port and install vacuum gauge.

AEC649A

2. 3. 4. 5.

Start engine and let it idle. Select “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Rev engine up to 2,000 rpm. Touch “Qd” and “Qu” on CONSULT-II screen to adjust “PURG VOL CONT/V” opening.

SEF012Z

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 4.

EC-916

DTC P0441 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

3

CHECK PURGE FLOW

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Stop engine. 3. Disconnect vacuum hose connected to EVAP canister purge volume control solenoid valve at EVAP service port and install vacuum gauge.

GI MA EM LC

AEC649A

4. Start engine and let it idle for at least 80 seconds. 5. Check vacuum gauge indication when revving engine up to 2,000 rpm. Vacuum should exist. 6. Release the accelerator pedal fully and let idle. Vacuum should not exist.

FE CL MT

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 4.

4

AT TF

CHECK EVAP PURGE LINE

1. Turn ignition switch OFF. 2. Check EVAP purge line for improper connection or disconnection. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-630. OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair it.

PD AX SU BR ST RS BT HA SC EL

EC-917

IDX

DTC P0441 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

5

CHECK EVAP PURGE HOSE AND PURGE PORT

1. Disconnect purge hoses connected to EVAP service port A and EVAP canister purge volume control solenoid valve B.

SEF367U

2. Blow air into each hose and EVAP purge port C. 3. Check that air flows freely.

SEF368U

OK or NG OK (with CONSULT-II)

䊳

GO TO 6.

OK (without CONSULTII)

䊳

GO TO 7.

NG

䊳

Repair or clean hoses and/or purge port.

EC-918

DTC P0441 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

6

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

GI MA EM LC

SEF985Y

If OK, inspection end. If NG, go to following step. 3. Check air passage continuity.

FE CL MT AT TF

SEF660U

PD AX MTBL0241

If NG, replace the EVAP canister purge volume control solenoid valve.

SU

OK or NG

BR

OK

䊳

GO TO 8.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

ST RS BT HA SC EL

EC-919

IDX

DTC P0441 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

Without CONSULT-II Check air passage continuity.

SEF661U

MTBL0242

If NG, replace the EVAP canister purge volume control solenoid valve. OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

8

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

1. Turn ignition switch OFF. 2. Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair it.

9

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

AEC651A

2. Check connectors for water. Water should not exist. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

EC-920

DTC P0441 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

10

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR FUNCTION

Refer to “DTC Confirmation Procedure” for DTC P0452, P0453, EC-953.

GI

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP control system pressure sensor.

11

MA EM

CHECK EVAP CANISTER VENT CONTROL VALVE

Check air passage continuity. With CONSULT-II Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

LC

FE CL MT SEF991Y

Without CONSULT-II

AT TF MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

PD AX SU BR ST

AEC783A

Make sure new O-ring is installed properly.

RS

OK or NG

BT

OK

䊳

GO TO 12.

NG

䊳

Replace EVAP canister vent control valve.

HA SC EL

EC-921

IDX

DTC P0441 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

12 1. 2. 3. 4. 5.

CHECK CLOSED THROTTLE POSITION SWITCH With CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check indication of “CLSD THL/P SW”. Measurement must be made with closed throttle position switch installed in vehicle.

MTBL0355

If NG, adjust closed throttle position switch. Check the following items. Refer to “Basic Inspection”, EC-701.

MTBL0576

6. If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch. OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace throttle position switch with throttle position sensor.

EC-922

DTC P0441 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

13 1. 2. 3. 4.

CHECK CLOSED THROTTLE POSITION SWITCH Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect closed throttle position switch harness connector. Check continuity between closed throttle position switch terminals 4 and 5. Resistance measurement must be made with closed throttle position switch installed in vehicle.

GI MA EM LC

FE AEC654A

CL MT MTBL0247

If NG, adjust closed throttle position switch. Check the following items. Refer to “Basic Inspection”, EC-701.

AT TF PD AX MTBL0576

5. If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch. OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace throttle position switch with throttle position sensor.

14

SU BR ST

CHECK EVAP PURGE LINE

Inspect EVAP purge line (pipe and rubber tube). Check for evidence of leaks. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-630.

RS

OK or NG OK

䊳

GO TO 15.

NG

䊳

Replace it.

15

BT HA

CLEAN EVAP PURGE LINE

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

SC

GO TO 16.

EL

EC-923

IDX

DTC P0441 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d)

16

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-924

VG33E

DTC P0442 EVAP CONTROL SYSTEM

VG33E On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0744

NOTE: If DTC P0442 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-1099.) This diagnosis detects leaks in the EVAP purge line using engine intake manifold vacuum. If pressure does not increase, the ECM will check for leaks in the line between the fuel tank and EVAP canister purge volume control solenoid valve, under the following “Vacuum test” conditions. The vacuum cut valve bypass valve is opened to clear the line between the fuel tank and the EVAP canister purge volume control solenoid valve. The EVAP canister vent control valve will then be closed to shut the EVAP purge line off. The EVAP canister purge volume control solenoid valve is opened to depressurize the EVAP purge line using intake manifold vacuum. After this occurs, the EVAP canister purge volume control solenoid valve will be closed.

GI MA EM LC

FE CL MT AT TF PD AX SEC666C

SU Malfunction is detected when EVAP control system has a leak, EVAP control system does not operate properly. CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC0744S01

Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Fuel filler cap remains open or fails to close. Foreign matter caught in fuel filler cap. Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. Foreign matter caught in EVAP canister vent control valve. EVAP canister or fuel tank leaks EVAP purge line (pipe and rubber tube) leaks EVAP purge line rubber tube bent.

EC-925

BR ST RS BT HA SC EL IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33E

On Board Diagnosis Logic (Cont’d)

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit EVAP canister purge volume control solenoid valve and the circuit Fuel tank temperature sensor O-ring of EVAP canister vent control valve is missing or damaged. Water separator EVAP canister is saturated with water. EVAP control system pressure sensor Fuel level sensor and the circuit. Refueling EVAP vapor cut ORVR system leaks

EC-926

DTC P0442 EVAP CONTROL SYSTEM

VG33E DTC Confirmation Procedure

DTC Confirmation Procedure

SEC716C

SEC717C

SEC718C

SEC719C

NGEC0745

NOTE: 쐌 If DTC P0442 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-1099.) 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is between 1/4 to 3/4 full and vehicle is placed on flat level surface. 쐌 Open engine hood before conducting the following procedure. With CONSULT-II 1) Turn ignition switch ON. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 4) Make sure that the following conditions are met. COOLAN TEMP/S: 0 - 32°C (32 - 90°F) INT/A TEMP SE: More than 0°C (32°F) 5) Select “EVAP SML LEAK P0442” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-701. 6) Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-928. NOTE: Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. With GST NOTE: Be sure to read the explanation of “Driving Pattern” on EC-667 before driving vehicle. 1) Start engine. 2) Drive vehicle according to “Driving Pattern”, EC-667. 3) Stop vehicle. 4) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is not set yet, go to the following step. 쐌 If SRT of EVAP system is set, the result will be OK. 5) Turn ignition switch OFF and wait at least 5 seconds. 6) Start engine. It is not necessary to cool engine down before driving. 7) Drive vehicle again according to the “Driving Pattern”, EC-667. 8) Stop vehicle. 9) Select “MODE 3” with GST. 쐌 If P0442 is displayed on the screen, go to “Diagnostic Procedure”, EC-928. 쐌 If P0441 is displayed on the screen, go to “Diagnostic Procedure” for “DTC P0441”, EC-916. 쐌 If P0442 and P0441 are not displayed on the screen, go to the following step.

EC-927

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33E

DTC Confirmation Procedure (Cont’d)

10) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is set, the result will be OK. 쐌 If SRT of EVAP system is not set, go to step 6.

Diagnostic Procedure 1

NGEC0967

CHECK FUEL FILLER CAP DESIGN

1. Turn ignition switch “OFF”. 2. Check for genuine NISSAN fuel filler cap design.

SEF915U

OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace with genuine NISSAN fuel filler cap.

2

CHECK FUEL FILLER CAP INSTALLATION

Check that the cap is tightened properly by rotating the cap clockwise. OK or NG OK

䊳

GO TO 3.

NG

䊳

쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard.

3

CHECK FUEL FILLER CAP FUNCTION

Check for air releasing sound while opening the fuel filler cap. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 4.

4

CHECK FUEL TANK VACUUM RELIEF VALVE

Refer to “Evaporative Emission System”, EC-626. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace fuel filler cap with a genuine one.

EC-928

DTC P0442 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

5

INSTALL THE PRESSURE PUMP

To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely.

GI MA EM LC AEC649A

FE CL MT SEF916U

NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. Models with CONSULT-II

䊳

GO TO 6.

Models without CONSULT-II

䊳

GO TO 7.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-929

IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

6

CHECK FOR EVAP LEAK

With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system.

PEF917U

4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-630.

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

EC-930

DTC P0442 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

7

CHECK FOR EVAP LEAK

Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.)

GI MA EM LC

AEC632A

4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-630.

FE CL MT AT TF PD AX

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

SU BR ST RS BT HA SC EL

EC-931

IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace water separator.

9

CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT

Refer to “DTC Confirmation Procedure”, EC-947. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair or replace EVAP canister vent control valve and O-ring or harness/connector.

10

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

SEF596U

Yes or No Yes

䊳

GO TO 11.

No (With CONSULT-II)

䊳

GO TO 13.

No (Without CONSULTII)

䊳

GO TO 14.

EC-932

DTC P0442 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

11

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb).

GI

OK or NG OK (With CONSULT-II)

䊳

GO TO 13.

OK (Without CONSULTII)

䊳

GO TO 14.

NG

䊳

GO TO 12.

MA EM LC

12

DETECT MALFUNCTIONING PART

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

13 1. 2. 3. 4. 5.

FE

Repair hose or replace EVAP canister.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

CL

With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100.0%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm.

MT AT TF PD AX SEF984Y

SU

OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 15.

BR ST

14 1. 2. 3. 4. 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist.

RS BT HA

OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 15.

SC EL

EC-933

IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

15

CHECK VACUUM HOSE

Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-620. OK or NG OK

䊳

GO TO 16.

NG

䊳

Repair or reconnect the hose.

16

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

SEF985Y

OK or NG OK

䊳

GO TO 18.

NG

䊳

GO TO 17.

EC-934

DTC P0442 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

17

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

GI MA EM LC

SEF266X

FE CL MT SEF334X

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

AT TF PD AX SU

SEF266X

BR ST RS BT

SEF335X

HA

OK or NG OK

䊳

GO TO 18.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

SC EL

EC-935

IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

18

CHECK FUEL TANK TEMPERATURE SENSOR

1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit and fuel pump terminals 1 and 2 by heating with hot water or heat gun as shown in the figure.

SEF974Y

OK or NG OK

䊳

GO TO 19.

NG

䊳

Replace fuel tank temperature sensor.

19

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

1. 2. 3. 4.

Remove EVAP control system pressure sensor with its harness connector connected. Remove hose from EVAP control system pressure sensor. Turn ignition switch “ON”. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or over 101.3 kPa (760 mmHg, 29.92 inHg) of pressure. 5. Check input voltage between ECM terminal 62 and ground.

SEC649C

CAUTION: 쐌 Discard and EVAP control system pressure 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. OK or NG OK

䊳

GO TO 20.

NG

䊳

Replace EVAP control system pressure sensor.

20

CHECK EVAP PURGE LINE

Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to “Evaporative Emission System”, EC-626. OK or NG OK

䊳

GO TO 21.

NG

䊳

Repair or reconnect the hose.

EC-936

DTC P0442 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

21

CLEAN EVAP PURGE LINE

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

GI

GO TO 22.

MA 22

CHECK REFUELING EVAP VAPOR LINE

Check refueling EVAP vapor line between EVAP canister and fuel tank for clogging, kink, looseness and improper connection. For location, refer to “ON BOARD REFUELING VAPOR RECOVERY (ORVR)”, EC-632.

EM

OK or NG

LC

OK

䊳

GO TO 23.

NG

䊳

Repair or replace hoses and tubes.

23

CHECK SIGNAL LINE AND RECIRCULATION LINE

Check signal line and recirculation line between filler neck tube and fuel tank for clogging, kink, cracks, looseness and improper connection. OK or NG OK

䊳

GO TO 24.

NG

䊳

Repair or replace hoses, tubes or filler neck tube.

24

CHECK REFUELING CONTROL VALVE

FE CL MT

1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage.

AT TF PD AX SU BR ST RS BT

SEF706Z

HA

OK or NG OK

䊳

GO TO 25.

NG

䊳

Replace refueling control valve with fuel tank.

SC EL

EC-937

IDX

DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d)

25

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “Fuel Level Sensor Unit Check”. OK or NG OK

䊳

GO TO 26.

NG

䊳

Replace fuel level sensor unit.

26

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-938

VG33E

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Description

Description

NGEC0747

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

Throttle position switch

Closed throttle position

Heated oxygen sensors 1 (front)

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Fuel tank temperature sensor

Fuel temperature in fuel tank

Vehicle speed sensor

Vehicle speed

NGEC0747S01

ECM function

GI

Actuator

MA EM

EVAP canEVAP canister purge volume ister purge control solenoid valve flow control

LC

FE CL

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.

MT AT TF PD AX

COMPONENT DESCRIPTION

NGEC0747S02

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.

SU BR ST RS

SEF337U

CONSULT-II Reference Value in Data Monitor Mode

BT

NGEC0748

Specification data are reference values. MONITOR ITEM

PURG VOL C/V

HA CONDITION

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch OFF Shift lever: “N” No-load

SPECIFICATION

Idle (Vehicle stopped)

0%

2,000 rpm

—

EC-939

SC EL IDX

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E ECM Terminals and Reference Value

ECM Terminals and Reference Value

NGEC0749

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 the ECM terminals, such as the ground. TERMINAL NO.

4

WIRE COLOR

OR/B

ITEM

ECM relay (Self shutoff)

CONDITION

DATA (DC Voltage)

[Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

0 - 1.5V

[Ignition switch OFF] 쐌 A few seconds passed after turning ignition switch OFF

BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed

5

R/Y

EVAP canister purge volume control solenoid valve

SEF994U

BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Engine speed is 2,000 rpm (More than 100 seconds after starting engine)

SEF995U

67

B/P Power supply for ECM [Ignition switch ON]

72

B/P

117

B/P

Current return

[Engine is running] 쐌 Idle speed

EC-940

BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V)

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E On Board Diagnosis Logic

On Board Diagnosis Logic

=NGEC0750

Malfunction is detected when an excessively low (P0444) or high (P0445) voltage signal is sent to ECM through the valve.

POSSIBLE CAUSE 쐌 쐌

NGEC0750S01

Harness or connectors (The valve circuit is open or shorted.) EVAP canister purge volume control solenoid valve

GI MA EM LC

DTC Confirmation Procedure

SEF058Y

NGEC0751

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. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle. 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 13 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-943. With GST Follow the procedure “With CONSULT-II”.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-941

IDX

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Wiring Diagram

Wiring Diagram

NGEC0752

LEC813

EC-942

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0753

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector.

GI MA EM LC

AEC652A

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

FE CL MT AT

SEF646W

Voltage: Battery voltage

TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

PD AX

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F36, M81 쐌 Harness connectors M65, E43 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM relay 䊳

SU BR

Repair harness or connectors.

ST 3

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 5 and solenoid terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG

RS BT HA

OK (With CONSULT-II)

䊳

GO TO 5.

OK (Without CONSULTII)

䊳

GO TO 6.

SC

NG

䊳

GO TO 4.

EL

EC-943

IDX

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M81, F36 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM 䊳

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

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.

SEF985Y

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

EC-944

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure (Cont’d)

6

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II 1. Check air passage continuity under the following conditions.

GI MA EM LC

SEF660U

FE CL MTBL0241

MT

Without CONSULT-II 1. Check air passage continuity under the following conditions.

AT TF PD AX SEF661U

SU BR MTBL0242

ST

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

7

RS BT

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

HA SC EL

EC-945

IDX

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33E

Component Description

Component Description

SEF032W

NGEC0754

The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid valve responds to signals from the ECM. When the ECM sends an ON signal, the coil in the solenoid valve is energized. A plunger will then move to seal the canister vent. The ability to seal the vent is necessary for the on board diagnosis of other evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis.

SEF143S

CONSULT-II Reference Value in Data Monitor Mode

NGEC0755

Specification data are reference values. MONITOR ITEM VENT CONT/V

CONDITION

SPECIFICATION

쐌 Ignition switch: ON

OFF

ECM Terminals and Reference Value

NGEC0756

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO. 108

R/G

ITEM

CONDITION

EVAP canister vent control [Ignition switch ON] valve

EC-946

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

=NGEC0757

Malfunction is detected when an improper voltage signal is sent to ECM through EVAP canister vent control valve.

POSSIBLE CAUSE 쐌 쐌

NGEC0757S01

Harness or connectors (The valve circuit is open or shorted.) EVAP canister vent control valve

GI MA EM LC

DTC Confirmation Procedure

NGEC0758

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. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle.

FE CL MT

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 8 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-949. With GST Follow the procedure “With CONSULT-II”. 1) 2) 3) 4)

AT TF PD AX

SEF058Y

SU BR ST RS BT HA SC EL

EC-947

IDX

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33E

Wiring Diagram

Wiring Diagram

NGEC0759

LEC814

EC-948

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0760

INSPECTION START

GI

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

MA EM

CHECK EVAP CANISTER VENT CONTROL VALVE CIRCUIT

LC

1. Turn ignition switch OFF and then turn ON. 2. Select “VENT CONTROL/V” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON/OFF” on CONSULT-II screen.

FE CL MT SEF989Y

4. Check for operating sound of the valve. Clicking noise should be heard. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 3.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-949

IDX

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK EVAP CANISTER VENT CONTROL VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect EVAP canister vent control valve harness connector.

SEF143S

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

SEF648W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M67, C1 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between EVAP canister vent control valve and fuse 䊳

5

Repair harness or connectors.

CHECK EVAP CANISTER VENT CONTROL VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 108 and valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

EC-950

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure (Cont’d)

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C1, M67 쐌 Harness connectors M81, F36 쐌 Harness for open or short between EVAP canister vent control valve and ECM 䊳

GI MA

Repair open circuit or short to ground or short to power in harness or connectors.

EM 7

CHECK EVAP CANISTER VENT CONTROL VALVE

With CONSULT-II 1. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time.

LC

FE CL MT SEF991Y

AT

Without CONSULT-II 1. Check air passage continuity and operation delay time under the following conditions.

TF PD MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

AX SU BR ST RS

AEC783A

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace EVAP canister vent control valve.

8

BT HA SC

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

EL

INSPECTION END

EC-951

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

Component Description

Component Description

NGEC0761

The EVAP control system pressure sensor detects pressure in the purge line. The sensor output voltage to the ECM increases as pressure increases. The EVAP control system pressure sensor is not used to control the engine system. It is used only for on board diagnosis.

SEF052VC

SEF946SB

CONSULT-II Reference Value in Data Monitor Mode

NGEC0762

Specification data are reference values. MONITOR ITEM EVAP SYS PRES

CONDITION

SPECIFICATION

쐌 Ignition switch: ON

Approx. 1.8 - 4.8V

ECM Terminals and Reference Value

NGEC0763

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

42

B/W

Sensors’ power supply

[Ignition switch ON]

Approximately 5V

43

BR

Sensors’ ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

62

Y

EVAP control system pres[Ignition switch ON] sure sensor

EC-952

Approximately 1.8 - 4.8V

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

=NGEC0764

Malfunction is detected when an excessively low (P0452) or high (P0453) voltage signal from EVAP control system pressure sensor is sent to ECM.

GI

POSSIBLE CAUSE

MA

쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC0764S01

Harness or connectors (The EVAP control system pressure sensor circuit is open or shorted.) Rubber hose to EVAP control system pressure sensor is clogged, vent, kinked, disconnected or improper connection. EVAP control system pressure sensor EVAP canister vent control valve EVAP canister purge volume control solenoid valve EVAP canister Rubber hose from EVAP canister vent control valve to water separator

EM LC

FE CL MT

DTC Confirmation Procedure

NGEC0765

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. TESTING CONDITION: Always perform test at a temperature of 5°C (41°F) or more.

AT TF PD AX

With CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 5 seconds. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Make sure that “TANK F/TEMP SE” is more than 0°C (32°F). Start engine and wait at least 20 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-955. With GST Follow the procedure “With CONSULT-II”. 1) 2) 3) 4) 5) 6) 7)

SEF194Y

SU BR ST RS BT HA SC EL

EC-953

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

Wiring Diagram

Wiring Diagram

NGEC0766

WEC181A

EC-954

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0767

CHECK RUBBER TUBE

GI

1. Turn ignition switch OFF. 2. Check rubber tube connected to the sensor for clogging, vent, kink, disconnection or improper connection.

MA EM LC

AEC651A

OK or NG OK

䊳

GO TO 2.

NG

䊳

Reconnect, repair or replace.

2

FE CL MT

RETIGHTEN GROUND SCREWS

1. Loosen and retighten engine ground screws.

AT TF PD AX LEC518

SU 䊳

GO TO 3.

BR 3

CHECK CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector. 2. Check sensor harness connector for water. Water should not exist. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace harness connector.

ST RS BT HA SC EL

EC-955

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

Diagnostic Procedure (Cont’d)

4

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR POWER SUPPLY CIRCUIT

1. Turn ignition switch ON. 2. Check voltage between terminal 3 and ground with CONSULT-II or tester.

SEF889U

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C3, B113 and B101, M67 쐌 Harness connectors M58, F28 쐌 Harness for open or short between EVAP control system pressure sensor and ECM 䊳

6

Repair harness or connectors.

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

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 power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C3, B113 and B101, M67 쐌 Harness connectors F27, M59 쐌 Joint connector-4 (if equipped) 쐌 Harness for open or short between EVAP control system pressure sensor and ECM 䊳

Repair open circuit or short to power in harness or connectors.

EC-956

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

Diagnostic Procedure (Cont’d)

8

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 62 and sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

MA EM

OK or NG OK (With CONSULT-II)

䊳

GO TO 10.

OK (Without CONSULTII)

䊳

GO TO 11.

NG

䊳

GO TO 9.

9

GI

LC

DETECT MALFUNCTIONING PART

FE

Check the following. 쐌 Harness connectors C3, B113 and B101, M67 쐌 Harness connectors M59, F27 쐌 Harness for open or short between ECM and EVAP control system pressure sensor 䊳

CL

Repair open circuit or short to ground or short to power in harness or connectors.

MT 10

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

AT TF PD AX SU

SEF068Y

BR

OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 11.

ST RS BT HA SC EL

EC-957

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

Diagnostic Procedure (Cont’d)

11

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II 1. Check air passage continuity under the following conditions.

SEF660U

MTBL0241

Without CONSULT-II 1. Check air passage continuity under the following conditions.

SEF661U

MTBL0242

AEC652A

OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EC-958

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

Diagnostic Procedure (Cont’d)

12

CHECK EVAP CANISTER VENT CONTROL VALVE

With CONSULT-II 1. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time under the following conditions.

GI MA EM LC

SEF991Y

FE Without CONSULT-II 1. Check air passage continuity and operation delay time under the following conditions.

CL MT MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

AT TF PD AX SU

AEC783A

Make sure new O-ring is installed properly.

BR OK or NG

OK

䊳

GO TO 13.

NG

䊳

Replace EVAP canister vent control valve.

13

ST

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

Refer to “Component Inspection”, EC-961 OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace EVAP control system pressure sensor.

RS BT HA SC EL

EC-959

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

Diagnostic Procedure (Cont’d)

14

CHECK RUBBER TUBE

Check obstructed rubber tube connected to EVAP canister vent control valve. OK or NG OK

䊳

GO TO 15.

NG

䊳

Clean, repair or replace rubber tube.

15 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 16.

NG

䊳

Replace water separator.

16

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

SEF596U

Yes or No Yes

䊳

GO TO 17.

No

䊳

GO TO 19.

EC-960

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

Diagnostic Procedure (Cont’d)

17

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb).

GI

OK or NG OK

䊳

GO TO 19.

NG

䊳

GO TO 18.

18

MA EM

DETECT MALFUNCTIONING PART

LC

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

19

Repair hose or replace EVAP canister.

FE

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT

1. Reconnect harness connectors disconnected. 2. Disconnect harness connectors C3, B113. 3. Check harness continuity between harness connector B113 terminal 6 and engine ground. Continuity should exist. 4. Also check harness for short to power.

CL MT

OK or NG OK

䊳

GO TO 21.

NG

䊳

GO TO 20.

20

AT TF

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors B113 and B101, M67 쐌 Harness connectors M59, F27 쐌 Joint connector-1 (if equipped) 쐌 Harness for open between harness connector B113 and engine ground 䊳

PD AX

Repair open circuit or short to power in harness or connectors.

SU 21

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

BR

INSPECTION END

ST RS

Component Inspection EVAP CONTROL SYSTEM PRESSURE SENSOR 1. 2. 3.

NGEC1500

BT

NGEC1500S01

Remove EVAP control system pressure sensor with its harness connector connected. Remove hose from EVAP control system pressure sensor. Install a vacuum pump to EVAP control system pressure sensor.

HA SC EL

EC-961

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33E

Component Inspection (Cont’d)

4.

LEC199A

Turn ignition switch ON and check output voltage between ECM terminal 62 and ground under the following conditions. Applied vacuum kPa (mmHg, inHg)

Voltage V

Not applied

1.8 – 4.8

-26.7 (-200, -7.87)

2.1 to 2.5V lower than above value

CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply vacuum below -93.3 kPa (-700 mmHg, -27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 5. If NG, replace EVAP control system pressure sensor.

EC-962

DTC P0455 EVAP CONTROL SYSTEM

VG33E On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0954

NOTE: If DTC P0455 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-1103.) This diagnosis detects a very large leak (fuel filler cap fell off etc.) in the EVAP system between the fuel tank and the EVAP canister purge volume control solenoid valve.

GI MA EM LC

FE CL MT AT SEC666C

TF Malfunction is detected when EVAP control system has a very large leak, such as fuel filler cap fell off, EVAP control system does not operate properly. CAUTION: 쐌 Fuel filler cap remains open or fails to close. 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC0954S01

Fuel filler cap remains open or fails to close. Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Foreign matter caught in fuel filler cap. Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. Foreign matter caught in EVAP canister vent control valve. EVAP canister or fuel tank leaks EVAP purge line (pipe and rubber tube) leaks EVAP purge line rubber tube bent. Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit EVAP canister purge volume control solenoid valve and the circuit Fuel tank temperature sensor

EC-963

PD AX SU BR ST RS BT HA SC EL IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33E

On Board Diagnosis Logic (Cont’d)

쐌 쐌 쐌 쐌

O-ring of EVAP canister vent control valve is missing or damaged. EVAP control system pressure sensor Refueling control valve ORVR system leaks

DTC Confirmation Procedure

NGEC0955

CAUTION: Never remove fuel filter cap during the DTC confirmation procedure.

EC-964

DTC P0455 EVAP CONTROL SYSTEM

VG33E

DTC Confirmation Procedure (Cont’d)

SEC716C

SEC717C

SEC718C

SEC719C

NOTE: 쐌 If DTC P0455 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-1103.) 쐌 Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is between 1/4 to 3/4 full and vehicle is placed on flat level surface. 쐌 Open engine hood before conducting the following procedure. With CONSULT-II 1) Tighten fuel filter cap securely until ratcheting sound is heard. 2) Turn ignition switch ON. 3) Turn ignition switch OFF and wait at least 5 seconds. 4) Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that the following conditions are met. COOLAN TEMP/S: 0 - 32°C (32 - 90°F) INT/A TEMP SE: More than 0°C (32°F) 6) Select “EVAP SML LEAK P0442” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-701. 7) Make sure that “OK” is displayed. If “NG” is displayed, select “SELF-DIAG RESULTS” mode with CONSULT-II and make sure that “EVAP GROSS LEAK [P0455] is displayed, refer to “Diagnostic Procedure”, EC-966. If P0442 is displayed, perform “Diagnostic Procedure” for DTC P0442. With GST NOTE: Be sure to read the explanation of “Driving Pattern” on EC-667 before driving vehicle. 1) Start engine. 2) Drive vehicle according to “Driving Pattern”, EC-667. 3) Stop vehicle. 4) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is not set yet, go to the following step. 쐌 If SRT of EVAP system is set, the result will be OK. 5) Turn ignition switch “OFF” and wait at least 5 seconds. 6) Start engine. It is not necessary to cool engine down before driving. 7) Drive vehicle again according to the “Driving Pattern”, EC-667. 8) Stop vehicle. 9) Select “MODE 3” with GST. 쐌 If P0455 is displayed on the screen, go to “Diagnostic Procedure”, EC-966.

EC-965

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33E

DTC Confirmation Procedure (Cont’d)

쐌

If P0442 is displayed on the screen, go to “Diagnostic Procedure”, EC-928. 쐌 If P0441 is displayed on the screen, go to “Diagnostic Procedure” for “DTC P0441”, EC-916. 쐌 If P0442, P0455 and P0441 are not displayed on the screen, go to the following step. 10) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is set, the result will be OK. 쐌 If SRT of EVAP system is not set, go to step 6.

Diagnostic Procedure 1

NGEC0956

CHECK FUEL FILLER CAP DESIGN

1. Turn ignition switch OFF. 2. Check for genuine NISSAN fuel filler cap design.

SEF915U

OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace with genuine NISSAN fuel filler cap.

2

CHECK FUEL FILLER CAP INSTALLATION

Check that the cap is tightened properly by rotating the cap clockwise. OK or NG OK

䊳

GO TO 3.

NG

䊳

쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard.

3

CHECK FUEL FILLER CAP FUNCTION

Check for air releasing sound while opening the fuel filler cap. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-966

DTC P0455 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

4

CHECK FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)

1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum.

GI MA EM LC

SEF445Y

FE CL MT AT SEF943S

Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace fuel filler cap with a genuine one.

5

PD AX SU

CHECK EVAP PURGE LINE

Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks, improper connection or disconnection. Refer to “Evaporative Emission System”, EC-627. OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair or reconnect the hose.

6

TF

CLEAN EVAP PURGE LINE

BR ST RS BT

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

7

GO TO 7.

HA

CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT

Refer to “DTC Confirmation Procedure”, EC-947.

SC

OK or NG

EL

OK

䊳

GO TO 8.

NG

䊳

Repair or replace EVAP canister vent control valve and O-ring or harness/connector.

EC-967

IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

8

INSTALL THE PRESSURE PUMP

To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely.

AEC649A

SEF916U

NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. Models with CONSULT-II

䊳

GO TO 9.

Models without CONSULT-II

䊳

GO TO 10.

EC-968

DTC P0455 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

9

CHECK FOR EVAP LEAK

With CONSULT-II 1. Turn ignition switch ON. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system.

GI MA EM LC

FE PEF917U

4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-630.

CL MT AT TF PD

SEF200U

OK or NG OK

䊳

GO TO 11.

NG

䊳

Repair or replace.

AX SU BR ST RS BT HA SC EL

EC-969

IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

10

CHECK FOR EVAP LEAK

Without CONSULT-II 1. Turn ignition switch OFF. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.)

AEC632A

4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-630.

SEF200U

OK or NG OK

䊳

GO TO 12.

NG

䊳

Repair or replace.

EC-970

DTC P0455 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

11 1. 2. 3. 4. 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100.0%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm.

GI MA EM LC

FE SEF984Y

Vacuum should exist.

CL OK or NG

OK

䊳

GO TO 14.

NG

䊳

GO TO 13.

12 1. 2. 3. 4. 5.

MT

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist. OK or NG

OK

䊳

GO TO 15.

NG

䊳

GO TO 13.

13

AT TF PD AX SU BR

CHECK VACUUM HOSE

Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-620. OK or NG OK (With CONSULT-II)

䊳

GO TO 14.

OK (Without CONSULTII)

䊳

GO TO 15.

NG

䊳

Repair or reconnect the hose.

ST RS BT HA SC EL

EC-971

IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

14

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

SEF985Y

If OK, inspection end. If NG, go to following step. 3. Check air passage continuity.

SEF660U

MTBL0241

OK or NG OK

䊳

GO TO 16.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EC-972

DTC P0455 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

15

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

Without CONSULT-II Check air passage continuity.

GI MA EM LC

SEF661U

FE CL MTBL0242

MT AT TF PD AEC652A

OK or NG OK

䊳

GO TO 16.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

AX SU BR ST RS BT HA SC EL

EC-973

IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

16

CHECK FUEL TANK TEMPERATURE SENSOR

Check resistance by heating with hot water or heat gun as shown in the figure.

AEC052B

MTBL0234

AEC933A

OK or NG OK

䊳

GO TO 17.

NG

䊳

Replace fuel tank temperature sensor.

EC-974

DTC P0455 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure (Cont’d)

17 1. 2. 3. 4. 5.

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR Remove EVAP control system pressure sensor with its harness connector connected. Remove hose from EVAP control system pressure sensor. Turn ignition switch ON. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. Check input voltage between ECM terminal 62 and ground.

GI MA EM LC

SEC649C

CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or over 101.3 kPa (760 mmHg, 29.92 inHg) of pressure. 쐌 Discard and EVAP control system pressure 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.

FE CL MT AT TF PD

AEC651A

OK or NG OK

䊳

GO TO 18.

NG

䊳

Replace EVAP control system pressure sensor.

18

AX SU BR

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

ST

INSPECTION END

RS BT HA SC EL

EC-975

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0990

This diagnosis detects very small leaks in the EVAP line between the fuel tank and the EVAP canister purge volume control solenoid valve using intake manifold vacuum (negative pressure when P0456) or fuel tank vapor pressure (positive pressure when P1456) in the same way as conventional EVAP small leak diagnosis. If the ECM judges a leak equivalent to a very small leak, the very small leak DTC P0456 or P1456 will be detected. If the ECM judges a leak equivalent to a small leak, the EVAP small leak DTC P0442 or P1442 will be detected. Correspondingly, if the ECM judges there is no leak, the diagnosis result is OK.

SEC666C

Malfunction is detected when EVAP control system has a very small leak, EVAP control system does not operate properly. CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC0990S02

Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Fuel filler cap remains open or fails to close. Foreign matter caught in fuel filler cap. Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. Foreign matter caught in EVAP canister vent control valve. EVAP canister or fuel tank leaks EVAP purge line (pipe and rubber tube) leaks EVAP purge line rubber tube bent. Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit

EC-976

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

On Board Diagnosis Logic (Cont’d)

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

EVAP canister purge volume control solenoid valve Fuel tank temperature sensor O-ring of EVAP canister vent control valve is missing or damaged. Water separator EVAP canister is saturated with water. Fuel level sensor and the circuit EVAP control system pressure sensor Refueling control valve ORVR system leaks

DTC Confirmation Procedure

SEC720C

SEC721C

SEC722C

MA EM LC

NGEC0992

CAUTION: Never remove fuel filler cap during the DTC confirmation procedure. NOTE: 쐌 If DTC P0456 or P1456 is displayed with P0442, perform TROUBLE DIAGNOSIS FOR DTC P0456 or P1456 first. 쐌 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. 쐌 After repair, make sure that the hoses and clips are installed properly. TESTING CONDITION: 쐌 Open engine hood before conducting following procedure. 쐌 If any of following condition is met just before the DTC confirmation procedure, leave the vehicle for more than 1 hour. a) Fuel filler cap is removed. b) Refilled or drained the fuel. c) EVAP component parts is/are removed. 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Make sure the following conditions are met. FUEL LEVEL SE: 1.08 - 0.2V COOLAN TEMP/S: 0 - 32°C (32 - 90°F) FUEL T/TMP SE: 0 - 35°C (32 - 95°F) INT A/TEMP SE: More than 0°C (32°F) If NG, turn ignition switch “OFF” and leave the vehicle in a cool place (soak the vehicle) or refilling/draining fuel until the output voltage condition of the “FUEL LEVEL SE” meets within the range above and leave the vehicle for more than 1 hour. Then start from step 1). 3) Turn ignition switch “OFF” and wait at least 5 seconds. 4) Turn ignition switch “ON”. 5) Select “EVAP VERY/SML LEAK P0456 or P1456” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. 6) Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-979.

EC-977

GI

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

DTC Confirmation Procedure (Cont’d)

NOTE: 쐌 If the engine speed cannot be maintained within the range displayed on CONSULT-II screen, go to “Basic inspection”, EC-701. 쐌 Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly.

Overall Function Check

NGEC1001

With GST Use this procedure to check the overall function of the EVAP very small leak function. During this check, a 1st trip DTC might not be confirmed.

SEF462UA

CAUTION: 쐌 Never use compressed air, doing so may damage the EVAP system. 쐌 Do not start engine. 쐌 Do not exceeded 4.12 kPa (0.042 kg/cm2, 0.6 psi). 1) Attach the EVAP service port adapter securely to the EVAP service port. 2) Set the pressure pump and a hose. 3) Also set a vacuum gauge via 3-way connector and a hose. 4) Turn ignition switch “ON”. 5) Connect GST and select mode 8. 6) Using mode 8 control the EVAP canister vent control valve (close) and vacuum cut valve bypass valve (open). 7) Apply pressure and make sure the following conditions are satisfied. Pressure to be applied: 2.7 kPa (20 mmHg, 0.79 inHg) Time to be waited after the pressure drawn in to the EVAP system and the pressure to be dropped: 60 seconds and the pressure should not be dropped more than 0.4 kPa (3 mmHg, 0.12 inHg) If NG, go to diagnostic procedure, EC-979. NOTE: For more information, refer to GST instruction manual.

EC-978

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0993

CHECK FUEL FILLER CAP DESIGN

GI

1. Turn ignition switch “OFF”. 2. Check for genuine NISSAN fuel filler cap design.

MA EM LC SEF915U

OK or NG

FE

OK

䊳

GO TO 2.

NG

䊳

Replace with genuine NISSAN fuel filler cap.

CL 2

CHECK FUEL FILLER CAP INSTALLATION

Check that the cap is tightened properly by rotating the cap clockwise.

MT

OK or NG OK

䊳

GO TO 3.

NG

䊳

쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard.

3

AT TF

CHECK FUEL FILLER CAP FUNCTION

Check for air releasing sound while opening the fuel filler cap.

PD

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

AX SU BR ST RS BT HA SC EL

EC-979

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

4

CHECK FUEL TANK VACUUM RELIEF VALVE

1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum.

SEF445Y

SEF943S

Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace fuel filler cap with a genuine one.

EC-980

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

5

INSTALL THE PRESSURE PUMP

To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely.

GI MA EM LC AEC649A

FE CL MT SEF916U

NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. Models with CONSULT-II

䊳

GO TO 6.

Models without CONSULT-II

䊳

GO TO 7.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-981

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

6

CHECK FOR EVAP LEAK

With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system.

PEF917U

4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-630.

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

EC-982

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK FOR EVAP LEAK

Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.)

GI MA EM LC

AEC632A

4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-630.

FE CL MT AT TF PD AX

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

SU BR ST RS BT HA SC EL

EC-983

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace water separator.

9

CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT

Refer to “DTC Confirmation Procedure”, EC-947. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair or replace EVAP canister vent control valve and O-ring or harness/connector.

10

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Does water drain from the EVAP canister?

SEF596U

Yes or No Yes

䊳

GO TO 11.

No (With CONSULT-II)

䊳

GO TO 13.

No (Without CONSULTII)

䊳

GO TO 14.

EC-984

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

11

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb).

GI

OK or NG OK (With CONSULT-II)

䊳

GO TO 13.

OK (Without CONSULTII)

䊳

GO TO 14.

NG

䊳

GO TO 12.

MA EM LC

12

DETECT MALFUNCTIONING PART

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

13 1. 2. 3. 4. 5.

FE

Repair hose or replace EVAP canister.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

CL

With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100.0%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm.

MT AT TF PD AX SEF984Y

SU

OK or NG OK

䊳

GO TO 16.

NG

䊳

GO TO 15.

BR ST

14 1. 2. 3. 4. 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist.

RS BT HA

OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 15.

SC EL

EC-985

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

15

CHECK VACUUM HOSE

Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-620. OK or NG OK (With CONSULT-II)

䊳

GO TO 16.

OK (Without CONSULTII)

䊳

GO TO 17.

NG

䊳

Repair or reconnect the hose.

16

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

SEF985Y

OK or NG OK

䊳

GO TO 18.

NG

䊳

GO TO 17.

EC-986

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

17

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

GI MA EM LC

WEC547

FE CL MT AT SEF334X

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

TF PD AX SU

WEC547

BR ST RS BT

SEF335X

HA

OK or NG

SC

OK

䊳

GO TO 18.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EL

EC-987

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

18

CHECK FUEL TANK TEMPERATURE SENSOR

1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit and fuel pump terminals 1 and 2 by heating with hot water or heat gun as shown in the figure.

SEF974Y

OK or NG OK

䊳

GO TO 19.

NG

䊳

Replace fuel level sensor unit.

19

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

1. 2. 3. 4.

Remove EVAP control system pressure sensor with its harness connector connected. Remove hose from EVAP control system pressure sensor. Turn ignition switch “ON”. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or over 101.3 kPa (760 mmHg, 29.92 inHg) of pressure. 5. Check input voltage between ECM terminal 62 and ground.

SEC649C

CAUTION: 쐌 Discard and EVAP control system pressure 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. OK or NG OK

䊳

GO TO 20.

NG

䊳

Replace EVAP control system pressure sensor.

20

CHECK EVAP PURGE LINE

Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to “Evaporative Emission System”, EC-626. OK or NG OK

䊳

GO TO 21.

NG

䊳

Repair or reconnect the hose.

EC-988

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33E

Diagnostic Procedure (Cont’d)

21

CLEAN EVAP PURGE LINE

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

GI

GO TO 22.

MA 22

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “Fuel Level Sensor Unit Check”.

EM OK or NG

OK

䊳

GO TO 23.

NG

䊳

Replace fuel level sensor unit.

23

LC

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

FE

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-989

IDX

DTC P0460 FUEL LEVEL SENSOR

VG33E

Component Description

Component Description

NGEC0968

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

SEF800Z

ECM Terminals and Reference Value

NGEC0974

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)

46

OR/B

Fuel level sensor

[Ignition switch “ON”]

Approximately 0 - 4.8V Output voltage varies with fuel level.

66

B

Fuel level sensor ground

[Engine is running] 쐌 Idle speed

Approximately 0V

On Board Diagnosis Logic

NGEC0969

When the vehicle is parked, naturally the fuel level in the fuel tank is stable. It means that output signal of the fuel level sensor does not change. If ECM senses sloshing signal from the sensor, fuel level sensor malfunction is detected. Malfunction is detected when even though the vehicle is parked, a signal being varied is sent from the fuel level sensor to ECM.

POSSIBLE CAUSE 쐌 쐌

Fuel level sensor circuit (The fuel level sensor circuit is open or shorted.) Fuel level sensor

EC-990

NGEC0969S01

DTC P0460 FUEL LEVEL SENSOR

VG33E DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC0971

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

SEF195Y

1) 2) 3) 4)

MA

NGEC0971S01

Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait maximum of 2 consecutive minutes. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-993.

WITH GST

GI

EM LC

NGEC0971S02

Follow the procedure “WITH CONSULT-II” above.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-991

IDX

DTC P0460 FUEL LEVEL SENSOR

VG33E

Wiring Diagram

Wiring Diagram

NGEC0972

WEC993

EC-992

DTC P0460 FUEL LEVEL SENSOR

VG33E Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4.

=NGEC0973

CHECK FUEL LEVEL SENSOR POWER SUPPLY CIRCUIT

GI

Turn ignition switch “OFF”. Disconnect fuel level sensor until and fuel pump harness connector. Turn ignition switch “ON”. Check voltage between fuel level sensor unit and fuel pump terminal 2 and ground with CONSULT-II or a tester.

MA EM LC

FE SEC650C

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

MT

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M67, B101 쐌 Harness for open or short between combination meter and fuel level sensor until and fuel pump 䊳

3

CL

Repair or replace harness or connectors.

CHECK FUEL LEVEL SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check harness continuity between fuel level sensor unit and fuel pump terminal 4 and body ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power.

AT TF PD AX SU

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to power in harness or connectors.

BR ST

4

CHECK FUEL LEVEL SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 46 and fuel level sensor unit and fuel pump terminal 2, ECM terminal 66 and fuel level sensor unit and fuel pump terminal 4. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

RS BT

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

HA SC EL

EC-993

IDX

DTC P0460 FUEL LEVEL SENSOR

VG33E

Diagnostic Procedure (Cont’d)

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M67, B101 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuel level sensor 䊳

6

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “Fuel Level Sensor Unit Check”. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace fuel level sensor unit.

7

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-994

DTC P0461 FUEL LEVEL SENSOR

VG33E Component Description

Component Description

=NGEC0975

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

GI MA EM LC

SEF800Z

On Board Diagnosis Logic

NGEC0976

Driving long distances naturally affect fuel gauge level. This diagnosis detects the fuel gauge malfunction of the gauge not moving even after a long distance has been driven. Malfunction is detected when the output signal of the fuel level sensor does not change within the specified range even though the vehicle has been driven a long distance.

POSSIBLE CAUSE 쐌 쐌

FE CL

NGEC0976S01

Harness or connectors (The level sensor circuit is open or shorted.) Fuel level sensor

MT AT TF PD AX

Overall Function Check

NGEC0978

Use this procedure to check the overall function of the fuel level sensor function. During this check, a 1st trip DTC might not be confirmed. WARNING: When performing following procedure, be sure to observe the handling of the fuel. Refer to FE-5, “Fuel Tank”. TESTING CONDITION: Before starting overall function check, preparation of draining fuel and refilling fuel is required.

WITH CONSULT-II

SEF195Y

NGEC0978S01

NOTE: Start from step 11, if it is possible to confirm that the fuel cannot be drained by 30 (7-7/8 US gal, 6-5/8 Imp gal) in advance. 1) Prepare a fuel container and a spare hose. 2) Release fuel pressure from fuel line, refer to “Fuel Pressure Release”, EC-644. 3) Remove the fuel feed hose on the fuel level sensor unit. 4) Connect a spare fuel hose where the fuel feed hose was removed.

EC-995

SU BR ST RS BT HA SC EL IDX

DTC P0461 FUEL LEVEL SENSOR

VG33E

Overall Function Check (Cont’d)

5)

Turn ignition switch “OFF” and wait at least 5 seconds then turn “ON”. 6) Select “FUEL LEVEL SE” in “DATA MONITOR” mode with CONSULT-II. 7) Check “FUEL LEVEL SE” output voltage and note it. 8) Select “FUEL PUMP” in “ACTIVE TEST” mode with CONSULT-II. 9) Touch “ON” and drain fuel approximately 30 (7-7/8 US gal, 6-5/8 Imp gal) and stop it. 10) Fill fuel into the fuel tank for 30 (7-7/8 US gal, 6-5/8 Imp gal). 11) Check “FUEL LEVEL SE” output voltage and note it. 12) Check “FUEL LEVEL SE” output voltage and confirm whether the voltage changes more than 0.03V during step 7 to 11. If NG, check the fuel level sensor, refer to EL-89, “FUEL LEVEL SENSOR UNIT CHECK”.

WITH GST

SEF802Z

NGEC0978S02

NOTE: Start from step 11, if it is possible to confirm that the fuel cannot be drained by 30 (7-7/8 US gal, 6-5/8 Imp gal) in advance. 1) Prepare a fuel container and a spare hose. 2) Release fuel pressure from fuel line, refer to “Fuel Pressure Release”, EC-644. 3) Remove the fuel feed hose on the fuel level sensor unit. 4) Connect a spare fuel hose where the fuel feed hose was removed. 5) Turn ignition switch “OFF”. 6) Set voltmeters probe between ECM terminal 46 (fuel level sensor signal) and ground. 7) Turn ignition switch “ON”. 8) Check voltage between ECM terminal 46 and ground and note it. 9) Drain fuel by 30 (7-7/8 US gal, 6-5/8 Imp gal) from the fuel tank using proper equipment. 10) Fill fuel into the fuel tank for 30 (7-7/8 US gal, 6-5/8 Imp gal). 11) Confirm that the voltage between ECM terminal 46 and ground changes more than 0.03V during step 8 - 10. If NG, check component of fuel level sensor, refer to EL-89, “FUEL LEVEL SENSOR UNIT CHECK”.

EC-996

DTC P0462, P0463 FUEL LEVEL SENSOR

VG33E Component Description

Component Description

NGEC0979

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

GI MA EM LC

SEF800Z

ECM Terminals and Reference Value

NGEC0985

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

FE

DATA (DC Voltage)

CL

46

OR/B

Fuel level sensor

[Ignition switch “ON”]

Approximately 0 - 4.8V Output voltage varies with fuel level.

MT

66

B

Fuel level sensor ground

[Engine is running] 쐌 Idle speed

Approximately 0V

AT TF PD AX

On Board Diagnosis Logic

NGEC0980

ECM receives two signals from the fuel level sensor circuit. One is fuel level sensor power supply circuit, and the other is fuel level sensor ground circuit. This diagnosis indicates the former, to detect open or short circuit malfunction. Malfunction is detected when an excessively low (P0462) or high (P0463) voltage is sent from the sensor is sent to ECM.

POSSIBLE CAUSE 쐌 쐌

Fuel level sensor circuit (The fuel level sensor circuit is open or shorted.) Fuel level sensor

NGEC0980S01

SU BR ST RS BT HA SC EL

EC-997

IDX

DTC P0462, P0463 FUEL LEVEL SENSOR

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC0982

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at ignition switch “ON”.

WITH CONSULT-II 1) 2) 3) 4)

NGEC0982S01

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”, EC-1000.

WITH GST Follow the procedure “WITH CONSULT-II” above. SEF195Y

EC-998

NGEC0982S02

DTC P0462, P0463 FUEL LEVEL SENSOR

VG33E Wiring Diagram

Wiring Diagram

NGEC0983

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC994

EC-999

EL IDX

DTC P0462, P0463 FUEL LEVEL SENSOR

VG33E

Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4.

=NGEC0984

CHECK FUEL LEVEL SENSOR POWER SUPPLY CIRCUIT Turn ignition switch “OFF”. Disconnect fuel level sensor until and fuel pump harness connector. Turn ignition switch “ON”. Check voltage between fuel level sensor unit and fuel pump terminal 2 and ground with CONSULT-II or tester.

SEC650C

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M67, B101 쐌 Harness for open or short between combination meter and fuel level sensor until and fuel pump 䊳

3

Repair or replace harness or connectors.

CHECK FUEL LEVEL SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check harness continuity between fuel level sensor unit and fuel pump terminal 4 and body ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to power in harness or connectors.

4

CHECK FUEL LEVEL SENSOR INPUT CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 46 and fuel level sensor unit and fuel pump 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

䊳

GO TO 6.

NG

䊳

GO TO 5.

EC-1000

DTC P0462, P0463 FUEL LEVEL SENSOR

VG33E

Diagnostic Procedure (Cont’d)

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M67, B101 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuel level sensor 䊳

GI MA

Repair open circuit or short to ground or short to power in harness on connectors.

EM 6

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “Fuel Level Sensor Unit Check”. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace fuel level sensor unit.

7

LC

FE

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

CL

INSPECTION END

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1001

IDX

DTC P0500 VSS

VG33E

Component Description

Component Description

NGEC0768

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.

AEC110

ECM Terminals and Reference Value

NGEC0769

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 2 - 3V

29

G/B

Vehicle speed sensor

[Engine is running] 쐌 Lift up the vehicle 쐌 In 1st gear position 쐌 Vehicle speed is 40 km/h (25 MPH) SEF996U

On Board Diagnosis Logic

NGEC0770

Malfunction is detected when the almost 0 km/h (0 MPH) signal from vehicle speed sensor is sent to ECM even when vehicle is being driven.

POSSIBLE CAUSE 쐌 쐌

NGEC0770S01

Harness or connector (The vehicle speed sensor circuit is open or shorted.) Vehicle speed sensor

DTC Confirmation Procedure

NGEC0771

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 5 seconds before conducting the next test. TESTING CONDITION: Steps 1 and 2 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle.

EC-1002

DTC P0500 VSS

VG33E DTC Confirmation Procedure (Cont’d)

1) 2)

SEF196Y

3) 4) 5)

With CONSULT-II Start engine Read “VHCL SPEED SE” 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-1005. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Warm engine up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds.

ENG SPEED

More than 1,400 rpm (A/T models) More than 2,000 rpm (M/T models)

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

4.5 - 9.0 msec

Selector lever

Suitable position

PW/ST SIGNAL

OFF

6)

MA EM LC

FE CL

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1005.

Overall Function Check

GI

NGEC0772

Use this procedure to check the overall function of the vehicle speed sensor circuit. During this check, a 1st trip DTC might not be confirmed. With GST 1) Lift up drive wheels. 2) Start engine. 3) Read vehicle speed sensor signal in “MODE 1” with GST. The vehicle speed sensor on GST should be able to exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. 4) If NG, go to “Diagnostic Procedure”, EC-1005.

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1003

IDX

DTC P0500 VSS

VG33E

Wiring Diagram

Wiring Diagram

NGEC0773

WEC995

EC-1004

DTC P0500 VSS

VG33E Diagnostic Procedure

Diagnostic Procedure 1

CHECK VEHICLE SPEED SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 29 and meter terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power.

NGEC0774

GI MA EM

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and combination meter 䊳

3

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK SPEEDOMETER FUNCTION

FE CL MT

Make sure that speedometer functions properly. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

AT TF

CHECK SPEEDOMETER CIRCUIT FOR OPEN AND SHORT

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness connectors F43, F201 쐌 Harness for open or short between combination meter and vehicle speed sensor OK or NG OK

䊳

Check combination meter and vehicle speed sensor. Refer to EL section.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

PD AX SU BR

5

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

ST

INSPECTION END

RS BT HA SC EL

EC-1005

IDX

DTC P0505 ISC SYSTEM

VG33E

Description

Description

NGEC0775

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

Park/neutral 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

Vehicle speed

Ambient air temperature switch

Ambient air temperature

Intake air temperature sensor

Intake air temperature

Absolute pressure sensor

Ambient barometic pressure

NGEC0775S01

ECM function

Idle air control

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 bypasses the throttle valve via IACV-AAC valve. The IACV-AAC valve repeats ON/OFF operation according to the signal sent from the ECM. The camshaft position sensor detects the actual engine speed and sends a signal to the ECM. The ECM then controls the ON/OFF time 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 and power steering).

COMPONENT DESCRIPTION IACV-AAC Valve

NGEC0775S02 NGEC0775S0201

The IACV-AAC valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of air that will flow through the valve. The more air that flows through the valve, the higher the idle speed.

SEF040E

EC-1006

DTC P0505 ISC SYSTEM

VG33E

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NGEC0776

Specification data are reference values. MONITOR ITEM

IACV-AAC/V

CONDITION 쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

SPECIFICATION

Idle

10 - 20%

2,000 rpm

—

GI MA EM

ECM Terminals and Reference Value

NGEC0777

LC

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

FE ITEM

CONDITION

DATA (DC Voltage)

CL

8 - 11V

MT

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

AT SEF005V

101

OR/L

IACV-AAC valve

TF

7 - 10V

PD [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 3,000 rpm

AX SEF692W

SU BR ST RS

On Board Diagnosis Logic

NGEC0778

Malfunction is detected when (Malfunction A) the IACV-AAC valve does not operate properly, (Malfunction B) the IACV-AAC valve does not operate properly.

POSSIBLE CAUSE 쐌 쐌 쐌

Harness or connectors (The IACV-AAC valve circuit is open.) Harness or connectors (The IACV-AAC valve circuit is shorted.) IACV-AAC valve

EC-1007

NGEC0778S01

BT HA SC EL IDX

DTC P0505 ISC SYSTEM

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC0779

NOTE: 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. 쐌 Perform “PROCEDURE FOR MALFUNCTION A” first. If 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”.

PROCEDURE FOR MALFUNCTION A

SEF058Y

PROCEDURE FOR MALFUNCTION B

SEF174Y

NGEC0779S01

TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch “ON”. With CONSULT-II 1) Turn ignition switch ON. 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”, EC-1010. With GST Follow the procedure “With CONSULT-II”.

NGEC0779S02

TESTING CONDITION: 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) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON again and select “DATA MONITOR” mode with CONSULT-II. 4) Start engine and run it for at least 1 minute at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1010. With GST Follow the procedure “With CONSULT-II”.

EC-1008

DTC P0505 ISC SYSTEM

VG33E Wiring Diagram

Wiring Diagram

NGEC0780

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC996

EC-1009

EL IDX

DTC P0505 ISC SYSTEM

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0781

CHECK IACV-AAC VALVE POWER SUPPLY CIRCUIT

1. Stop engine. 2. Disconnect IACV-AAC valve harness connector.

LEC514

3. Turn ignition switch ON. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF651W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness connectors F37, F101 쐌 Fuse block (J/B) connector M27 쐌 10A fuse 쐌 Harness for open or short between IACV-AAC valve and fuse 䊳

3

Repair harness or connectors.

CHECK IACV-AAC VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 101 and IACV-AAC valve terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-1010

DTC P0505 ISC SYSTEM

VG33E Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F101, F37 쐌 Harness for open or short between IACV-AAC valve and ECM 䊳

5

GI MA

Repair open circuit or short to ground or short to power in harness or connectors.

EM

CHECK IACV-AAC VALVE

1. Disconnect IACV-AAC valve harness connector. 2. Remove IACV-AAC valve. 쐌 Check IACV-AAC valve resistance.

LC

FE CL SEF202V

Resistance: Approximately 10Ω [at 20°C (68°F)] 쐌 Check plunger for seizing or sticking. 쐌 Check for broken spring. 3. Supply battery voltage between IACV-AAC valve connector terminals. Plunger should move.

MT AT TF

OK or NG

PD

OK

䊳

GO TO 6.

NG

䊳

Replace IACV-AAC valve.

AX 6

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

SU

INSPECTION END

BR ST RS BT HA SC EL

EC-1011

IDX

DTC P0510 CTP SWITCH

VG33E

Component Description

Component Description

NGEC0782

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 A/T 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 volume control solenoid valve when the throttle position sensor is malfunctioning. SEF505V

CONSULT-II Reference Value in Data Monitor Mode

NGEC0783

Specification data are reference values. MONITOR ITEM CLSD THL/P SW

CONDITION 쐌 Engine: After warming up, idle the engine

SPECIFICATION

Throttle valve: Idle position

ON

Throttle valve: Slightly open

OFF

ECM Terminals and Reference Value

NGEC0784

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 the ECM terminals, such as the ground. TERWIRE MINAL COLOR NO.

28

BR/W

ITEM

Throttle position switch (Closed position)

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Warm-up condition 쐌 Accelerator pedal fully released

BATTERY VOLTAGE (11 - 14V)

[Ignition switch “ON”] 쐌 Accelerator pedal depressed

Approximately 0V

On Board Diagnosis Logic

NGEC0785

Malfunction is detected when battery voltage from the closed throttle position switch is sent to ECM with the throttle valve opened.

POSSIBLE CAUSE 쐌 쐌 쐌

Harness or connectors (The closed throttle position switch circuit is shorted.) Closed throttle position switch Throttle position sensor

EC-1012

NGEC0785S01

DTC P0510 CTP SWITCH

VG33E DTC Confirmation Procedure

DTC Confirmation Procedure

SEF197Y

Condition

SEF198Y

ON

Throttle valve: Slightly open

OFF

5) 6)

GI MA EM LC

Signal indication

Throttle valve: Idle position

FE

If the result is NG, go to “Diagnostic Procedure”, EC-1015. 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. More than 2.5V

VHCL SPEED SE

More than 5 km/h (3 MPH)

Selector lever

Suitable position

Driving location

Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test.

MT

TF

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1015.

Overall Function Check

CL

AT

THRTL POS SEN

7)

SEF872U

NGEC0786

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 5 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, wait at least 5 seconds and then start engine. 3) Select “CLSD THL/P SW” in “DATA MONITOR” mode. 4) Check the signal under the following conditions.

NGEC0787

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 28 (Closed throttle position switch signal) and ground under the following conditions. At idle: Battery voltage At 2,000 rpm: Approximately 0V 3) If NG, go to “Diagnostic Procedure”, EC-1015.

PD AX SU BR ST RS BT HA SC EL

EC-1013

IDX

DTC P0510 CTP SWITCH

VG33E

Wiring Diagram

Wiring Diagram

NGEC0788

AEC964A

EC-1014

DTC P0510 CTP SWITCH

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0789

CHECK CLOSED THROTTLE POSITION SWITCH POWER SUPPLY CIRCUIT

GI

1. Turn ignition switch OFF. 2. Disconnect throttle position switch harness connector.

MA EM LC

AEC653A

3. Turn ignition switch ON. 4. Check voltage between terminal 5 and engine ground with CONSULT-II or tester.

FE CL MT AT

SEF715U

Voltage: Battery voltage

TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

PD AX

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between throttle position switch and ECM relay 쐌 Harness for open or short between throttle position switch and ECM 䊳

3

Repair harness or connectors.

CHECK CLOSED THROTTLE POSITION SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 28 and switch terminal 4. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power.

SU BR ST RS BT

OK or NG

HA

OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

SC EL

EC-1015

IDX

DTC P0510 CTP SWITCH

VG33E

Diagnostic Procedure (Cont’d)

4

ADJUST THROTTLE POSITION SWITCH

Check the following items. Refer to “Basic Inspection”, EC-701.

MTBL0576

with CONSULT-II

䊳

GO TO 5.

without CONSULT-II

䊳

GO TO 6.

5 1. 2. 3. 4. 5.

CHECK CLOSED THROTTLE POSITION SWITCH With CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check indication of “CLSD THL/P SW”. Measurement must be made with closed throttle position switch installed in vehicle.

MTBL0355

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

EC-1016

DTC P0510 CTP SWITCH

VG33E Diagnostic Procedure (Cont’d)

6 1. 2. 3. 4.

CHECK CLOSED THROTTLE POSITION SWITCH Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect closed throttle position switch harness connector. Check continuity between closed throttle position switch terminals 4 and 5. Resistance measurement must be made with closed throttle position switch installed in vehicle.

GI MA EM LC

FE AEC654A

CL MT MTBL0247

OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 7.

7

AT TF

ADJUST THROTTLE POSITION SWITCH

PD

Check the following items. Refer to “Basic Inspection”, EC-701.

AX SU BR MTBL0576

If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch.

ST

OK or NG OK (with CONSULT-II)

䊳

GO TO 8.

OK (without CONSULTII)

䊳

GO TO 9.

NG

䊳

Replace throttle position switch.

RS BT HA SC EL

EC-1017

IDX

DTC P0510 CTP SWITCH

VG33E

Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4. 5.

CHECK THROTTLE POSITION SENSOR With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine (ignition switch OFF). Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check voltage of “THRTL POS SEN”.

MTBL0230

Voltage measurement must be made with throttle position sensor installed in vehicle. If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-701. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace throttle position sensor.

9 1. 2. 3. 4.

CHECK 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 23 (Throttle position sensor signal) and ground. Voltage measurement must be made with throttle position sensor installed in vehicle.

MTBL0231

If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-701. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace throttle position sensor.

10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-1018

DTC P0600 A/T CONTROL

VG33E System Description

System Description

NGEC0790

These circuit lines are used to control the smooth shifting up and down of A/T during the hard acceleration/ deceleration. Voltage signals are exchanged between ECM and TCM (Transmission Control Module).

ECM Terminals and Reference Value

MA NGEC0791

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO. 26

PU/W

GI

EM LC

ITEM

CONDITION

DATA (DC Voltage)

A/T signal No. 1

[Ignition switch “ON”] [Engine is running] 쐌 Idle speed

6 - 8V

6 - 8V 0V

27

P/B

A/T signal No. 2

[Ignition switch “ON”] [Engine is running] 쐌 Idle speed

35

G/R

A/T signal No. 3

[Ignition switch “ON”]

FE CL MT

On Board Diagnosis Logic

NGEC0792

Malfunction is detected when ECM receives incorrect voltage from TCM (Transmission Control Module) continuously.

AT

POSSIBLE CAUSE

TF

쐌

NGEC0792S01

Harness or connectors [The circuit between ECM and TCM (Transmission Control Module) is open or shorted.]

PD AX SU BR ST RS BT HA SC EL

EC-1019

IDX

DTC P0600 A/T CONTROL

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF058Y

=NGEC0793

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. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine, and rev engine more than 1,000 rpm once, then let it idle for more than 40 seconds. 4) If DTC is detected, go to “Diagnostic Procedure”, EC-1022.

Overall Function Check

NGEC0794

Use this procedure to check the overall function of the A/T control circuit. During this check, a DTC might not be confirmed. Without CONSULT-II 1) Start engine. 2) Check voltage between ECM terminal 26 and ground. ECM terminal 27 and ground. Voltage: 6 - 8V 3) If NG, go to “Diagnostic Procedure”, EC-1022. SEF755U

EC-1020

DTC P0600 A/T CONTROL

VG33E Wiring Diagram

Wiring Diagram

NGEC0795

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC997

EC-1021

EL IDX

DTC P0600 A/T CONTROL

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0796

CHECK A/T CONTROL INPUT SIGNAL CIRCUIT FOR OPEN

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector and TCM (Transmission Control Module) harness connector.

SEF324V

AEC655A

3. Check harness continuity between ECM terminal 26 and terminal 5, ECM terminal 27 and terminal 6, ECM terminal 35 and terminal 7. Refer to Wiring Diagram. Continuity should exist. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness for open or short between ECM and TCM (Transmission Control Module) 䊳

3

Repair harness or connectors.

CHECK A/T CONTROL INPUT SIGNAL CIRCUIT FOR SHORT

1. Check harness continuity between ECM terminal 26 and ground, ECM terminal 27 and ground, ECM terminal 35 and ground. Refer to Wiring Diagram. Continuity should not exist. 2. Also check harness for short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-1022

DTC P0600 A/T CONTROL

VG33E Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and TCM (Transmission Control Module). 䊳

GI

Repair open circuit or short to ground or short to power in harness.

MA 5

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1023

IDX

DTC P0605 ECM

VG33E

Component Description

Component Description

NGEC0797

The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the engine.

SEC220B

On Board Diagnosis Logic

NGEC0798

Malfunction is detected when ECM calculation function is malfunctioning.

POSSIBLE CAUSE 쐌

NGEC0798S01

ECM

DTC Confirmation Procedure

NGEC0799

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 Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine. Run engine for at least 2 seconds at idle speed. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1025. With GST Follow the procedure “With CONSULT-II”. 1) 2) 3) 4) 5)

SEF058Y

EC-1024

DTC P0605 ECM

VG33E Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4. 5.

INSPECTION START

NGEC0800

GI

With CONSULT-II Turn ignition switch ON. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See EC-1024. Is the 1st trip DTC P0605 displayed again?

With GST Turn ignition switch ON. Select MODE 4 with GST. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See EC-1024. 5. Is the 1st trip DTC P0605 displayed again?

MA EM LC

1. 2. 3. 4.

FE Yes or No

Yes

䊳

Replace ECM.

No

䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1025

IDX

DTC P1143, P1163 HO2S1

VG33E

Component Description

Component Description

NGEC0615

The heated oxygen sensor 1 is placed into the front tube. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NGEC0616

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 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

NGEC0617

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor (bank 1) [Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

51

G

Heated oxygen sensor (bank 2) SEF002V

EC-1026

DTC P1143, P1163 HO2S1

VG33E On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0618

To judge the malfunction, the output from the heated oxygen sensor 1 is monitored to determine whether the “rich” output is sufficiently high and whether the “lean” output is sufficiently low. When both the outputs are shifting to the lean side, the malfunction will be detected. Malfunction is detected when the maximum and minimum voltage from the sensor are not reached to the specified voltages.

POSSIBLE CAUSE SEF300U

쐌 쐌 쐌 쐌 쐌

Heated oxygen sensor 1 Heated oxygen sensor 1 heater Fuel pressure Injectors Intake air leaks

GI MA EM

NGEC0618S01

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1027

IDX

DTC P1143, P1163 HO2S1

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC0619

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 Before performing following procedure, confirm that battery voltage is more than 11V at idle.

With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine and wait at least 5 seconds. Turn ignition switch “ON” and select “HO2S1 (B1)/(B2) P1143/ P1163” 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 50 seconds or more.) 1) 2) 3)

SEC704C

ENG SPEED

1,200 - 3,100 rpm

Vehicle speed

Less than 100 km/h (62 MPH)

B/FUEL SCHDL

2.8 - 11 msec

Selector lever

Suitable position

SEC705C

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-1029.

SEC706C

EC-1028

DTC P1143, P1163 HO2S1

VG33E Overall Function Check

Overall Function Check

SEF919UA

NGEC0620

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3) Check one of the following with engine speed held at 2,000 rpm constant under no load. 쐌 The maximum voltage is over 0.6V at least one time. 쐌 The minimum voltage is over 0.1V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-1029.

GI MA EM LC

FE CL MT

Diagnostic Procedure 1

NGEC0621

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

AT TF PD AX SU

LEC518

䊳

2

ST

GO TO 2.

RETIGHTEN HEATED OXYGEN SENSOR 1

RS

Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

BR

GO TO 3.

BT HA SC EL

EC-1029

IDX

DTC P1143, P1163 HO2S1

VG33E

Diagnostic Procedure (Cont’d)

3

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 “CLEAR”.

SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine? Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-673. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6.

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171, P0174. Refer to EC-853.

No

䊳

GO TO 4.

EC-1030

DTC P1143, P1163 HO2S1

VG33E Diagnostic Procedure (Cont’d)

4

CHECK HEATED OXYGEN SENSOR 1 HEATER

1. Stop engine. 2. Check heated oxygen sensor 1 harness protector color.

GI MA EM LC SEF505YB

3. Check resistance between HO2S1 terminals 3 and 1.

FE CL MT AT AEC158A

Resistance: 2.3 - 4.3Ω at 25°C (77°F) 4. Check continuity between HO2S1 terminals 2 and 1, 3 and 2. Continuity should not exist. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

TF PD AX

OK or NG OK (With CONSULT-II)

䊳

GO TO 5.

OK (Without CONSULTII)

䊳

GO TO 6.

NG

䊳

SU BR

Replace malfunctioning heated oxygen sensor 1.

ST RS BT HA SC EL

EC-1031

IDX

DTC P1143, P1163 HO2S1

VG33E

Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 1

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 with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below.

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace malfunctioning heated oxygen sensor 1.

EC-1032

DTC P1143, P1163 HO2S1

VG33E Diagnostic Procedure (Cont’d)

6

CHECK FRONT HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

GI MA EM LC

SEF796Z

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.

FE CL

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

MT

REPLACE HEATED OXYGEN SENSOR 1

AT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

TF

7

PD AX SU SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

BR ST

Replace malfunctioning heated oxygen sensor 1.

RS BT HA SC EL

EC-1033

IDX

DTC P1143, P1163 HO2S1

VG33E

Diagnostic Procedure (Cont’d)

8

CHECK HO2S1 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. 3. For circuit, refer to “DTC P0134, P0154 HEATED OXYGEN SENSOR 1 (BANK 1)/(BANK 2) (CIRCUIT)”, EC-822. 4. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 5. Also check harness for short to power. 6. Then reconnect joint connector. OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair open circuit or short to power in harness or connectors.

9

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. For circuit, refer to “DTC P0134, P0154 HEATED OXYGEN SENSOR (BANK 1)/(BANK 2) (CIRCUIT)”, EC-822. 䊳

INSPECTION END

EC-1034

DTC P1144, P1164 HO2S1

VG33E Component Description

Component Description

NGEC0622

The heated oxygen sensor 1 is placed into the front tube. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V.

GI MA EM LC

SEF463R

FE CL MT

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

AT

CONDITION

TF

NGEC0623

Specification data are reference values. MONITOR ITEM

SPECIFICATION

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

AX SU

ECM Terminals and Reference Value

NGEC0624

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 the ECM terminals, such as the ground. TERMINAL NO.

PD

BR ST

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

RS 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1 (Bank 1)

BT [Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

51

G

HA

Heated oxygen sensor 1 (Bank 2) SEF002V

SC EL

EC-1035

IDX

DTC P1144, P1164 HO2S1

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0625

To judge the malfunction, the output from the heated oxygen sensor 1 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. Malfunction is detected when the maximum and minimum voltages from the sensor are beyond the specified voltages.

POSSIBLE CAUSE SEF299U

쐌 쐌 쐌 쐌

Heated oxygen sensor 1 Fuel pressure Injectors Heated oxygen sensor 1 heater

EC-1036

NGEC0625S01

DTC P1144, P1164 HO2S1

VG33E DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC0626

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

GI MA EM LC

FE CL MT With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine and wait at least 5 seconds. Turn ignition switch ON and select “HO2S1 (B1)/(B2) P1144/ P1164” 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 50 seconds or more.) 1) 2) 3)

SEC707C

END SPEED

1,200 - 3,100 rpm

Vehicle speed

Less than 100 km/h (62 MPH)

B/FUEL SCHDL

2.8 - 11 msec

Selector lever

Suitable position

SEC708C

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-1038.

AT TF PD AX SU BR ST RS BT HA SC EL

SEC709C

EC-1037

IDX

DTC P1144, P1164 HO2S1

VG33E

Overall Function Check

Overall Function Check

SEF919UA

Diagnostic Procedure 1

NGEC0627

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3) Check one of the following with engine speed held at 2,000 rpm constant under no load. 쐌 The maximum voltage is below 0.8V at least one time. 쐌 The minimum voltage is below 0.35V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-1038.

NGEC0628

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC518

䊳

2

GO TO 2.

RETIGHTEN HEATED OXYGEN SENSOR 1

Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

GO TO 3.

EC-1038

DTC P1144, P1164 HO2S1

VG33E Diagnostic Procedure (Cont’d)

3

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 “CLEAR”.

GI MA EM LC

SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6. 7. 8.

FE CL

Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-673. Make sure DTC P0000 is displayed. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine?

MT AT TF PD

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0172, P0175. Refer to EC-862.

No

䊳

GO TO 4.

AX SU

4

CHECK HO2S 1 CONNECTOR FOR WATER

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

BR ST RS BT SEF505YB

3. Disconnect heated oxygen sensor 1 harness connector. 4. Check connectors for water. Water should not exist.

HA SC

OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair or replace harness or connectors.

EL

EC-1039

IDX

DTC P1144, P1164 HO2S1

VG33E

Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 1 HEATER

Check resistance between HO2S1 terminals 3 and 1.

AEC158A

Resistance: 2.3 - 4.3Ω at 25°C (77°F) Check continuity between HO2S1 terminals 2 and 1, 3 and 2. Continuity should not exist. 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. OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

GO TO 8.

EC-1040

DTC P1144, P1164 HO2S1

VG33E Diagnostic Procedure (Cont’d)

6

CHECK HEATED OXYGEN SENSOR 1

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 with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

GI MA EM LC

FE SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below.

CL MT AT TF PD

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

AX SU BR ST RS SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BT HA

OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

SC EL

EC-1041

IDX

DTC P1144, P1164 HO2S1

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

SEF796Z

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. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 8.

8

REPLACE HEATED OXYGEN SENSOR 1

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 1.

EC-1042

DTC P1144, P1164 HO2S1

VG33E Diagnostic Procedure (Cont’d)

9

CHECK HO2S1 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. For circuit, refer to “DTC P0134, P0154 HEATED OXYGEN SENSOR (BANK 1)/(BANK 2) (CIRCUIT)”, EC-822. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector.

GI MA EM LC

OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

FE

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. For circuit, refer to “DTC P0134, P0154 FRONT HEATED OXYGEN SENSOR (BANK 1)/(BANK 2) (CIRCUIT)”, EC-822. 䊳

CL

INSPECTION END

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1043

IDX

DTC P1146, P1166 HO2S2

VG33E

Component Description

Component Description

SEF327R

NGEC0651

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NGEC0652

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up

Revving engine from idle up to 2,000 rpm LEAN +, RICH

ECM Terminals and Reference Value

NGEC0653

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 the ECM terminals, such as the ground. TERMINAL NO. 56 57

WIRE COLOR

ITEM

CONDITION

OR

Heated oxygen sensor 2 (bank 1)

Y

Heated oxygen sensor 2 (bank 2)

[Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 2,000 rpm

On Board Diagnosis Logic

DATA (DC Voltage)

0 - Approximately 1.0V

NGEC0654

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the minimum voltage of sensor is sufficiently low during the various driving condition such as fuelcut. Malfunction is detected when the minimum voltage from the sensor is not reached to the specified voltage. SEF972Z

EC-1044

DTC P1146, P1166 HO2S2

VG33E On Board Diagnosis Logic (Cont’d)

POSSIBLE CAUSE 쐌 쐌 쐌 쐌

NGEC0654S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 2 Fuel pressure Injectors

GI MA EM LC

DTC Confirmation Procedure

SEC710C

SEC711C

NGEC0655

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. TESTING CONDITION: Open engine hood before conducting following procedure With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that “COOLANT TEMP/S” is more than 70°C (158°F). 6) Select “HO2S2 (B1)/(B2) P1146/P1166” of “HO2S2” in DTC WORK SUPPORT” mode with CONSULT. 7) Start engine and follow the instructions of CONSULT-II. 8) Make sure that “OK” is displayed after touching “SELF_DIAG RESULTS”. If NG is displayed, refer to “DIAGNOSTIC PROCEDURE”, EC-1049. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. a) Stop engine and cool down “COOLANT TEMP/SE” to less than 70°C (158°F). b) Turn ignition switch ON. c) Select “DATA MONITOR” mode with CONSULT-II. d) Start engine. e) Perform from step 6) again when the “COOLANT TEMP/S” reaches to 70°C (158°F)

FE CL MT AT TF PD AX SU BR ST RS

SEC712C

BT HA SC EL

EC-1045

IDX

DTC P1146, P1166 HO2S2

VG33E

Overall Function Check

Overall Function Check

SEF922UA

=NGEC0656

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. 4) Check the voltage when racing 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 0.48V 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 “O/D” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-1049.

EC-1046

DTC P1146, P1166 HO2S2

VG33E Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0657 NGEC0657S01

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC174A

EC-1047

IDX

DTC P1146, P1166 HO2S2

VG33E

Wiring Diagram (Cont’d)

LEFT BANK

NGEC0657S02

WEC175A

EC-1048

DTC P1146, P1166 HO2S2

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0658

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

LEC518

䊳

FE

GO TO 2.

CL 2

CLEAR THE SELF-LEARNING DATA

MT

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 “CLEAR”.

AT TF PD AX SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine?

SU BR

Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-673. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6.

ST RS BT HA

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0172, P0175. Refer to EC-863.

No

䊳

GO TO 3.

SC EL

EC-1049

IDX

DTC P1146, P1166 HO2S2

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 2 harness protector color.

SEF372ZA

3. Disconnect corresponding heated oxygen sensor 2 harness connector.

WEC546

4. Disconnect ECM harness connector. 5. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram.

MTBL0951

Continuity should exist. 6. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram.

MTBL0952

Continuity should not exist. 7. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1050

DTC P1146, P1166 HO2S2

VG33E Diagnostic Procedure (Cont’d)

4

CHECK HO2S GROUND CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power.

GI MA

OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

GO TO 5.

5

EM LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-3 (if equipped) 쐌 Harness for open between heated oxygen sensor 2 and engine ground. 䊳

6

FE

Repair open circuit or short to power in harness or connectors.

CL

CHECK HEATED OXYGEN SENSOR 2

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)/(B2)” as the monitor item with CONSULTII. 4. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

MT AT TF PD AX SU

SEF989RD

“HO2S2 (B1)/(B2)” should be above 0.62V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

BR ST RS BT HA SC EL

EC-1051

IDX

DTC P1146, P1166 HO2S2

VG33E

Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without 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. Set voltmeter probes between ECM terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (depress and release accelerator pedal as soon as possible)

SEF797ZB

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 “O/D” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

REPLACE HEATED OXYGEN SENSOR 2

1. Stop vehicle and turn ignition switch OFF. 2. Check heated oxygen sensor 2 harness protector color.

SEF372ZA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 2.

EC-1052

DTC P1146, P1166 HO2S2

VG33E Diagnostic Procedure (Cont’d)

9

CHECK HO2S2 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector-3. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-3. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

CHECK INTERMITTENT INCIDENT

GI MA EM LC

FE

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1053

IDX

DTC P1147, P1167 HO2S2

VG33E

Component Description

Component Description

SEF327R

NGEC0659

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NGEC0660

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up

Revving engine from idle up to 2,000 rpm LEAN +, RICH

ECM Terminals and Reference Value

NGEC0661

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 the ECM terminals, such as the ground. TERMINAL NO. 56 57

WIRE COLOR

ITEM

CONDITION

OR

Heated oxygen sensor 2 (bank 1)

Y

Heated oxygen sensor 2 (bank 2)

[Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 2,000 rpm

On Board Diagnosis Logic

DATA (DC Voltage)

0 - Approximately 1.0V

NGEC0662

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the maximum voltage of the sensor is sufficiently high during the various driving condition such as fuel-cut. Malfunction is detected when the maximum voltage from the sensor is not reached to the specified voltage. SEF303UB

EC-1054

DTC P1147, P1167 HO2S2

VG33E On Board Diagnosis Logic (Cont’d)

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌

NGEC0662S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 2 Fuel pressure Injectors Intake air leaks

GI MA EM LC

DTC Confirmation Procedure

SEC713C

SEC714C

NGEC0663

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. TESTING CONDITION: Open engine hood before conducting following procedure With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that “COOLANT TEMP/S” is more than 70°C (158°F). 6) Select “HO2S2 (B1)/(B2), P1147/P1167” of “HO2S2” in DTC WORK SUPPORT” mode with CONSULT-II. 7) Start engine and follow the instructions of CONSULT-II. 8) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If NG is displayed, refer to “DIAGNOSTIC PROCEDURE”, EC-1059. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. a) Stop engine and cool down “COOLANT TEMP/SE” to less than 70°C (158°F). b) Turn ignition switch ON. c) Select “DATA MONITOR” mode with CONSULT-II. d) Start engine. e) Perform from step 6) again when the “COOLANT TEMP/S” reaches to 70°C (158°F)

FE CL MT AT TF PD AX SU BR ST RS

SEC715C

BT HA SC EL

EC-1055

IDX

DTC P1147, P1167 HO2S2

VG33E

Overall Function Check

Overall Function Check

SEF922UA

=NGEC0664

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. 4) Check the voltage when racing 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 0.62V 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 “O/D” OFF (A/T). The voltage should be above 0.62V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-1059.

EC-1056

DTC P1147, P1167 HO2S2

VG33E Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC0665 NGEC0665S01

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC174A

EC-1057

IDX

DTC P1147, P1167 HO2S2

VG33E

Wiring Diagram (Cont’d)

LEFT BANK

NGEC0665S02

WEC175A

EC-1058

DTC P1147, P1167 HO2S2

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0666

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

LEC518

䊳

FE

GO TO 2.

CL 2

CLEAR THE SELF-LEARNING DATA

MT

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 “CLEAR”.

AT TF PD AX SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine?

SU BR

Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-673. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6.

ST RS BT HA

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171, P0174. Refer to EC-854.

No

䊳

GO TO 3.

SC EL

EC-1059

IDX

DTC P1147, P1167 HO2S2

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 2 harness protector color.

SEF372ZA

3. Disconnect corresponding heated oxygen sensor 2 harness connector. 4. Disconnect ECM harness connector. 5. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram.

SEC661C

Continuity should exist. 6. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram.

SEC662C

Continuity should not exist. 7. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1060

DTC P1147, P1167 HO2S2

VG33E Diagnostic Procedure (Cont’d)

4

CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power.

GI MA

OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

GO TO 5.

5

EM LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-3 (if equipped) 쐌 Harness for open between heated oxygen sensor 2 and engine ground. 䊳

6

FE

Repair open circuit or short to power in harness or connectors.

CL

CHECK HEATED OXYGEN SENSOR 2

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)/(B2)” as the monitor item with CONSULTII. 4. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

MT AT TF PD AX SU

SEF989RD

“HO2S2 (B1)/(B2)” should be above 0.62V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V at least once when the “FUEL INJECTION” is −25%. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BR ST RS

OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

BT HA SC EL

EC-1061

IDX

DTC P1147, P1167 HO2S2

VG33E

Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without 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. Set voltmeter probes between ECM terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (depress and release accelerator pedal as soon as possible)

SEF797ZB

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 “O/D” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

REPLACE HEATED OXYGEN SENSOR 2

1. Stop vehicle and turn ignition switch OFF. 2. Check heated oxygen sensor 2 harness protector color.

SEF372ZA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 2.

EC-1062

DTC P1147, P1167 HO2S2

VG33E Diagnostic Procedure (Cont’d)

9

CHECK HO2S2 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to “HARNESS LAYOUT”, EL-250.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

CHECK INTERMITTENT INCIDENT

GI MA EM LC

FE

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1063

IDX

DTC P1148, P1168 CLOSED LOOP CONTROL

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0808

★ The closed loop control has the one trip detection logic. Malfunction is detected when the closed loop control function for right bank does not operate even when vehicle is driving in the specified condition, the closed loop control function for left bank does not operate even when vehicle is driving in the specified condition.

POSSIBLE CAUSE 쐌 쐌 쐌

NGEC0808S01

The heated oxygen sensor 1 circuit is open or shorted. Heated oxygen sensor 1 Heated oxygen sensor 1 heater

DTC Confirmation Procedure

NGEC0809

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Never raise engine speed above 3,200 rpm during the “DTC Confirmation Procedure”. If the engine speed limit is exceeded, retry the procedure from step 2. 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

With CONSULT-II Start engine and warm it up to normal operating temperature. Select “DATA MONITOR” mode with CONSULT-II. Hold engine speed at 2,000 rpm and check one of the following. 쐌 “HO2S1 (B1)/(B2)” voltage should go above 0.70V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage should go below 0.21V at least once. If the check result is NG, perform “Diagnosis Procedure”, EC-1065.

1) 2) 3)

SEF967Y

EC-1064

DTC P1148, P1168 CLOSED LOOP CONTROL

VG33E

DTC Confirmation Procedure (Cont’d)

4) 5)

If the check result is OK, perform the following step. Let engine idle at least 5 minutes. Maintain the following condition at least 50 consecutive seconds.

B/FUEL SCHDL

3.3 msec or more

ENG SPEED

1,600 rpm or more

Selector lever

Suitable position

VHCL SPEED SE

More than 71 km/h (44 MPH)

6)

GI MA EM

During this test, P0134 and/or P0154 may be displayed on CONSULT-II screen. If DTC is detected, go to “Diagnostic Procedure”, EC-1065.

LC

FE CL MT

Overall Function Check

SEF919UA

NGEC0810

Use this procedure to check the overall function of the closed loop control. During this check, a 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 50 [heated oxygen sensor 1 (bank 1) signal] or 51 [heated oxygen sensor 1 (bank 2) signal] and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no-load. 쐌 The voltage should go above 0.70V at least once. 쐌 The voltage should go below 0.21V at least once. 4) If NG, go to “Diagnostic Procedure”, EC-1065.

AT TF PD AX SU BR ST RS

Diagnostic Procedure

NGEC0811

BT

Perform trouble diagnosis for “DTC P0133, P0153”, EC-808.

HA SC EL

EC-1065

IDX

DTC P1217 ENGINE OVER TEMPERATURE

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0904

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. Malfunction is detected when engine coolant temperature reaches an abnormally high temperature. CAUTION: When a malfunction is indicated be sure to replace the coolant, follow the procedure in “Changing Engine Coolant”, “ENGINE MAINTENANCE”, MA-28. Also, replace the engine oil. 1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pouring coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to “Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-15. 2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.

POSSIBLE CAUSE 쐌 Cooling fan (Crankshaft driven) 쐌 Radiator hose 쐌 Radiator 쐌 Radiator cap 쐌 Water pump 쐌 Thermostat For more information, refer to OVERHEATING”, EC-1070.

Overall Function Check

SEF621W

NGEC0904S01

“MAIN

12

CAUSES

OF

NGEC0905

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-1067. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-1067. 3) Start engine. 4) Make sure that cooling fan (crankshaft driven) operates. 5) If NG, go to “Diagnostic Procedure”, EC-1067.

EC-1066

DTC P1217 ENGINE OVER TEMPERATURE

VG33E

Overall Function Check (Cont’d)

1)

2)

3)

4)

Without CONSULT-II 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-1067. Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-1067. Start engine and make sure that cooling fan (crankshaft driven) operates. Be careful not to overheat engine. If NG, go to “Diagnostic Procedure”, EC-1067.

GI MA EM LC

FE CL MT

Diagnostic Procedure 1

NGEC0907

CHECK COOLING FAN (CRANKSHAFT DRIVEN) OPERATION

Start engine and make sure that cooling fan (crankshaft driven) operates.

TF

OK or NG OK

䊳

GO TO 2.

NG

䊳

Check cooling fan (crankshaft driven). Refer to LC-16, “Cooling Fan”.

2

AT

PD AX

CHECK COOLING SYSTEM FOR LEAK

Apply pressure to the cooling system with a tester, and check if the pressure drops. CAUTION: Higher than the specified pressure may cause radiator damage. Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi)

SU BR ST RS BT SLC754A

Pressure should not drop. OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following for leak 쐌 Hose 쐌 Radiator 쐌 Water pump Refer to “Water Pump”, LC-12.

EC-1067

HA SC EL IDX

DTC P1217 ENGINE OVER TEMPERATURE

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK RADIATOR CAP

Apply pressure to cap with a tester and check radiator cap relief pressure.

SLC755A

Radiator cap relief pressure: 59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi) OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace radiator cap.

4

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: 82°C (180°F) [standard] Valve lift: More than 10 mm/95°C (0.39 in/203°F) 3. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to “Thermostat”, LC-13. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace thermostat

EC-1068

DTC P1217 ENGINE OVER TEMPERATURE

VG33E

Diagnostic Procedure (Cont’d)

5

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

GI MA EM LC SEF152P



FE CL MTBL0229

MT AT TF PD SEF012P

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace engine coolant temperature sensor.

6

AX SU BR

CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-1070. 䊳

ST

INSPECTION END

RS BT HA SC EL

EC-1069

IDX

DTC P1217 ENGINE OVER TEMPERATURE

VG33E

Main 12 Causes of Overheating

Main 12 Causes of Overheating Engine

Step

Inspection item

OFF

1

쐌 쐌 쐌 쐌

2

Equipment

Standard

NGEC0908

Reference page

쐌 Visual

No blocking

쐌 Coolant mixture

쐌 Coolant tester

50 - 50% coolant mixture See “RECOMMENDED FLUIDS AND LUBRICANTS”,MA-13.

3

쐌 Coolant level

쐌 Visual

Coolant up to MAX level in reservoir tank and radiator filler neck

See “Changing Engine Coolant”, “ENGINE MAINTENANCE”, MA-28.

4

쐌 Radiator cap

쐌 Pressure tester

59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi) (Limit)

See “System Check”, “ENGINE COOLING SYSTEM”, LC-28.

ON*1

5

쐌 Coolant leaks

쐌 Visual

No leaks

See “System Check”, “ENGINE COOLING SYSTEM”, LC-29.

ON*1

6

쐌 Thermostat

쐌 Touch the upper and lower radiator hoses

Both hoses should be hot

See “Thermostat” and “Radiator”, “ENGINE COOLING SYSTEM”, LC-31, LC-32.

ON*1

7

쐌 Cooling fan (Crankshaft driven)

쐌 Visual

Operating

See LC-34, “Cooling Fan”.

OFF

8

쐌 Combustion gas leak

쐌 Color checker chemical tester 4 Gas analyzer

Negative

—

ON*2

9

쐌 Coolant temperature gauge

쐌 Visual

Gauge less than 3/4 when driving

—

쐌 Coolant overflow to reservoir tank

쐌 Visual

No overflow during driving and idling

See “Changing Engine Coolant”, “ENGINE MAINTENANCE”, MA-28.

Blocked Blocked Blocked Blocked

radiator condenser radiator grille bumper

—

OFF*3

10

쐌 Coolant return from 쐌 Visual reservoir tank to radiator

Should be initial level in reservoir tank

See “ENGINE MAINTENANCE”, MA-26.

OFF

11

쐌 Cylinder head

0.1 mm (0.004 in) Maximum distortion (warping)

See “Inspection”, “CYLINDER HEAD DISTORTION”, EM-96.

12

쐌 Cylinder block and pis- 쐌 Visual tons

No scuffing on cylinder walls or piston

See “Inspection”, “CYLINDER BLOCK DISTORTION AND WEAR”, EM-117.

쐌 Straight gauge feeler gauge

*1: Engine running at 3,000 rpm for 10 minutes. *2: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *3: After 60 minutes of cool down time. For more information, refer to “Engine Cooling System”, “OVERHEATING CAUSE ANALYSIS”, LC-35.

EC-1070

DTC P1336 CKP SENSOR (OBD)

VG33E Component Description

Component Description

SEF804Z

NGEC0818

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.

GI MA EM LC

FE CL MT

WEC549

ECM Terminals and Reference Value

NGEC0819

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (AC Voltage) 1 - 2V (AC range)

AT TF PD AX SU

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

BR SEF690W

47

L

Crankshaft position sensor (OBD)

ST

3 - 4V (AC range)

RS [Engine is running] 쐌 Engine speed is 2,000 rpm

BT SEF691W

HA SC EL

EC-1071

IDX

DTC P1336 CKP SENSOR (OBD)

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0820

Malfunction is detected when a chipping of the flywheel or drive plate gear tooth (cog) is detected by the ECM.

POSSIBLE CAUSE 쐌 쐌 쐌

NGEC0820S01

Harness or connectors Crankshaft position sensor (OBD) Drive plate/Flywheel

DTC Confirmation Procedure

NGEC0821

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 Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 2 minutes at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1074. With GST Follow the procedure “With CONSULT-II”. 1)

SEF058Y

EC-1072

DTC P1336 CKP SENSOR (OBD)

VG33E Wiring Diagram

Wiring Diagram

NGEC0822

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC179A

EC-1073

EL IDX

DTC P1336 CKP SENSOR (OBD)

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0823

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC518

䊳

2

GO TO 2.

CHECK CKPS (OBD) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.

WEC549

2. Check continuity between ECM terminal 47 and sensor terminal 2. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Harness for open or short between ECM and crankshaft position sensor (OBD) 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1074

DTC P1336 CKP SENSOR (OBD)

VG33E Diagnostic Procedure (Cont’d)

4

CHECK CKPS (OBD) GROUND CIRCUIT FOR OPEN AND SHORT

1. Reconnect ECM harness connectors. 2. Check harness continuity between CKPS (OBD) terminal 1 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power.

GI MA

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

EM LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Joint connector-4 (if equipped) 쐌 Harness for open between crankshaft position sensor (OBD) and ECM 䊳

6

Repair open circuit or short to ground or short to power in harness or connectors.

FE CL

CHECK IMPROPER INSTALLATION

1. Loosen and retighten the fixing bolt of the crankshaft position sensor (OBD). 2. Perform “DTC Confirmation Procedure”, EC-1072 again.

MT

Is a 1st trip DTC P1336 detected? Yes

䊳

GO TO 7.

No

䊳

INSPECTION END

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1075

IDX

DTC P1336 CKP SENSOR (OBD)

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK 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. Check resistance as shown in the figure.

SEF504V

Resistance: Approximately 512 - 632Ω [at 20°C (68°F)] OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace crankshaft position sensor (OBD).

8

CHECK CKPS (OBD) SHIELD CIRCUIT FOR OPEN AND SHORT

1. Disconnect harness connectors F38, F102. 2. Check harness continuity between harness connector F38 terminal 6 and engine ground. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 10.

NG

䊳

GO TO 9.

9

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Joint connector-1 (if equipped) 쐌 Harness for open between harness connector F38 and engine ground 䊳

Repair open circuit or short to power in harness or connectors.

EC-1076

DTC P1336 CKP SENSOR (OBD)

VG33E Diagnostic Procedure (Cont’d)

10

CHECK GEAR TOOTH

Visually check for chipping flywheel or drive plate gear tooth (cog).

GI

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace the flywheel or drive plate.

11

MA EM

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1077

IDX

DTC P1442 EVAP CONTROL SYSTEM

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1048

NOTE: If DTC P1440 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-1099.) This diagnosis detects leaks in the EVAP purge line using of vapor pressure in the fuel tank. The EVAP canister vent control valve is closed to shut the EVAP purge line. The vacuum cut valve bypass valve will then be opened to clear the line between the fuel tank and the EVAP canister purge volume control solenoid valve. The EVAP control system pressure sensor can now monitor the pressure inside the fuel tank. If pressure increases, the PCM will check for leaks in the line between the vacuum cut valve and EVAP canister purge volume control solenoid valve.

SEC666C

Malfunction is detected when EVAP control system has a leak, EVAP control system does not operate properly. CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC1048S02

Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Fuel filler cap remains open or fails to close Foreign matter caught in fuel filler cap Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve Foreign matter caught in EVAP canister vent control valve EVAP canister EVAP purge line (pipe and rubber tube) leaks EVAP purge line rubber tube bent

EC-1078

DTC P1442 EVAP CONTROL SYSTEM

VG33E

On Board Diagnosis Logic (Cont’d)

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit EVAP canister purge volume control solenoid valve Absolute pressure sensor Fuel tank temperature sensor O-ring of EVAP canister vent control valve is missing or damaged Water separator EVAP canister is saturated with water Fuel level sensor and the circuit EVAP control system pressure sensor Refueling control valve ORVR system leaks Foreign matter caught in EVAP canister purge volume control solenoid valve

GI MA EM LC

FE CL MT

DTC Confirmation Procedure

NGEC1050

Refer to “P0456, P1456 EVAP CONTROL SYSTEM (VERY SMALL LEAK) (NEGATIVE PRESSURE)”, EC-976.

AT TF PD AX

Diagnostic Procedure

NGEC1051

Refer to “P0456, P1456 EVAP CONTROL SYSTEM (VERY SMALL LEAK) (NEGATIVE PRESSURE)”, EC-976.

SU BR ST RS BT HA SC EL

EC-1079

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Description

Description

NGEC0845

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

Throttle position switch

Closed throttle position

Heated oxygen sensors 1 (front)

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Fuel tank temperature sensor

Fuel temperature in fuel tank

Vehicle speed sensor

Vehicle speed

NGEC0845S01

ECM function

Actuator

EVAP canEVAP canister purge volume ister purge control solenoid valve flow control

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

NGEC0845S02

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

NGEC0846

Specification data are reference values. MONITOR ITEM

PURG VOL C/V

CONDITION 쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch OFF Shift lever: “N” No-load

SPECIFICATION

Idle (Vehicle stopped)

0%

2,000 rpm

—

EC-1080

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E ECM Terminals and Reference Value

ECM Terminals and Reference Value

NGEC0847

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

4

OR/B

ITEM

ECM relay (Self shutoff)

CONDITION

DATA (DC Voltage)

MA EM

[Engine is running] [Ignition switch OFF] 0 - 1.5V 쐌 For a few seconds after turning ignition switch OFF [Ignition switch OFF] 쐌 A few seconds passed after turning ignition switch OFF

GI

LC

BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V)

FE CL

[Engine is running] 쐌 Idle speed

MT 5

R/Y

EVAP canister purge volume control solenoid valve

SEF994U

AT

BATTERY VOLTAGE (11 - 14V)

TF [Engine is running] 쐌 Engine speed is 2,000 rpm

PD SEF995U

67

B/P

72

B/P

117

B/P

Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

AX SU BR ST RS

On Board Diagnosis Logic

NGEC0848

Malfunction is detected when the canister purge flow is detected during the specified driving conditions, even when EVAP canister purge volume control solenoid valve is completely closed.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌

NGEC0848S01

EVAP control system pressure sensor EVAP canister purge volume control solenoid valve (The valve is stuck open.) EVAP canister vent control valve EVAP canister

EC-1081

BT HA SC EL IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E DTC Confirmation Procedure

쐌

Hoses (Hoses are connected incorrectly or clogged.)

DTC Confirmation Procedure

NGEC0849

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. TESTING CONDITION: Always perform test at a temperature of 5°C (41°F) or more.

1) 2) 3) 4) 5) 6) SEF205Y

7)

1) 2) 3) 4) 5) SEF206Y

With CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 5 seconds. Turn ignition switch ON. Select “PURG VOL CN/V P1444” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Start engine and let it idle until “TESTING” on CONSULT-II changes to “COMPLETED”. (It will take for approximately 10 seconds.) 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-1084. With GST Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 5 seconds. Start engine and let it idle for at least 20 seconds. Select “MODE 7” with GST. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1084.

SEF237Y

EC-1082

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Wiring Diagram

Wiring Diagram

NGEC0850

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC813

EC-1083

EL IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0851

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector.

AEC652A

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and engine ground with CONSULT-II or tester.

SEF646W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F36, M81 쐌 Harness connectors M65, E43 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM relay 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM 䊳

3

Repair harness or connectors.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 5 and solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-1084

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M81, F36 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM 䊳

GI MA

Repair open circuit or short to ground or short to power in harness or connectors.

EM 5

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

Check disconnection or improper connection of hose connected to EVAP control system pressure sensor.

LC

OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair it.

6

FE

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

CL MT AT TF AEC651A

2. Check connectors for water. Water should not exist.

PD OK or NG

OK

䊳

GO TO 7.

NG

䊳

Replace EVAP control system pressure sensor.

AX SU BR ST RS BT HA SC EL

EC-1085

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4. 5.

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR Remove EVAP control system pressure sensor with its harness connector connected. Remove hose from EVAP control system pressure sensor. Turn ignition switch ON. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. Check input voltage between ECM terminal 62 and ground.

SEC649C

CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or over 101.3 kPa (760 mmHg, 29.92 inHg) of pressure. 쐌 Discard and EVAP control system pressure sensor which has been dropped from a height of more than 0.5m (19.7in) onto a hard surface such as a concrete floor; use a new one. OK or NG OK (with CONSULT-II)

䊳

GO TO 8.

OK (without CONSULTII)

䊳

GO TO 9.

NG

䊳

Replace EVAP control system pressure sensor.

EC-1086

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure (Cont’d)

8

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

GI MA EM LC

SEF985Y

If OK, inspection end. If NG, go to following step. 3. Check air passage continuity.

FE CL MT AT TF

SEF660U

PD AX MTBL0241

If NG, replace the EVAP canister purge volume control solenoid valve.

SU

OK or NG

BR

OK

䊳

GO TO 10.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

ST RS BT HA SC EL

EC-1087

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure (Cont’d)

9

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

Without CONSULT-II Check air passage continuity.

SEF661U

MTBL0242

If NG, replace the EVAP canister purge volume control solenoid valve. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EC-1088

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure (Cont’d)

10

CHECK EVAP CANISTER VENT CONTROL VALVE

Check air passage continuity. With CONSULT-II Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

GI MA EM LC

SEF991Y

FE

Without CONSULT-II

CL MT MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

AT TF PD AX AEC783A

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP canister vent control valve.

11

SU BR ST

CHECK RUBBER TUBE

Check for obstructed rubber tube connected to EVAP canister vent control valve.

RS

OK or NG

BT

OK

䊳

GO TO 12.

NG

䊳

Clean, repair or replace rubber tube.

HA SC EL

EC-1089

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure (Cont’d)

12 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 13.

NG

䊳

Replace water separator.

13

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

SEF596U

Yes or No Yes

䊳

GO TO 14.

No

䊳

GO TO 16.

14

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 16.

NG

䊳

GO TO 15.

EC-1090

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33E Diagnostic Procedure (Cont’d)

15

DETECT MALFUNCTIONING PART

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

16

Repair hose or replace EVAP canister.

GI MA EM

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1091

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33E

Component Description

Component Description

SEF032W

NGEC0852

The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid valve responds to signals from the ECM. When the ECM sends an ON signal, the coil in the solenoid valve is energized. A plunger will then move to seal the canister vent. The ability to seal the vent is necessary for the on board diagnosis of other evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis.

SEF143S

CONSULT-II Reference Value in Data Monitor Mode

NGEC0853

Specification data are reference values. MONITOR ITEM VENT CONT/V

CONDITION

SPECIFICATION

쐌 Ignition switch: ON

OFF

ECM Terminals and Reference Value

NGEC0854

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 the ECM terminals, such as the ground. TERMINAL NO. 108

WIRE COLOR R/G

ITEM EVAP canister vent control valve

CONDITION

[Ignition switch ON]

EC-1092

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

=NGEC0855

Malfunction is detected when EVAP canister vent control valve remains closed under specified driving conditions.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌

MA EM LC

DTC Confirmation Procedure

SEF201Y

NGEC0855S01

EVAP canister vent control valve EVAP control system pressure sensor and the circuit Blocked rubber tube to EVAP canister vent control valve Water separator EVAP canister is saturated with water.

GI

NGEC0856

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 5 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) Drive vehicle at a speed of approximately 80 km/h (50 MPH) for a maximum of 15 minutes. NOTE: If a malfunction exists, NG result may be displayed quicker. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1095. With GST Follow the procedure “With CONSULT-II”.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1093

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33E

Wiring Diagram

Wiring Diagram

NGEC0857

LEC814

EC-1094

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0858

CHECK RUBBER TUBE

GI

1. Turn ignition switch OFF. 2. Check obstructed rubber tube connected to EVAP canister vent control valve.

MA EM LC

SEF143S

FE

OK or NG OK

䊳

GO TO 2.

NG

䊳

Clean, repair or replace rubber tube.

2 1. 2. 3. 4.

CL MT

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

AT TF PD AX SU SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 3.

NG

䊳

Replace water separator.

BR ST RS BT HA SC EL

EC-1095

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK EVAP CANISTER VENT CONTROL VALVE AND O-RING

Check air passage continuity. With CONSULT-II Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

SEF991Y

Without CONSULT-II

MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

AEC783A

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace EVAP canister vent control valve and O-ring.

EC-1096

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure (Cont’d)

4

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

GI MA EM LC

SEF596U

Yes or No Yes

䊳

GO TO 5.

No

䊳

GO TO 7.

5

CL

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

6

MT AT TF

DETECT MALFUNCTIONING PART

PD

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

FE

AX

Repair hose or replace EVAP canister.

SU 7

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

Check disconnection or improper connection of hose connected to EVAP control system pressure sensor.

BR

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair it.

ST RS BT HA SC EL

EC-1097

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure (Cont’d)

8

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

AEC651A

2. Check connectors for water. Water should not exist. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace EVAP control system pressure sensor.

9

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR FUNCTION

Refer to “DTC Confirmation Procedure” for DTC P0452, P0453, EC-953. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-1098

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33E

Component Description

Component Description

SEF032W

NGEC0864

NOTE: If DTC P1448 is displayed with P0442, perform trouble diagnosis for DTC P1448 first. The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid valve responds to signals from the ECM. When the ECM sends an ON signal, the coil in the solenoid valve is energized. A plunger will then move to seal the canister vent. The ability to seal the vent is necessary for the on board diagnosis of other evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis.

GI MA EM LC

FE CL MT

SEF143S

CONSULT-II Reference Value in Data Monitor Mode

AT

CONDITION

TF

NGEC0865

Specification data are reference values. MONITOR ITEM VENT CONT/V

SPECIFICATION

쐌 Ignition switch: ON

OFF

PD

ECM Terminals and Reference Value

NGEC0866

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 the ECM terminals, such as the ground. TERMINAL NO. 108

WIRE COLOR R/G

ITEM EVAP canister vent control valve

CONDITION

[Ignition switch ON]

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

AX SU BR ST RS

On Board Diagnosis Logic

NGEC0867

Malfunction is detected when EVAP canister vent control valve remains opened under specified driving conditions.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌

HA

NGEC0867S01

EVAP canister vent control valve EVAP control system pressure sensor and circuit Blocked rubber tube to EVAP canister vent control valve Water separator EVAP canister is saturated with water. Vacuum cut valve

EC-1099

BT

SC EL IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC0868

NOTE: 쐌 If DTC P1448 is displayed with P0442, perform trouble diagnosis for DTC P1448 first. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test.

SEC716C

With CONSULT-II TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is less than 3/4 full and vehicle is placed on flat level surface. 쐌 Always perform test at a temperature of 0 to 30°C (32 to 86°F). 쐌 It is better that the fuel level is low. 1) Turn ignition switch ON. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 4) Make sure that the following conditions are met. COOLAN TEMP/S

0 - 32°C (32 - 90°F)

INT/A TEMP SE

More than 0°C (32°F)

5)

SEC717C

Select “EVAP SML LEAK P0442” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-701. 6) Make sure that “OK” is displayed. If “NG” is displayed, go to the following step. NOTE: Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. 7) Stop engine and wait at least 5 seconds, then turn ON. 8) Disconnect hose from water separator. 9) Select “VENT CONTROL/V” of “ACTIVE TEST” mode with CONSULT-II. 10) Touch ON and OFF alternately.

SEC718C

11) Make sure the following. Condition VENT CONTROL/V

Air passage continuity between A and B

ON

No

OFF

Yes

If the result is NG, go to “Diagnostic Procedure”, EC-1103. If the result is OK, go to “Diagnostic Procedure” for DTC P0442, EC-925. SEF013Z

EC-1100

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33E

Overall Function Check

Overall Function Check

NGEC0869

Use this procedure to check the overall function of the EVAP canister vent control valve circuit. During this check, a DTC might not be confirmed. Without CONSULT-II 1) Disconnect hose from water separator. 2) Disconnect EVAP canister vent control valve harness connector. 3) Verify the following. Condition

Air passage continuity

12V direct current supply between terminals 1 and 2

No

No supply

Yes

AEC783A

If the result is NG, go to “Diagnostic Procedure”, EC-1103. If the result is OK, go to “Diagnostic Procedure” for DTC P0442, EC-925.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1101

IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33E

Wiring Diagram

Wiring Diagram

NGEC0870

LEC814

EC-1102

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0871

CHECK RUBBER TUBE

GI

1. Turn ignition switch OFF. 2. Check obstructed rubber tube connected to EVAP canister vent control valve.

MA EM LC

SEF143S

FE

OK or NG OK

䊳

GO TO 2.

NG

䊳

Clean, repair or replace rubber tube.

2 1. 2. 3. 4.

CL MT

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

AT TF PD AX SU SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 3.

NG

䊳

Replace water separator.

BR ST RS BT HA SC EL

EC-1103

IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK EVAP CANISTER VENT CONTROL VALVE AND O-RING

Check air passage continuity. With CONSULT-II Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

SEF991Y

Without CONSULT-II

MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

AEC783A

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace EVAP canister vent control valve and O-ring.

EC-1104

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure (Cont’d)

4

CHECK VACUUM CUT VALVE

Check vacuum cut valve as follows:

GI MA EM LC SEF379Q

1. 2. 3. 4. 5. 6. 7.

Plug port C and D with fingers. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Open port C and D. Blow air in port A check that air flows freely out of port C. Blow air in port B check that air flows freely out of port D.

FE CL

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace vacuum cut valve.

5

MT AT

CHECK IF EVAP CANISTER SATURATED WITH WATER

TF

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

PD AX SU BR SEF596U

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 8.

6

ST RS

CHECK EVAP CANISTER

BT

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace the EVAP canister.

HA SC EL

EC-1105

IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33E

Diagnostic Procedure (Cont’d)

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

8

Repair hose or replace EVAP canister.

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair it.

9

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

AEC651A

2. Check connectors for water. Water should not exist. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

10

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR FUNCTION

Refer to “DTC Confirmation Procedure” for DTC P0452, P0453, EC-953. OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP control system pressure sensor.

11

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-1106

DTC P1464 FUEL LEVEL SENSOR

VG33E Component Description

Component Description

NGEC0994

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

GI MA EM LC

SEF800Z

ECM Terminals and Reference Value

NGEC1000

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

FE

DATA (DC Voltage)

CL

46

OR/B

Fuel level sensor

[Ignition switch “ON”]

Approximately 0 - 4.8V Output voltage varies with fuel level.

MT

66

B

Fuel level sensor ground

[Engine is running] 쐌 Idle speed

Approximately 0V

AT TF PD AX

On Board Diagnosis Logic

NGEC0995

ECM receives two signals from the fuel level sensor. One is fuel level sensor power supply circuit, and the other is fuel level sensor ground circuit. This diagnosis indicates the latter to detect open circuit malfunction. Malfunction is detected when a high voltage from the sensor is sent to ECM.

POSSIBLE CAUSE 쐌

BR ST

NGEC0995S01

Fuel level sensor circuit (The fuel level sensor circuit is open or shorted.)

DTC Confirmation Procedure

SU

RS

NGEC0997

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.

BT HA SC EL

EC-1107

IDX

DTC P1464 FUEL LEVEL SENSOR

VG33E

DTC Confirmation Procedure (Cont’d)

WITH CONSULT-II 1) 2) 3) 4)

NGEC0997S01

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”, EC-1110.

WITH GST Follow the procedure “WITH CONSULT-II” above. SEF195Y

EC-1108

NGEC0997S02

DTC P1464 FUEL LEVEL SENSOR

VG33E Wiring Diagram

Wiring Diagram

NGEC0998

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC998

EC-1109

EL IDX

DTC P1464 FUEL LEVEL SENSOR

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

CHECK FUEL LEVEL SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 66 and body ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

1. Check the following. 쐌 Harness connectors F36, M81 쐌 Harness for open and short between ECM and body ground 䊳

3

Replace open circuit or short to power in harness or connectors.

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “Fuel Level Sensor Unit Check”. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace fuel level sensor unit.

4

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739 OK or NG 䊳

INSPECTION END

EC-1110

=NGEC0999

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33E Description

Description

NGEC0872

COMPONENT DESCRIPTION

SEF186S

NGEC0872S01

The vacuum cut valve and vacuum cut valve bypass valve are installed in parallel on the EVAP purge line between the fuel tank and the EVAP canister. The vacuum cut valve prevents the intake manifold vacuum from being applied to the fuel tank. The vacuum cut valve bypass valve is a solenoid type valve and generally remains closed. It opens only for on board diagnosis. The vacuum cut valve bypass valve responds to signals from the ECM. When the ECM sends an ON (ground) signal, the valve is opened. The vacuum cut valve is then bypassed to apply intake manifold vacuum to the fuel tank.

EVAPORATIVE EMISSION SYSTEM DIAGRAM

GI MA EM LC

NGEC0872S02

FE CL MT AT TF PD SEC666C

CONSULT-II Reference Value in Data Monitor Mode

AX SU

NGEC0873

Specification data are reference values. MONITOR ITEM VC/V BYPASS/V

CONDITION

BR

SPECIFICATION

쐌 Ignition switch: ON

OFF

ST

ECM Terminals and Reference Value

NGEC0874

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 the ECM terminals, such as the ground. TERMINAL NO. 120

WIRE COLOR P/B

ITEM Vacuum cut valve bypass valve

CONDITION

[Ignition switch ON]

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

RS BT HA SC EL

EC-1111

IDX

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0875

Malfunction is detected when an improper voltage signal is sent to ECM through vacuum cut valve bypass valve.

POSSIBLE CAUSE 쐌 쐌

NGEC0875S01

Harness or connectors (The vacuum cut valve bypass valve circuit is open or shorted.) Vacuum cut valve bypass valve

DTC Confirmation Procedure

NGEC0876

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at idle speed.

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1114. With GST Follow the procedure “With CONSULT-II”. 1) 2) 3) 4)

SEF058Y

EC-1112

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33E Wiring Diagram

Wiring Diagram

NGEC0877

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC999

EC-1113

EL IDX

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0878

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

CHECK VACUUM CUT VALVE BYPASS VALVE CIRCUIT

With CONSULT-II 1. Turn ignition switch OFF and then ON. 2. Select “VC/V BYPASS/V” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON/OFF” on CONSULT-II screen.

SEF014Z

4. Make sure that clicking sound is heard from the vacuum cut valve bypass valve. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 3.

EC-1114

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK VACUUM CUT VALVE BYPASS VALUE POWER SUPPLY CIRCUIT

Without CONSULT-II 1. Turn ignition switch OFF. 2. Disconnect vacuum cut valve bypass valve harness connector.

GI MA EM LC

SEF186S

FE

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

CL MT AT SEF659W

Voltage: Battery voltage

TF

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

PD AX

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M67, B101 and B113, C3 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between vacuum cut valve bypass valve and fuse 䊳

5

Repair harness or connectors.

CHECK VACUUM CUT VALVE BYPASS VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 120 and valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

SU BR ST RS BT HA SC EL

EC-1115

IDX

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33E

Diagnostic Procedure (Cont’d)

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C3, B113 and B101, M67 쐌 Harness connectors M81, F36 쐌 Harness for open or short between vacuum cut valve bypass valve and ECM 䊳

7

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK VACUUM CUT VALVE BYPASS VALVE

With CONSULT-II 1. Perform “VC/V BYPASS/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time under the following conditions.

SEF016Z

Without CONSULT-II 1. Check air passage continuity and operation delay time under the following conditions.

SEF351Q

MTBL0242

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace vacuum cut valve bypass valve.

8

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-1116

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33E Description

Description

NGEC0879

COMPONENT DESCRIPTION

SEF186S

NGEC0879S01

The vacuum cut valve and vacuum cut valve bypass valve are installed in parallel on the EVAP purge line between the fuel tank and the EVAP canister. The vacuum cut valve prevents the intake manifold vacuum from being applied to the fuel tank. The vacuum cut valve bypass valve is a solenoid type valve and generally remains closed. It opens only for on board diagnosis. The vacuum cut valve bypass valve responds to signals from the ECM. When the ECM sends an ON (ground) signal, the valve is opened. The vacuum cut valve is then bypassed to apply intake manifold vacuum to the fuel tank.

EVAPORATIVE EMISSION SYSTEM DIAGRAM

GI MA EM LC

NGEC0879S02

FE CL MT AT TF PD SEC666C

CONSULT-II Reference Value in Data Monitor Mode

AX SU

NGEC0880

Specification data are reference values. MONITOR ITEM VC/V BYPASS/V

CONDITION

BR

SPECIFICATION

쐌 Ignition switch: ON

OFF

ST

ECM Terminals and Reference Value

NGEC0881

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 the ECM terminals, such as the ground. TERMINAL NO. 120

WIRE COLOR P/B

ITEM Vacuum cut valve bypass valve

CONDITION

[Ignition switch ON]

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

RS BT HA SC EL

EC-1117

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33E

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC0882

Malfunction is detected when vacuum cut valve bypass valve does not operate properly.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC0882S01

Vacuum cut valve bypass valve Vacuum cut valve Bypass hoses for clogging EVAP control system pressure sensor and circuit EVAP canister vent control valve Hose between fuel tank and vacuum cut valve clogged Hose between vacuum cut valve and EVAP canister clogged EVAP canister EVAP purge port of fuel tank for clogging

DTC Confirmation Procedure

SEF210Y

NGEC0883

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 5 seconds before conducting the next test. TESTING CONDITION: Always perform test at a temperature of 5 to 30°C (41 to 86°F). With CONSULT-II 1) Turn ignition switch ON. 2) Start engine and warm it up to normal operating temperature. 3) Turn ignition switch OFF and wait at least 5 seconds. 4) Start engine and let it idle for at least 70 seconds. 5) Select “VC CUT/V BP/V P1491” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. 6) Touch “START”. 7) 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 at least 30 seconds.)

SEF211Y

ENG SPEED

More than 500 rpm

Selector lever

Suitable position

Vehicle speed

More than 37 km/h (23 MPH)

B/FUEL SCHDL

1.0 - 10.0 msec

8)

If “TESTING” is not displayed after 5 minutes, retry from step 3. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-1121.

SEF239Y

EC-1118

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33E

Overall Function Check

Overall Function Check

NGEC0884

Use this procedure to check the overall function of vacuum cut valve bypass valve. During this check, the 1st trip DTC might not be confirmed. Without CONSULT-II 1) Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. 2) Apply vacuum to port A and check that there is no suction from port B. 3) Apply vacuum to port B and check that there is suction from port A. 4) Blow air in port B and check that there is a resistance to flow out of port A. 5) Supply battery voltage to the terminal. 6) Blow air in port A and check that air flows freely out of port B. 7) Blow air in port B and check that air flows freely out of port A. 8) If NG, go to “Diagnostic Procedure”, EC-1121.

GI MA EM LC

FE CL MT

SEF530Q

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1119

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33E

Wiring Diagram

Wiring Diagram

NGEC0885

LEC999

EC-1120

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0886

INSPECTION START

GI

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2 1. 2. 3. 4. 5. 6. 7. 8. 9.

MA EM

CHECK VACUUM CUT VALVE BYPASS VALVE OPERATION

LC

With CONSULT-II Turn ignition switch OFF. Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Turn ignition switch ON. Select “VC/V BYPASS/V” in “ACTIVE TEST” mode with CONSULT-II and touch “ON”. Blow air in port A and check that air flows freely out of port B. Blow air in port B and check that air flows freely out of port A.

FE CL MT AT TF SEF017Z

PD

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 5.

AX SU BR ST RS BT HA SC EL

EC-1121

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33E

Diagnostic Procedure (Cont’d)

3 1. 2. 3. 4. 5. 6. 7. 8. 9.

CHECK VACUUM CUT VALVE BYPASS VALVE OPERATION Without CONSULT-II Turn ignition switch OFF. Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Disconnect vacuum cut valve bypass valve harness connector. Supply battery voltage to the terminal. Blow air in port A and check that air flows freely out of port B. Blow air in port B and check that air flows freely out of port A.

SEF914U

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 5.

4

CHECK EVAP PURGE LINE

1. Check EVAP purge line between EVAP canister and fuel tank for clogging or disconnection. 2. Check EVAP purge port of fuel tank for clogging. 3. Check EVAP canister. Refer to EC-627. OK or NG OK

䊳

GO TO 8.

NG (Step 1)

䊳

Repair it.

NG (Step 2)

䊳

Clean EVAP purge port.

NG (Step 3)

䊳

Replace EVAP canister.

5

CHECK BYPASS HOSE

Check bypass hoses for clogging. OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair or replace hoses.

EC-1122

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33E

Diagnostic Procedure (Cont’d)

6

CHECK VACUUM CUT VALVE BYPASS VALVE

With CONSULT-II 1. Perform “VC/V BYPASS/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time under the following conditions.

GI MA EM LC

SEF016Z

FE

1. Check air passage continuity and operation delay time under the following conditions. Without CONSULT-II

CL MT AT TF SEF351Q

PD AX MTBL0242

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace vacuum cut valve bypass valve.

SU BR ST RS BT HA SC EL

EC-1123

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK VACUUM CUT VALVE

Check vacuum cut valve as follows:

SEF379Q

1. 2. 3. 4. 5. 6. 7.

Plug port C and D with fingers. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Open port C and D. Blow air in port A check that air flows freely out of port C. Blow air in port B check that air flows freely out of port D. OK or NG

OK

䊳

GO TO 8.

NG

䊳

Replace vacuum cut valve.

8

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

1. Turn ignition switch OFF. 2. Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair it

9

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

AEC651A

2. Check connectors for water. Water should not exist. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

EC-1124

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33E

Diagnostic Procedure (Cont’d)

10

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR FUNCTION

Refer to “DTC Confirmation Procedure” for DTC P0452, P0453, EC-953.

GI

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP control system pressure sensor.

11

MA EM

CHECK EVAP CANISTER VENT CONTROL VALVE

Check air passage continuity. With CONSULT-II Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

LC

FE CL MT SEF991Y

Without CONSULT-II

AT TF MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

PD AX SU BR ST

AEC783A

Make sure new O-ring is installed properly.

RS

OK or NG

BT

OK

䊳

GO TO 12.

NG

䊳

Replace EVAP canister vent control valve.

HA 12

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

SC

INSPECTION END

EL

EC-1125

IDX

DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE

VG33E

Component Description

Component Description

NGEC0887

The malfunction information related to A/T (Automatic Transmission) 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 A/T related repair.

ECM Terminals and Reference Value

NGEC0888

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 the ECM terminals, such as the ground. TERMINAL NO. 7

WIRE COLOR G/B

ITEM

CONDITION [Ignition switch ON] [Engine is running]

A/T check signal

On Board Diagnosis Logic

DATA (DC Voltage)

0 - 3.0V

NGEC0889

Malfunction is detected when an incorrect signal from TCM (Transmission control module) is sent to ECM.

POSSIBLE CAUSE 쐌 쐌 쐌

DTC Confirmation Procedure

SEF985Y

NGEC0889S01

Harness or connectors [The communication line circuit between ECM and TCM (Transmission control module) is open or shorted.] Dead (Weak) battery TCM (Transmission control module)

NGEC0890

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle. With CONSULT-II 1) Turn ignition switch ON. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and wait at least 40 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1128. With GST Follow the procedure “With CONSULT-II”.

EC-1126

DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE

VG33E Wiring Diagram

Wiring Diagram

NGEC0891

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC674

EC-1127

EL IDX

DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0892

CHECK A/T DIAGNOSIS COMMUNICATION LINE INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector and TCM (Transmission Control Module) harness connector.

SEF324V

AEC655A

3. Check harness continuity between ECM terminal 7 and TCM (Transmission Control Module) terminal 15. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness for open or short between ECM and TCM (Transmission Control Module) 䊳

3

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-1128

DTC P1706 PNP SWITCH

VG33E Component Description

Component Description

NGEC0893

When the gear position is “P” (A/T models only) or “N”, park/neutral position (PNP) switch is “ON”. ECM detects the position because the continuity of the line (the “ON” signal) exists. For A/T models, the park/neutral position (PNP) switch assembly also includes a transmission range switch to detect selector lever position.

GI MA EM LC

AEC877A

CONSULT-II Reference Value in Data Monitor Mode

NGEC0894

Specification data are reference values. MONITOR ITEM P/N POSI SW

CONDITION 쐌 Ignition switch: ON

SPECIFICATION

Shift lever: “P” or “N”

ON

Except above

OFF

FE CL

ECM Terminals and Reference Value

NGEC0895

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 the ECM terminals, such as the ground. TERMINAL NO.

22

WIRE COLOR

L/B

ITEM

CONDITION

[Ignition switch ON] 쐌 Gear position is “N” or “P” (A/T models) Park/neutral position (PNP) 쐌 Gear position is neutral (M/T models) switch [Ignition switch ON] 쐌 Except the above gear position

DATA (DC Voltage)

MT AT TF PD

Approximately 0V

AX

Approximately 5V

SU BR ST RS

On Board Diagnosis Logic

NGEC0896

Malfunction is detected when the signal of the park/neutral position (PNP) switch is not changed in the process of engine starting and driving.

POSSIBLE CAUSE 쐌 쐌

NGEC0896S01

Harness or connectors [The park/neutral position (PNP) switch circuit is open or shorted.] Park/neutral position (PNP) switch

EC-1129

BT HA SC EL IDX

DTC P1706 PNP SWITCH

VG33E

DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC0897

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 5 seconds before conducting the next test.

With CONSULT-II 1) Turn ignition switch ON. 2) Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions. Position (Selector lever) “N” and “P” position

ON

Except the above position

OFF

SEF212Y

3) 4) 5)

SEF213Y

Known good signal

If NG, go to “Diagnostic Procedure”, EC-1133. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds.

ENG SPEED

1,600 - 2,700 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

3.3 - 13 msec

VHCL SPEED SE

More than 64 km/h (40 MPH)

Selector lever

Suitable position

6)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1133.

EC-1130

DTC P1706 PNP SWITCH

VG33E Overall Function Check

Overall Function Check

=NGEC0898

Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Turn ignition switch ON. 2) Check voltage between ECM terminal 22 and body ground under the following conditions. Condition (Gear position) SEF877U

MA EM

Voltage (V) (Known-good data)

“P” and “N” position

Approx. 0

Except the above position

Approx. 5

3)

GI

LC

If NG, go to “Diagnostic Procedure”, EC-1133.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1131

IDX

DTC P1706 PNP SWITCH

VG33E

Wiring Diagram

Wiring Diagram

NGEC0899

WEC001A

EC-1132

DTC P1706 PNP SWITCH

VG33E Diagnostic Procedure

Diagnostic Procedure FOR M/T MODELS 1

NGEC0900 NGEC0900S01

GI

CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect park/neutral position (PNP) switch harness connector.

MA EM LC

AEC877A

3. Check harness continuity between PNP switch terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power.

FE CL

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

MT AT

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F201, F43 쐌 Harness for open between park/neutral position (PNP) switch and engine ground 䊳

3

Repair open circuit or short to power in harness or connectors.

CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 22 and PNP switch 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

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

PD AX SU BR ST

DETECT MALFUNCTIONING PART

RS

Check the following. 쐌 Harness connectors F43, F201 쐌 Harness for open or short between ECM and park/neutral position (PNP) switch 䊳

TF

BT

Repair open circuit or short to ground or short to power in harness or connectors.

HA 5

CHECK PARK/NEUTRAL POSITION (PNP) SWITCH

Refer to “Position Switch Check”, “ON-VEHICLE SERVICE”, MT-8.

SC

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace park/neutral position (PNP) switch.

EC-1133

EL IDX

DTC P1706 PNP SWITCH Diagnostic Procedure (Cont’d)

6

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-1134

VG33E

DTC P1706 PNP SWITCH

VG33E Diagnostic Procedure (Cont’d)

FOR A/T MODELS 1 1. 2. 3. 4. 5.

=NGEC0900S02

CHECK PNP SWITCH POWER SUPPLY CIRCUIT-I

GI

Turn ignition switch OFF. Disconnect park/neutral position (PNP) relay. Turn ignition switch ON. Shift selector lever to “P” or “N” position. Check voltage between terminal 2 and ground with CONSULT-II or tester.

MA EM LC

SEF661W

FE

Voltage: Battery voltage OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 2.

2

CL MT

CHECK PNP SWITCH POWER SUPPLY CIRCUIT-II

AT

1. Turn ignition switch “OFF. 2. Disconnect park/neutral position (PNP) switch harness connector.

TF PD AX SU AEC662A

3. Check harness continuity between park/neutral position (PNP) switch terminal 2 and park/neutral position (PNP) relay terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power.

BR ST

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

3

RS

CHECK PNP SWITCH POWER SUPPLY CIRCUIT-III

1. Turn ignition switch ON. 2. Check voltage between park/neutral position (PNP) switch terminal 1 and ground with CONSULT-II or tester. Refer to Wiring Diagram. Voltage: Battery voltage OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

BT HA SC EL

EC-1135

IDX

DTC P1706 PNP SWITCH

VG33E

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between park/neutral position (PNP) switch and fuse 䊳

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK PARK/NEUTRAL POSITION (PNP) SWITCH

Refer to “Component Inspection”, AT-109. OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace park/neutral position (PNP) switch.

6

CHECK PNP RELAY GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between relay terminals 1, 6 and body ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 8.

NG (With power door lock)

䊳

GO TO 7.

NG (Without power door lock)

䊳

Repair open circuit or short to power in harness or connectors.

7

DETECT MALFUNCTIONING PART

Check the circuit between park/neutral position (PNP) relay and body ground. Refer to “STARTING SYSTEM”, SC-10. OK or NG OK

䊳

GO TO 11.

NG

䊳

Repair or replace.

8

CHECK PNP RELAY INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 22 and relay terminal 7. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 10.

NG

䊳

GO TO 9.

9

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F36, M81 쐌 Harness connectors M65, E43 쐌 Harness for open or short between ECM and park/neutral position (PNP) relay 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1136

DTC P1706 PNP SWITCH

VG33E Diagnostic Procedure (Cont’d)

10

CHECK PARK/NEUTRAL POSITION (PNP) RELAY

1. Apply 12V direct current between park/neutral position (PNP) relay terminals 1 and 2. 2. Check continuity between park/neutral position (PNP) relay terminals 3 and 5, 6 and 7.

GI MA EM LC

SEC202B

12V (1 and 2) applied: Continuity should exist. No voltage applied: Continuity should not exist.

FE

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace park/neutral position (PNP) relay.

CL MT

11

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

AT

INSPECTION END

TF PD AX SU BR ST RS BT HA SC EL

EC-1137

IDX

IGNITION SIGNAL

VG33E

Component Description

Component Description

NGEC0812

IGNITION COIL & POWER TRANSISTOR

SEF928V

NGEC0812S01

The power transistor switches on and off the ignition coil primary circuit according to the ECM signal. As the primary circuit is turned on and off, the proper high voltage is induced in the secondary circuit. The distributor is not repairable except for the distributor cap and rotor head. NOTE: The rotor screw which secures the distributor rotor head to the distributor shaft must be torqued properly. : 3.6±0.3 N·m (37±3 kg-cm, 32±3 in-lb)

ECM Terminals and Reference Value

NGEC0813

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) Approximately 0.7V

[Engine is running] 쐌 Idle speed

SEF988U

1

PU/W

Ignition signal

1.1 - 1.5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

SEF989U

EC-1138

IGNITION SIGNAL

VG33E Wiring Diagram

Wiring Diagram

NGEC0816

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC182A

EC-1139

EL IDX

IGNITION SIGNAL

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0817

INSPECTION START

Turn ignition switch OFF, and restart engine. Is engine running? Yes or No Yes (With CONSULT-II)

䊳

GO TO 2.

Yes (Without CONSULTII)

䊳

GO TO 3.

No

䊳

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.

SEF981Z

OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Let engine idle. 2. Read the voltage signal between ECM terminal 1 and ground with an oscilloscope. 3. Verify that the oscilloscope screen shows the signal wave as shown below.

SEC073C

OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

EC-1140

IGNITION SIGNAL

VG33E Diagnostic Procedure (Cont’d)

4

CHECK IGNITION COIL POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect ignition coil harness connector.

GI MA EM LC

AEC656A

3. Turn ignition switch ON. 4. Check voltage between terminal 7 and ground with CONSULT-II or tester.

FE CL MT AT SEF721U

Voltage: Battery voltage OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

PD AX

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M59, F27 쐌 Harness for open or short between ignition coil and ignition switch 䊳

6

TF

SU

Repair harness or connectors.

BR

CHECK POWER TRANSISTOR GROUND CIRCUIT FOR OPEN AND SHORT

ST

1. Turn ignition switch OFF. 2. Disconnect power transistor harness connector. 3. Check harness continuity between power transistor terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

RS BT HA SC EL

EC-1141

IDX

IGNITION SIGNAL

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK POWER TRANSISTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 1 and power transistor 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

䊳

GO TO 8.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

8

CHECK IGNITION COIL

1. Disconnect ignition coil harness connector. 2. Check resistance as shown in the figure.

SEF013S

AEC657A

MTBL0248

For checking secondary coil, remove distributor cap and measure resistance between coil tower metal tip 9 and terminal 7. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace distributor assembly.

EC-1142

IGNITION SIGNAL

VG33E Diagnostic Procedure (Cont’d)

9

CHECK POWER TRANSISTOR

1. Disconnect camshaft position sensor & power transistor harness connector and ignition coil harness connector. 2. Check power transistor resistance between terminals 2 and 8.

GI MA EM LC

SEF015S

FE MTBL0249

CL

OK or NG

MT

OK

䊳

GO TO 10.

NG

䊳

Replace distributor assembly.

AT 10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

TF

INSPECTION END

PD AX SU BR ST RS BT HA SC EL

EC-1143

IDX

INJECTOR

VG33E

Component Description

Component Description

NGEC0909

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 ball 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. SEF812J

CONSULT-II Reference Value in Data Monitor Mode

NGEC0910

Specification data are reference values. MONITOR ITEM

CONDITION

INJ PULSE-B2 INJ PULSE-B1

쐌 쐌 쐌 쐌

B/FUEL SCHDL

ditto

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

SPECIFICATION

Idle

2.4 - 3.7 msec

2,000 rpm

1.9 - 3.3 msec

Idle

1.0 - 1.6 msec

2,000 rpm

0.7 - 1.4 msec

ECM Terminals and Reference Value

NGEC0911

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed 102 104 106 109 111 113

W/B W/R W/G W/L W/PU W

Injector Injector Injector Injector Injector Injector

No. No. No. No. No. No.

1 3 5 2 4 6

SEF007V

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

SEF008V

EC-1144

INJECTOR

VG33E Wiring Diagram

Wiring Diagram

NGEC0912

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC003A

EC-1145

EL IDX

INJECTOR

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0913

INSPECTION START

Turn ignition switch to START. Is any cylinder ignited? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

CHECK OVERALL FUNCTION

With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

SEF806Z

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

䊳

INSPECTION END

NG

䊳

GO TO 3.

EC-1146

INJECTOR

VG33E Diagnostic Procedure (Cont’d)

3

CHECK INJECTOR POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect injector harness connector. 3. Check voltage between terminal 1 and ground with CONSULT-II or tester.

GI MA EM LC SEF671W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

CL

DETECT MALFUNCTIONING PART

MT

Check the following. 쐌 Harness connectors M59, F27 쐌 Harness connectors F37, F101 쐌 Fuse block (J/B) connector M26 쐌 10A fuse 쐌 Harness for open or short between injector and fuse 䊳

5

FE

AT

Repair harness or connectors.

CHECK INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between injector harness connector terminal 2 and ECM terminals 102, 104, 106, 109, 111, 113. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

TF PD AX SU

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

BR ST

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F37, F101 쐌 Harness connectors F38, F102 쐌 Harness for open or short between ECM and injector 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

RS BT HA SC EL

EC-1147

IDX

INJECTOR

VG33E

Diagnostic Procedure (Cont’d)

7

CHECK INJECTOR

1. Disconnect injector harness connector. 2. Check resistance between terminals as shown in the figure.

SEF625V

Resistance: 10 - 14Ω [at 25°C (77°F)] OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace injector.

8

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-1148

START SIGNAL

VG33E

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NGEC0914

Specification data are reference values. MONITOR ITEM START SIGNAL

CONDITION

SPECIFICATION

쐌 Ignition switch: ON , START , ON

MA

OFF , ON , OFF

ECM Terminals and Reference Value

NGEC0915

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

20

L/OR

ITEM

GI

CONDITION

LC

DATA (DC Voltage)

[Ignition switch ON]

Approximately 0V

[Ignition switch START]

BATTERY VOLTAGE (11 - 14V)

Start signal

EM

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1149

IDX

START SIGNAL

VG33E

Wiring Diagram

Wiring Diagram

NGEC0916

AEC975A

EC-1150

START SIGNAL

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0917

INSPECTION START

GI

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

MA EM

CHECK OVERALL FUNCTION

LC

With CONSULT-II 1. Turn ignition switch ON. 2. Check “START SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.

FE CL MT SEF072Y

AT

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

3

TF PD

CHECK OVERALL FUNCTION

Without CONSULT-II Check voltage between ECM terminal 20 and ground under the following conditions.

AX SU BR ST SEF733U

RS MTBL0148

BT

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

HA SC EL

EC-1151

IDX

START SIGNAL

VG33E

Diagnostic Procedure (Cont’d)

4

CHECK STARTING SYSTEM

Turn ignition switch OFF, then turn it to START. Does starter motor operate? Yes or No Yes

䊳

GO TO 5.

No

䊳

Refer to “STARTING SYSTEM”, SC-10.

5

CHECK FUSE

1. Turn ignition switch OFF. 2. Disconnect 7.5A fuse. 3. Check if 7.5A fuse is OK. OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace 7.5A fuse.

6

CHECK START SIGNAL INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 20 and fuse block. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuse 䊳

8

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-1152

FUEL PUMP

VG33E System Description

System Description Sensor

Input Signal to ECM

Camshaft position sensor

Engine speed

Ignition switch

Start signal

NGEC0918

ECM function Fuel pump control

GI

Actuator

MA

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 120° signal from the camshaft position sensor, it knows that the engine is rotating, and causes the pump to operate. If the 120° 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

EM LC

Fuel pump operation

Ignition switch is turned to ON.

Operates for 5 seconds

Engine running and cranking

FE

Operates

When engine is stopped

Stops in 1.5 seconds

Except as shown above

Stops

CL MT

Component Description

NGEC0919

The fuel pump with a fuel damper is an in-tank type (the pump and damper are located in the fuel tank).

AT TF PD AX

SEF018S

CONSULT-II Reference Value in Data Monitor Mode

SU

NGEC0920

Specification data are reference values. MONITOR ITEM

FUEL PUMP RLY

CONDITION

SPECIFICATION

쐌 Ignition switch is turned to ON. (Operates for 5 seconds.) 쐌 Engine running and cranking

ON

Except as shown above

OFF

BR ST RS BT HA SC EL

EC-1153

IDX

FUEL PUMP

VG33E

ECM Terminals and Reference Value

ECM Terminals and Reference Value

=NGEC0921

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

11

W/R

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch ON] 쐌 For 5 seconds after turning ignition switch “ON” [Engine is running]

0 - 1V

[Ignition switch ON] 쐌 More than 5 seconds after turning ignition switch ON

BATTERY VOLTAGE (11 - 14V)

Fuel pump relay

EC-1154

FUEL PUMP

VG33E Wiring Diagram

Wiring Diagram

NGEC0922

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC509

EC-1155

EL IDX

FUEL PUMP

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0923

CHECK OVERALL FUNCTION

1. Turn ignition switch ON. 2. Pinch fuel feed hose with fingers.

AEC663A

Fuel pressure pulsation should be felt on the fuel feed hose for 5 seconds after ignition switch is turned ON. OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 2.

2

CHECK FUEL PUMP RELAY POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect fuel pump relay.

SEF349V

3. Turn ignition switch ON. 4. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.

SEF674W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

EC-1156

FUEL PUMP

VG33E Diagnostic Procedure (Cont’d)

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuse block (J/B) connector M31 쐌 15A fuse 쐌 Harness for open or short between fuse and fuel pump relay 䊳

GI MA

Repair harness or connectors.

EM 4

CHECK FUEL PUMP POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect fuel pump harness connector.

LC

FE CL AEC933A

3. Check harness continuity between fuel pump terminal 2 and body ground, fuel pump terminal 1 and fuel pump relay 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

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

Check the following. 쐌 Harness connectors M67, B101 쐌 Harness for open or short between fuel pump and body ground 쐌 Harness for open or short between fuel pump and fuel pump relay

6

AT TF PD

DETECT MALFUNCTIONING PART

䊳

MT

AX SU

Repair open circuit or short to ground or short to power in harness or connectors.

BR

CHECK FUEL PUMP RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 11 and fuel pump relay terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

ST RS

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

BT HA

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuel pump relay 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1157

SC EL IDX

FUEL PUMP

VG33E

Diagnostic Procedure (Cont’d)

8

CHECK FUEL PUMP RELAY

With CONSULT-II 1. Reconnect fuel pump relay, fuel pump harness connector and ECM harness connector. 2. Turn ignition switch ON. 3. Turn fuel pump relay “ON” and “OFF” in “ACTIVE TEST” mode with CONSULT-II and check operating sound.

SEF073Y

Without CONSULT-II Check continuity between terminals 3 and 5.

SEF511P

12V direct current supply between terminals 1 and 2 Continuity exists No current supply Continuity does not exist OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace fuel pump relay.

EC-1158

FUEL PUMP

VG33E Diagnostic Procedure (Cont’d)

9

CHECK FUEL PUMP

1. Disconnect fuel pump harness connector. 2. Check resistance between terminals 1 and 2.

GI MA EM LC

SEF022S

Resistance: 0.2 - 5.0Ω [at 25°C (77°F)] OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace fuel pump.

10

FE CL MT

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1159

IDX

POWER STEERING OIL PRESSURE SWITCH

VG33E

Component Description

Component Description

NGEC0924

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.

LEC521

CONSULT-II Reference Value in Data Monitor Mode

NGEC0925

Specification data are reference values. MONITOR ITEM

PW/ST SIGNAL

CONDITION 쐌 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

NGEC0926

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

39

GY/R

ITEM

Power steering oil pressure switch

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Steering wheel is being fully turned

0V

[Engine is running] 쐌 Steering wheel is not being turned

Approximately 5V

EC-1160

POWER STEERING OIL PRESSURE SWITCH

VG33E Wiring Diagram

Wiring Diagram

NGEC0927

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC677

EC-1161

EL IDX

POWER STEERING OIL PRESSURE SWITCH

VG33E

Diagnostic Procedure

Diagnostic Procedure 1

NGEC0928

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

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.

SEF228Y

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Start engine. 2. Check voltage between ECM terminal 39 and ground.

SEF739U

MTBL0145

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

EC-1162

POWER STEERING OIL PRESSURE SWITCH

VG33E

Diagnostic Procedure (Cont’d)

4

CHECK POWER STEERING OIL PRESSURE SWITCH GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect power steering oil pressure switch harness connector.

GI MA EM LC

LEC521

3. Check harness continuity between switch terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power.

FE

OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair open circuit or short to power in harness or connectors.

5

CL MT

CHECK POWER STEERING OIL PRESSURE SWITCH INPUT SIGNAL CIRCUIT

AT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 39 and switch terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

TF

OK or NG

PD

OK

䊳

GO TO 6.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

AX 6

CHECK POWER STEERING OIL PRESSURE SWITCH

1. Disconnect power steering oil pressure switch harness connector then start engine. 2. Check continuity between terminals 1 and 2.

SU BR ST RS BT SEF679W

HA MTBL0254

SC

OK or NG

EL

OK

䊳

GO TO 7.

NG

䊳

Replace power steering oil pressure switch.

EC-1163

IDX

POWER STEERING OIL PRESSURE SWITCH Diagnostic Procedure (Cont’d)

7

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-1164

VG33E

IACV-FICD SOLENOID VALVE

VG33E Component Description

Component Description

NGEC0929

When the air conditioner is on, the IACV-FICD solenoid valve supplies additional air to adjust to the increased load. For more information, refer to “FAST IDLE CONTROL DEVICE (FICD)”, HA-84.

GI MA EM LC

LEC515

ECM Terminals and Reference Value

NGEC0930

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

9

12

21

B/Y

P

G/R

ITEM

Ambient air temperature switch

Air conditioner relay

Air conditioner switch

CONDITION

DATA (DC Voltage)

FE CL

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is above 25°C (77°F) 쐌 Air conditioner is operating

0V

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is below 19°C (66°F) 쐌 Air conditioner is operating

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is below 19°C (66°F) 쐌 Air conditioner is not operating

Approximately 5V

[Engine is running] 쐌 Both A/C switch and blower fan switch are “ON”*

0 - 1V

[Engine is running] 쐌 A/C switch is “OFF”

BATTERY VOLTAGE (11 - 14V)

SU

[Engine is running] 쐌 Both A/C switch and blower fan switch are “ON” (Compressor operates)*

Approximately 0V

BR

[Engine is running] 쐌 Air conditioner switch is “OFF”

Approximately 5V

ST

*: Any mode except “OFF”, ambient air temperature is above 25°C (77°F).

MT AT TF PD AX

RS BT HA SC EL

EC-1165

IDX

IACV-FICD SOLENOID VALVE

VG33E

Wiring Diagram

Wiring Diagram

NGEC0931

LEC510

EC-1166

IACV-FICD SOLENOID VALVE

VG33E Diagnostic Procedure

Diagnostic Procedure 1

NGEC0932

CHECK OVERALL FUNCTION

GI

1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm (in “N” position) If NG, adjust idle speed. 3. Turn air conditioner switch and blower fan switch ON. 4. Recheck idle speed.

MA EM LC

FE SEF742U

850 rpm or more (in “P” or “N” position)

CL OK or NG

OK

䊳

INSPECTION END

NG

䊳

GO TO 2.

2

MT AT

CHECK AIR CONDITIONER FUNCTION

Check if air conditioner compressor functions normally. OK or NG OK

䊳

GO TO 3.

NG

䊳

Refer to “Symptom Table”, “TROUBLE DIAGNOSES”, HA-28.

TF PD AX SU BR ST RS BT HA SC EL

EC-1167

IDX

IACV-FICD SOLENOID VALVE

VG33E

Diagnostic Procedure (Cont’d)

3

CHECK IACV-FICD SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn air conditioner switch and blower fan switch OFF. 2. Stop engine. 3. Disconnect IACV-FICD solenoid valve harness connector.

LEC515

4. Start engine, then turn air conditioner switch and blower fan switch ON. 5. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF680W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Harness for open or short between IACV-FICD solenoid valve and harness connector F27 䊳

5

Repair harness or connectors.

CHECK IACV-FICD SOLENOID VALVE GROUND CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect ambient air temperature switch harness connector. 3. Check harness continuity between switch terminal 1 and body ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 7.

EC-1168

IACV-FICD SOLENOID VALVE

VG33E Diagnostic Procedure (Cont’d)

6

CHECK IACV-FICD SOLENOID VALVE GROUND CIRCUIT WITH DIODE

1. Check harness continuity between switch terminal 2 and solenoid valve terminal 1.

GI MA EM LC SEF160X

Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

CL

DETECT MALFUNCTIONING PART

MT

Check the following. 쐌 Harness connectors F38, F102 쐌 Harness connectors F36, M81 쐌 Harness connectors M65, E43 쐌 Diode F35 쐌 Harness for open or short between ambient air temperature switch and body ground 쐌 Harness for open or short between IACV-FICD solenoid valve and ambient air temperature switch 䊳

FE

Repair open circuit or short to ground or short to power in harness or connectors.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1169

IDX

IACV-FICD SOLENOID VALVE

VG33E

Diagnostic Procedure (Cont’d)

8

CHECK IACV-FICD SOLENOID VALVE

Disconnect IACV-FICD solenoid valve harness connector. 쐌 Check for clicking sound when applying 12V direct current to terminals.

SEF682W

쐌 Check plunger for seizing or sticking. 쐌 Check for broken spring.

SEF097K

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace IACV-FICD solenoid valve.

9

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-739. 䊳

INSPECTION END

EC-1170

MIL & DATA LINK CONNECTORS

VG33E Wiring Diagram

Wiring Diagram

NGEC0933

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC183A

EC-1171

EL IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

VG33E

Fuel Pressure Regulator

Fuel Pressure Regulator

NGEC0934

2

Fuel pressure at idling kPa (kg/cm , psi) Vacuum hose is connected

Approximately 235 (2.4, 34)

Vacuum hose is disconnected

Approximately 294 (3.0, 43)

Idle Speed and Ignition Timing

NGEC0935

Base idle speed*1

No-load*4 (in “P” or N” position)

700±50 rpm

Target idle speed*2

No-load*4 (in “P” or N” position)

750±50 rpm

Air conditioner: ON

In “P” or N” position

850 rpm or more

Ignition timing*3

In “P” or N” position

10°±2° BTDC

Throttle position sensor idle position

*1: *2: *3: *4: 쐌 쐌 쐌

0.15 - 0.85V

Throttle position sensor harness connector disconnected or using CONSULT-II “WORK SUPPORT” mode Throttle position sensor harness connector connected Throttle position sensor harness connector disconnected Under the following conditions: Air conditioner switch: OFF Electric load: OFF (Lights, heater fan & rear window defogger) Steering wheel: Kept in straight-ahead position

Ignition Coil

NGEC0936

Primary voltage

12V

Primary resistance [at 20°C (68°F)]

Approximately 1.0Ω

Secondary resistance [at 20°C (68°F)]

Approximately 10 kΩ

Mass Air Flow Sensor Supply voltage

NGEC0937

Battery voltage (11 - 14)V

Output voltage at idle

1.0 - 1.7*V 3.3 - 4.8 g·m/sec at idle* 12.0 - 14.9 g·m/sec at 2,500 rpm*

Mass air flow (Using CONSULT-II or GST)

*: Engine is warmed up to normal operating temperature and running 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

Heated Oxygen Sensor 1 Heater Resistance [at 25°C (77°F)]

NGEC0938

NGEC0940

2.3 - 4.3Ω

Fuel Pump Resistance [at 25°C (77°F)]

NGEC0941

0.2 - 5.0Ω

IACV-AAC Valve Resistance [at 20°C (68°F)]

NGEC0942

Approximately 10.0Ω

EC-1172

SERVICE DATA AND SPECIFICATIONS (SDS)

VG33E Injector

Injector

NGEC0943

Resistance [at 25°C (77°F)]

GI

10 - 14Ω

Throttle Position Sensor

NGEC0945

Voltage [at normal operating temperature, engine off, ignition switch ON, (throttle opener disengaged, if so equipped)]

Throttle valve conditions

Completely closed (a)

MA EM

0.15 - 0.85V

Partially open

LC

Between (a) and (b)

Completely open (b)

3.5 - 4.7V

Calculated Load Value

NGEC0946

FE

Calculated load value % (Using CONSULT or GST) At idle

18.0 - 26.0

At 2,500 rpm

18.0 - 21.0

Intake Air Temperature Sensor Temperature °C (°F)

CL NGEC0947

MT

Resistance kΩ

20 (68)

2.1 - 2.9

80 (176)

0.27 - 0.38

Heated Oxygen Sensor 2 Heater Resistance [at 25°C (77°F)]

AT TF NGEC0948

2.3 - 4.3Ω

PD

Crankshaft Position Sensor (OBD) Resistance [at 20°C (68°F)]

NGEC0949

AX

512 - 632Ω

Fuel Tank Temperature Sensor Temperature °C (°F)

NGEC0950

SU

Resistance kΩ

20 (68)

2.3 - 2.7

50 (122)

0.79 - 0.90

BR ST RS BT HA SC EL

EC-1173

IDX

TROUBLE DIAGNOSIS — INDEX

VG33ER

Alphabetical & P No. Index for DTC

Alphabetical & P No. Index for DTC

NGEC1052

ALPHABETICAL INDEX FOR DTC

NGEC1052S01

DTC*1*2

Items (CONSULT-II screen terms)

Reference page CONSULT-II GST

Unable to access ECM

—

EC-1289

A/T 1ST GR FNCTN

P0731

AT-125

A/T 2ND GR FNCTN

P0732

AT-131

A/T 3RD GR FNCTN

P0733

AT-137

A/T 4TH GR FNCTN

P0734

AT-143

A/T COMM LINE

P0600*4

EC-1599

A/T DIAG COMM LINE

P1605

EC-1706

A/T TCC S/V FNCTN

P0744

AT-157

ATF TEMP SEN/CIRC

P0710

AT-110

CKP SEN/CIRCUIT

P0335

EC-1475

CKP SENSOR (COG)

P1336

EC-1651

CLOSED LOOP-B1

P1148

EC-1644

CLOSED LOOP-B2

P1168

EC-1644

CLOSED TP SW/CIRC

P0510

EC-1592

CMP SEN/CIRCUIT

P0340

EC-1481

CYL1 MISFIRE

P0301

EC-1462

CYL2 MISFIRE

P0302

EC-1462

CYL3 MISFIRE

P0303

EC-1462

CYL4 MISFIRE

P0304

EC-1462

CYL5 MISFIRE

P0305

EC-1462

CYL6 MISFIRE

P0306

EC-1462

ECM

P0605

EC-1604

ECT SEN/CIRCUIT

P0117*3

EC-1348

ECT SEN/CIRCUIT

P0118*3

EC-1348

ECT SENSOR

P0125

EC-1366

ENG OVER TEMP

P0217

EC-1449

ENG OVER TEMP

P1217

EC-1646

ENGINE SPEED SIG

P0725

AT-121

EVAP GROSS LEAK

P0455

EC-1543

EVAP PURG FLOW/MON

P0441

EC-1493

EVAP SMALL LEAK

P0442

EC-1505

EVAP SMALL LEAK

P1442

EC-1658

EVAP SYS PRES SEN

P0452

EC-1532

EVAP SYS PRES SEN

P0453

EC-1532

EVAP VERY SML LEAK

P0456

EC-1556

EC-1174

TROUBLE DIAGNOSIS — INDEX

VG33ER

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2

Items (CONSULT-II screen terms)

Reference page CONSULT-II GST

EVAP VERY SML LEAK

P1456

EC-1556

FTT SEN/CIRCUIT

P0182

EC-1444

FTT SEN/CIRCUIT

P0183

EC-1444

FTT SENSOR

P0181

EC-1444

FUEL LEV SEN SLOSH

P0460

EC-1570

FUEL LEVEL SEN/CIRC

P1464

EC-1687

FUEL LEVEL SENSOR

P0461

EC-1575

FUEL LEVL SEN/CIRC

P0462

EC-1577

FUEL LEVL SEN/CIRC

P0463

EC-1577

FUEL SYS-LEAN-B1

P0171

EC-1427

FUEL SYS-LEAN-B2

P0174

EC-1427

FUEL SYS-RICH-B1

P0172

EC-1436

FUEL SYS-RICH-B2

P0175

EC-1436

HO2S1 (B1)

P0132

EC-1374

HO2S1 (B1)

P0133

EC-1382

HO2S1 (B1)

P0134

EC-1396

HO2S1 (B1)

P1143

EC-1606

HO2S1 (B1)

P1144

EC-1615

HO2S1 (B2)

P0152

EC-1374

HO2S1 (B2)

P0153

EC-1382

HO2S1 (B2)

P0154

EC-1396

HO2S1 (B2)

P1163

EC-1606

HO2S1 (B2)

P1164

EC-1615

HO2S1 HTR (B1)

P0031

EC-1319

HO2S1 HTR (B1)

P0032

EC-1319

HO2S1 HTR (B2)

P0051

EC-1319

HO2S1 HTR (B2)

P0052

EC-1319

HO2S2 HTR (B1)

P0037

EC-1326

HO2S2 HTR (B1)

P0038

EC-1326

HO2S2 HTR (B2)

P0057

EC-1326

HO2S2 HTR (B2)

P0058

EC-1326

HO2S2 (B1)

P0138

EC-1407

HO2S2 (B1)

P0139

EC-1417

HO2S2 (B1)

P1146

EC-1624

HO2S2 (B1)

P1147

EC-1634

HO2S2 (B2)

P0158

EC-1407

HO2S2 (B2)

P0159

EC-1417

EC-1175

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — INDEX

VG33ER

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2

Items (CONSULT-II screen terms)

Reference page CONSULT-II GST

HO2S2 (B2)

P1166

EC-1624

HO2S2 (B2)

P1167

EC-1634

IAT SEN/CIRCUIT

P0112

EC-1343

IAT SEN/CIRCUIT

P0113

EC-1343

IAT SENSOR

P0127

EC-1343

ISC SYSTEM/CIRC

P0505

EC-1586

KNOCK SEN/CIRC-B1

P0327

EC-1471

KNOCK SEN/CIRC-B1

P0328

EC-1471

L/PRESS SOL/CIRC

P0745

AT-188

MAF SEN/CIRCUIT

P0101

EC-1334

MAF SEN/CIRCUIT

P0102*3

EC-1334

MAF SEN/CIRCUIT

P0103*3

EC-1334

MULTI CYL MISFIRE

P0300

EC-1462

NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED.

P0000

—

P-N POS SW/CIRCUIT

P1706

EC-1709

PNP SW/CIRC

P0705

AT-104

PURG VOLUME CONT/V

P0444

EC-1519

PURG VOLUME CONT/V

P0445

EC-1519

PURG VOLUME CONT/V

P1444

EC-1660

SCB/V CONT SOL/V

P0245

EC-1456

SFT SOL A/CIRC

P0750*3

AT-169

SFT SOL B/CIRC

P0755*3

AT-174

TCC SOLENOID/CIRC

P0740

AT-152

THERMSTAT FNCTN

P0128

EC-1372

TP SEN/CIRC A/T

P1705*5

TP SEN/CIRCUIT

P0121

EC-1353

TP SEN/CIRCUIT

P0122*3

EC-1353

TP SEN/CIRCUIT

P0123*3

EC-1353

TW CATALYST SYS-B1

P0420

EC-1488

TW CATALYST SYS-B2

P0430

EC-1488

VC CUT/V BYPASS/V

P1491

EC-1697

VC/V BYPASS/V

P1490

EC-1691

VEH SPD SEN/CIR AT

P0720

AT-116

VEH SPEED SEN/CIRC

P0500*5

EC-1582

VENT CONTROL VALVE

P0447

EC-1526

VENT CONTROL VALVE

P1446

EC-1672

EC-1176

AT-179

TROUBLE DIAGNOSIS — INDEX

VG33ER

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2

Items (CONSULT-II screen terms)

Reference page CONSULT-II GST

VENT CONTROL VALVE

P1448

GI

EC-1679

*1: 1st trip DTC No. 1 is the same as DTC No. *2: These numbers are prescribed by SAE J2012. *3: When the fail-safe operation occurs, the MIL illuminates. *4: This DTC is displayed with CONSULT-II only. *5: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. NOTE: Regarding D22 models, “B1” indicates bank 1, “B2” indicates bank 2.

MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1177

IDX

TROUBLE DIAGNOSIS — INDEX

VG33ER

Alphabetical & P No. Index for DTC (Cont’d)

P NO. INDEX FOR DTC

=NGEC1052S02

DTC*1*2

Items (CONSULT-II screen terms)

CONSULT-II GST —

Unable to access ECM

Reference page EC-1289

P0000

NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED.

P0031

HO2S1 HTR (B1)

EC-1319

P0032

HO2S1 HTR (B1)

EC-1319

P0037

HO2S2 HTR (B1)

EC-1326

P0038

HO2S2 HTR (B1)

EC-1326

P0051

HO2S1 HTR (B2)

EC-1319

P0052

HO2S1 HTR (B2)

EC-1319

P0057

HO2S2 HTR (B2)

EC-1326

P0058

HO2S2 HTR (B2)

EC-1326

P0101

MAF SEN/CIRCUIT

EC-1334

P0102*3

MAF SEN/CIRCUIT

EC-1334

P0103*3

MAF SEN/CIRCUIT

EC-1334

P0112

IAT SEN/CIRCUIT

EC-1343

P0113

IAT SEN/CIRCUIT

EC-1343

P0117*3

ECT SEN/CIRCUIT

EC-1348

P0118*3

ECT SEN/CIRCUIT

EC-1348

P0121

TP SEN/CIRCUIT

EC-1353

P0122*3

TP SEN/CIRCUIT

EC-1353

P0123*3

TP SEN/CIRCUIT

EC-1353

P0125

ECT SENSOR

EC-1366

P0127

IAT SENSOR

EC-1343

P0128

THERMSTAT FNCTN

EC-1372

P0132

HO2S1 (B1)

EC-1374

P0133

HO2S1 (B1)

EC-1382

P0134

HO2S1 (B1)

EC-1396

P0138

HO2S2 (B1)

EC-1407

P0139

HO2S2 (B1)

EC-1417

P0152

HO2S1 (B2)

EC-1374

P0153

HO2S1 (B2)

EC-1382

P0154

HO2S1 (B2)

EC-1396

P0158

HO2S2 (B2)

EC-1407

P0159

HO2S2 (B2)

EC-1417

P0171

FUEL SYS-LEAN-B1

EC-1427

P0172

FUEL SYS-RICH-B1

EC-1436

EC-1178

—

TROUBLE DIAGNOSIS — INDEX

VG33ER

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2

Items (CONSULT-II screen terms)

CONSULT-II GST

Reference page

P0174

FUEL SYS-LEAN-B2

EC-1427

P0175

FUEL SYS-RICH-B2

EC-1436

P0181

FTT SENSOR

EC-1444

P0182

FTT SEN/CIRCUIT

EC-1444

P0183

FTT SEN/CIRCUIT

EC-1444

P0217

ENG OVER TEMP

EC-1449

P0245

SCB/V CONT SOL/V

EC-1456

P0300

MULTI CYL MISFIRE

EC-1462

P0301

CYL1 MISFIRE

EC-1462

P0302

CYL2 MISFIRE

EC-1462

P0303

CYL3 MISFIRE

EC-1462

P0304

CYL4 MISFIRE

EC-1462

P0305

CYL5 MISFIRE

EC-1462

P0306

CYL6 MISFIRE

EC-1462

P0327

KNOCK SEN/CIRC-B1

EC-1471

P0328

KNOCK SEN/CIRC-B1

EC-1471

P0335

CKP SEN/CIRCUIT

EC-1475

P0340

CMP SEN/CIRCUIT

EC-1481

P0420

TW CATALYST SYS-B1

EC-1488

P0430

TW CATALYST SYS-B2

EC-1488

P0441

EVAP PURG FLOW/MON

EC-1493

P0442

EVAP SMALL LEAK

EC-1505

P0444

PURG VOLUME CONT/V

EC-1519

P0445

PURG VOLUME CONT/V

EC-1519

P0447

VENT CONTROL VALVE

EC-1526

P0452

EVAP SYS PRES SEN

EC-1532

P0453

EVAP SYS PRES SEN

EC-1532

P0455

EVAP GROSS LEAK

EC-1543

P0456

EVAP VERY SML LEAK

EC-1556

P0460

FUEL LEV SEN SLOSH

EC-1570

P0461

FUEL LEVEL SENSOR

EC-1575

P0462

FUEL LEVL SEN/CIRC

EC-1577

P0463

FUEL LEVL SEN/CIRC

EC-1577

P0500*5

VEH SPEED SEN/CIRC

EC-1582

P0505

ISC SYSTEM/CIRC

EC-1586

P0510

CLOSED TP SW/CIRC

EC-1592

A/T COMM LINE

EC-1599

P0600*4

EC-1179

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — INDEX

VG33ER

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2

Items (CONSULT-II screen terms)

CONSULT-II GST

Reference page

P0605

ECM

EC-1604

P0705

PNP SW/CIRC

AT-104

P0710

ATF TEMP SEN/CIRC

AT-110

P0720

VEH SPD SEN/CIR AT

AT-116

P0725

ENGINE SPEED SIG

AT-121

P0731

A/T 1ST GR FNCTN

AT-125

P0732

A/T 2ND GR FNCTN

AT-131

P0733

A/T 3RD GR FNCTN

AT-137

P0734

A/T 4TH GR FNCTN

AT-143

P0740

TCC SOLENOID/CIRC

AT-152

P0744

A/T TCC S/V FNCTN

AT-157

P0745

L/PRESS SOL/CIRC

AT-164

P0750*3

SFT SOL A/CIRC

AT-169

P0755*3

SFT SOL B/CIRC

AT-174

P1143

HO2S1 (B1)

EC-1606

P1144

HO2S1 (B1)

EC-1615

P1146

HO2S2 (B1)

EC-1624

P1147

HO2S2 (B1)

EC-1634

P1148

CLOSED LOOP-B1

EC-1644

P1163

HO2S1 (B2)

EC-1606

P1164

HO2S1 (B2)

EC-1615

P1166

HO2S2 (B2)

EC-1624

P1167

HO2S2 (B2)

EC-1634

P1168

CLOSED LOOP-B2

EC-1644

P1217

ENG OVER TEMP

EC-1646

P1336

CKP SENSOR (COG)

EC-1651

P1442

EVAP SMALL LEAK

EC-1658

P1444

PURG VOLUME CONT/V

EC-1660

P1446

VENT CONTROL VALVE

EC-1672

P1448

VENT CONTROL VALVE

EC-1679

P1456

EVAP VERY SML LEAK

EC-1556

P1464

FUEL LEVEL SEN/CIRK

EC-1687

P1490

VC/V BYPASS/V

EC-1691

P1491

VC CUT/V BYPASS/V

EC-1697

P1605

A/T DIAG COMM LINE

EC-1706

P1705*5 P1706

TP SEN/CIRC A/T

AT-179

P-N POS SW/CIRCUIT

EC-1709

EC-1180

TROUBLE DIAGNOSIS — INDEX

VG33ER

Alphabetical & P No. Index for DTC (Cont’d) DTC*1*2 CONSULT-II GST P1760

Items (CONSULT-II screen terms) O/R CLUTCH SOL/CIRC

Reference page

GI

AT-188

*1: 1st trip DTC No. 1 is the same as DTC No. *2: These numbers are prescribed by SAE J2012. *3: When the fail-safe operation occurs, the MIL illuminates. *4: This DTC is displayed with CONSULT-II only. *5: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. NOTE: Regarding D22 models, “B1” indicates bank 1, “B2” indicates bank 2.

MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1181

IDX

PRECAUTIONS

VG33ER

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGEC1053

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: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

Precautions for On Board Diagnostic (OBD) System of Engine and A/T

NGEC1054

The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the driver of a malfunction causing emission deterioration. CAUTION: 쐌 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 MIL to light up. 쐌 Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MIL to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) 쐌 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-6 “HARNESS CONNECTOR”. 쐌 Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MIL to light up due to the short circuit. 쐌 Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MIL to light up due to the malfunction of the EGR system or fuel injection system, etc. 쐌 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-1182

PRECAUTIONS

VG33ER Engine Fuel & Emission Control System

Engine Fuel & Emission Control System

NGEC1055

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC AEC045B

EC-1183

EL IDX

PRECAUTIONS

VG33ER

Precautions

Precautions

NGEC1056

쐌

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.

쐌

When connecting ECM harness connector, tighten securing bolt until the gap between orange indicators disappears. : 3 - 5 N·m (0.3 - 0.5 kg-m, 26 - 43 in-lb)

쐌

When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on ECM pin terminal, when connecting pin connectors.

쐌

Before replacing ECM, perform “ECM Terminals and Reference Value” inspection and make sure ECM functions properly. Refer to EC-1299.

쐌

After performing each TROUBLE DIAGNOSIS, perform “DTC Confirmation Procedure” or “Overall Function Check”. The DTC should not be displayed in the “DTC Confirmation Procedure” if the repair is completed. The “Overall Function Check” should be a good result if the repair is completed.

SEF289H

SEF308Q

SEF291H

MEF040D

SEF217U

EC-1184

PRECAUTIONS

VG33ER Precautions (Cont’d)

쐌

쐌

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 the ECM terminals, such as the ground.

GI MA EM LC

FE CL MT

SEF348N

쐌

Regarding model D22, “-B1” indicates the right bank and “-B2” indicates the left bank as shown in the figure.

AT TF PD AX

SEF099W

Wiring Diagrams and Trouble Diagnosis When you read Wiring diagrams, refer to the following: 쐌 GI-10, “HOW TO READ WIRING DIAGRAMS” 쐌 EL-10, “POWER SUPPLY ROUTING” When you perform trouble diagnosis, refer to the following: 쐌 GI-33, “How to Follow Test Groups in Trouble Diagnoses” 쐌 GI-22, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”

NGEC1057

SU BR ST RS BT HA SC EL

EC-1185

IDX

PREPARATION

VG33ER

Special Service Tools

Special Service Tools

NGEC1058

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description Loosening or tightening front heated oxygen sensor with 22 mm (0.87 in) hexagon nut

KV10117100 (J36471-A) Heated oxygen sensor wrench

NT379

Loosening or tightening rear heated oxygen sensor a: 22 mm (0.87 in)

KV10114400 (J-38365) Heated oxygen sensor wrench

NT636

(J-44321) Fuel pressure gauge kit

Checking fuel pressure

LEC642

Used to test the throttle position sensor

(J-45178) TPS test connector

LEC120A

Commercial Service Tools Tool name (Kent-Moore No.)

Description Locating the EVAP leak

Leak detector (J41416)

NT703

EC-1186

NGEC1059

PREPARATION

VG33ER Commercial Service Tools (Cont’d)

Tool name (Kent-Moore No.)

Description

GI Applying positive pressure through EVAP service port

EVAP service port adapter (J41413-OBD)

MA EM LC

NT704

Clamping the EVAP purge hose between the fuel tank and EVAP canister applied to DTC P1442 [EVAP control system (small leak-positive pressure)]

Hose clipper

FE CL

NT720

Checking fuel tank vacuum relief valve opening pressure

Fuel filler cap adapter

MT AT TF

NT653

Removing and installing engine coolant temperature sensor

Socket wrench

PD AX SU

NT705

Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with anti-seize lubricant shown in “Commercial Service Tools”. a: J-43897-18 (18 mm diameter with pitch 1.5 mm) for Zirconia Oxygen Sensor b: J-43897-12 (12 mm diameter with pitch 1.25 mm) for Titania Oxygen Sensor

Oxygen sensor thread cleaner (J-43897-18) (J-43897-12)

BR ST RS BT

AEM488

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads.

Anti-seize lubricant (Permatex姟 133AR or equivalent meeting MIL specification MIL-A-907)

HA SC EL

AEM489

EC-1187

IDX

PREPARATION

VG33ER

Commercial Service Tools (Cont’d) Tool name (Kent-Moore No.)

Description Cleaning fuel injectors

Fuel injector cleaner kit (J-45701)

LEC161A

EC-1188

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33ER

Engine Control Component Parts Location

Engine Control Component Parts Location

NGEC1060

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC808

EC-1189

EL IDX

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33ER

Engine Control Component Parts Location (Cont’d)

LEC762

EC-1190

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33ER Circuit Diagram

Circuit Diagram

NGEC1061

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC184A

EC-1191

EL IDX

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33ER

System Diagram

System Diagram

NGEC1062

LEC185A

EC-1192

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33ER

Vacuum Hose Drawing

Vacuum Hose Drawing

NGEC1063

Refer to “System Diagram”, EC-1192 for Vacuum Control System.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SEC295C

SC EL

EC-1193

IDX

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

VG33ER

System Chart

System Chart Input (Sensor) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

*1: *2: *3: *4:

Camshaft position sensor Mass air flow sensor Engine coolant temperature sensor Heated oxygen sensor 1 Ignition switch Throttle position sensor Closed throttle position switch *4 Park/neutral position (PNP) switch Air conditioner switch Knock sensor Intake air temperature sensor EVAP control system pressure sensor *1 Battery voltage Power steering oil pressure switch Vehicle speed sensor Fuel tank temperature sensor *1 Crankshaft position sensor (OBD) *1 Rear heated oxygen sensor *3 TCM (Transmission control module) *2 Ambient air temperature switch

NGEC1064

ECM Function

Output (Actuator)

Fuel injection & mixture ratio control

Injectors

Distributor ignition system

Power transistor

Idle air control system

IACV-AAC valve and IACV-FICD solenoid valve

Fuel pump control

Fuel pump relay

On board diagnostic system

MIL (On the instrument panel)

Supercharged air control

SCB valve control solenoid valve

Heated oxygen sensor 1 heater control

Heated oxygen sensor 1 heater

Heated oxygen sensor 2 heater control

Heated oxygen sensor 2 heater

EVAP canister purge flow control

EVAP canister purge volume control solenoid valve

Air conditioning cut control

Air conditioner relay

Cooling fan control

Cooling fan relays

ON BOARD DIAGNOSIS for EVAP system

쐌 EVAP canister vent control valve 쐌 Vacuum cut valve bypass valve

These sensors are not used to control the engine system. They are used only for the on board diagnosis. The DTC related to A/T will be sent to ECM. This sensor is not used to control the engine system under normal conditions. This switch will operate in place of the throttle position sensor to control EVAP parts if the sensor malfunctions.

EC-1194

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Multiport Fuel Injection (MFI) System

Multiport Fuel Injection (MFI) System DESCRIPTION Input/Output Signal Chart

NGEC1065

GI

NGEC1065S01

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

Density of oxygen in exhaust gas

Throttle position sensor

Throttle position Throttle valve idle position

Park/neutral position (PNP) switch

Gear position

Vehicle speed sensor

Vehicle speed

Ignition switch

Start signal

Air conditioner switch

Air conditioner operation

Knock sensor

Engine knocking condition

Battery

Battery voltage

Power steering oil pressure switch

Power steering operation

Heated oxygen sensor 2*

Density of oxygen in exhaust gas

ECM function

MA

Actuator

EM LC

Fuel injection & mixture ratio control

FE

Injectors

CL MT AT

* Under normal conditions, this sensor is not for engine control operation.

Basic Multiport Fuel Injection System

TF NGEC1065S02

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

NGEC1065S03

In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. 쐌 During warm-up 쐌 When starting the engine 쐌 During acceleration 쐌 Hot-engine operation 쐌 When selector lever is changed from “N” to “D” 쐌 High-load, high-speed operation 쐌 During deceleration 쐌 During high engine speed operation

PD AX SU BR ST RS BT HA SC EL

EC-1195

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Multiport Fuel Injection (MFI) System (Cont’d)

Mixture Ratio Feedback Control (Closed loop control)

NGEC1065S04

SEF336WB

The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The warm-up three way catalyst can then better reduce CO, HC and NOx emissions. This system uses a heated oxygen sensor 1 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, refer to EC-1396. This maintains the mixture ratio within the range of stoichiometric (ideal air-fuel mixture). This stage is referred to as the closed loop control condition. Heated oxygen sensor 2 is located downstream of the warm-up three way catalyst. Even if the switching characteristics of the heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal from the heated oxygen sensor 2.

Open Loop Control

NGEC1065S05

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. 쐌 Deceleration and acceleration 쐌 High-load, high-speed operation 쐌 Malfunction of heated oxygen sensor 1 or its circuit 쐌 Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature 쐌 High engine coolant temperature 쐌 During warm-up 쐌 When starting the engine

Mixture Ratio Self-learning Control

NGEC1065S06

The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the heated oxygen sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot wire) and characteristic changes during operation (i.e., 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 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-1196

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Multiport Fuel Injection (MFI) System (Cont’d)

Fuel Injection Timing

NGEC1065S07

GI MA EM LC SEF179U

Two types of systems are used. Sequential Multiport Fuel Injection System NGEC1065S0701 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 NGEC1065S0702 Fuel is injected simultaneously into all six cylinders twice each engine cycle. In other words, pulse signals of the same width are simultaneously transmitted from the ECM. The six 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

FE CL MT

NGEC1065S08

Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.

AT

Distributor Ignition (DI) System DESCRIPTION Input/Output Signal Chart Sensor

NGEC1066

TF

NGEC1066S01

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

Vehicle speed

Ignition switch

Start signal

Knock sensor

Engine knocking

Park/neutral position (PNP) switch

Gear position

Battery

Battery voltage

ECM function

Actuator

PD AX SU

Ignition timing con- Power transistor trol

BR ST RS BT HA SC EL

EC-1197

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Distributor Ignition (DI) System (Cont’d)

System Description

NGEC1066S02

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. 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. 쐌 At starting 쐌 During warm-up 쐌 At idle 쐌 At low battery voltage 쐌 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

NGEC1067 NGEC1067S01

Input Signal to ECM

Air conditioner switch

Air conditioner “ON” signal

Throttle position sensor

Throttle valve opening angle

Camshaft position sensor

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Vehicle speed sensor

Vehicle speed

Power steering oil pressure switch

Power steering operation

ECM function

Air conditioner cut control

System Description

Actuator

Air conditioner relay

NGEC1067S02

This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned OFF. 쐌 When the accelerator pedal is fully depressed. 쐌 When cranking the engine. 쐌 At high engine speeds. 쐌 When the engine coolant temperature becomes excessively high. 쐌 When operating power steering during low engine speed or low vehicle speed. 쐌 When engine speed is excessively low.

EC-1198

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Fuel Cut Control (at no load & high engine speed)

Fuel Cut Control (at no load & high engine speed) DESCRIPTION Input/Output Signal Chart Sensor

GI NGEC1068

NGEC1068S01

Input Signal to ECM

Vehicle speed sensor

Vehicle speed

Park/neutral position (PNP) switch

Neutral position

Throttle position sensor

Throttle position

Engine coolant temperature sensor

Engine coolant temperature

Camshaft position sensor

Engine speed

ECM function

EM Fuel cut control

LC

Injectors

If the engine speed is above 2,500 rpm with no load (for example, in neutral and engine speed over 2,500 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed. Fuel cut will operate until the engine speed reaches 2,000 rpm, then fuel cut is cancelled. NOTE: This function is different from deceleration control listed under “Multiport Fuel Injection (MFI) System”, EC-1195.

FE CL MT

Evaporative Emission System DESCRIPTION

MA

Actuator

NGEC1069

AT TF PD AX SU BR ST

SEF569XA

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.

RS BT HA SC EL

EC-1199

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Evaporative Emission System (Cont’d)

INSPECTION EVAP Canister

NGEC1070 NGEC1070S01

Check EVAP canister as follows: 1. Pinch the fresh air hose. 2. Blow air into port A and check that it flows freely out of port B.

AEC630A

Tightening Torque

NGEC1070S02

Tighten EVAP canister as shown in the figure. Make sure new O-ring is installed properly between EVAP canister and EVAP canister vent control valve.

AEC631A

Fuel Tank Vacuum Relief Valve (Built into fuel fillerNGEC1070S03 cap) 1. 2.

SEF445Y

Wipe clean valve housing. Check valve opening pressure and vacuum. Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) 3. If out of specification, replace fuel filler cap as an assembly. CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come ON

SEF943S

Vacuum Cut Valve and Vacuum Cut Valve Bypass NGEC1070S04 Valve Refer to EC-1697.

Evaporative Emission (EVAP) Canister Purge Volume Control Solenoid Valve NGEC1070S05 Refer to EC-1519.

Fuel Tank Temperature Sensor Refer to EC-1444.

EC-1200

NGEC1070S06

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Evaporative Emission System (Cont’d)

Evap Service Port

NGEC1070S07

Positive pressure is delivered to the EVAP system through the EVAP service port. If fuel vapor leakage in the EVAP system occurs, use a leak detector to locate the leak.

GI MA EM LC

SEF462UA

How to Detect Fuel Vapor Leakage

SEF200U

PEF838U

NGEC1070S08

CAUTION: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in EVAP system. NOTE: 쐌 Do not start engine. 쐌 Improper installation of EVAP service port adapter to the EVAP service port may cause a leak. With CONSULT-II 1) Attach the EVAP service port adapter securely to the EVAP service port. 2) Also attach the pressure pump and hose to the EVAP service port adapter. 3) Turn ignition switch ON. 4) Select the “EVAP SYSTEM CLOSE” of “WORK SUPPORT MODE” with CONSULT-II. 5) Touch “START”. A bar graph (Pressure indicating display) will appear on the screen. 6) Apply positive pressure to the EVAP system until the pressure indicator reaches the middle of the bar graph. 7) Remove EVAP service port adapter and hose with pressure pump. 8) Locate the leak using a leak detector. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-1203.

FE CL MT AT TF PD AX SU BR ST RS

PEF917U

BT HA SC EL

EC-1201

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Evaporative Emission System (Cont’d)

1) 2) 3)

4) SEF462UA

5) 6)

Without CONSULT-II Attach the EVAP service port adapter securely to the EVAP service port. Also attach the pressure pump with pressure gauge to the EVAP service port adapter. Apply battery voltage to between the terminals of both EVAP canister vent control valve and vacuum cut valve bypass valve to make a closed EVAP system. To locate the leak, deliver positive pressure to the EVAP system until pressure gauge points reach 1.38 to 2.76 kPa (0.014 to 0.028 kg/cm2, 0.2 to 0.4 psi). Remove EVAP service port adapter and hose with pressure pump. Locate the leak using a leak detector. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-1203.

AEC632A

EC-1202

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Evaporative Emission System (Cont’d)

EVAPORATIVE EMISSION LINE DRAWING

NGEC1071

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEC296C

EC-1203

EL IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Evaporative Emission System (Cont’d)

AEC886A

EC-1204

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR)

On Board Refueling Vapor Recovery (ORVR)

NGEC1072

SYSTEM DESCRIPTION

NGEC1072S01

GI MA EM LC

FE CL SEF206VA

From the beginning of refueling, the fuel tank pressure goes up. When the pressure reaches the setting value of the refueling control valve (RCV) opening pressure, the RCV is opened. After RCV opens, the air and vapor inside the fuel tank go through refueling EVAP vapor cut valve, RCV and refueling vapor line to the EVAP canister. The vapor is absorbed by the EVAP canister and the air is released to the atmosphere. When the refueling has reached the full level of the fuel tank, the refueling EVAP vapor cut valve is closed and refueling is stopped because of auto shut-off. The vapor which was absorbed by the EVAP canister is purged during driving. The RCV is always closed during driving and the evaporative emission control system is operated the same as conventional system. WARNING: When conducting inspections below, be sure to observe the following: 쐌 Put a “CAUTION: INFLAMMABLE” sign in workshop. 쐌 Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. 쐌 Be sure to furnish the workshop with a CO2 fire extinguisher. CAUTION: 쐌 Before removing fuel line parts, carry out the following procedures: a) Put drained fuel in an explosion-proof container and put lid on securely. b) Release fuel pressure from fuel line. Refer to “Fuel Pressure Release”, EC-1217. c) Disconnect battery ground cable. 쐌 Always replace O-ring when the fuel gauge retainer is removed. 쐌 Do not kink or twist hose and tube when they are installed. 쐌 Do not tighten hose and clamps excessively to avoid damaging hoses. 쐌 After installation, run engine and check for fuel leaks at connection. 쐌 Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire.

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1205

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

DIAGNOSTIC PROCEDURE Symptom: Fuel Odor from EVAP Canister Is Strong. 1

NGEC1072S02 NGEC1072S0201

CHECK EVAP CANISTER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 2.

NG

䊳

GO TO 3.

2

CHECK IF EVAP CANISTER SATURATED WITH WATER

Does water drain from the EVAP canister?

SEF596U

Yes or No Yes

䊳

GO TO 3.

No (With CONSULT-II)

䊳

GO TO 6.

No (Without CONSULTII)

䊳

GO TO 7.

3

REPLACE EVAP CANISTER

Replace EVAP canister with a new one. 䊳

GO TO 4.

EC-1206

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

4 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

GI MA EM LC

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator.

FE CL

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace water separator.

MT AT

5

DETECT MALFUNCTIONING PART

Check the EVAP hose between EVAP canister and water separator for clogging or poor connection. 䊳

Repair or replace EVAP hose.

TF PD AX SU BR ST RS BT HA SC EL

EC-1207

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

6 1. 2. a. b. c. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE With CONSULT-II Remove fuel tank. Refer to FE-5, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel feed hose located on the fuel level sensor unit retainer. Connect a spare fuel hose, one side to fuel level sensor unit retainer where the hose was removed and the other side to a fuel container. Drain fuel using “FUEL PUMP RELAY” in “ACTIVE TEST” mode with CONSULT-II. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel level sensor unit retainer with fuel level sensor unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel level sensor unit retainer remaining open and check that the pressure is applicable.

SEF707Z

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

EC-1208

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

7 1. 2. a. b. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE Without CONSULT-II Remove fuel tank. Refer to FE-5, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel level sensor unit retainer. Drain fuel from the tank using a hand pump into a fuel container. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel level sensor unit retainer with fuel level sensor unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel level sensor unit retainer remaining open and check that the pressure is applicable.

GI MA EM LC

FE CL MT AT TF PD AX SEF707Z

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

SU BR ST RS BT HA SC EL

EC-1209

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

8

CHECK REFUELING CONTROL VALVE

1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage.

SEF706Z

OK or NG OK

䊳

INSPECTION END

NG

䊳

Replace refueling control valve with fuel tank.

Symptom: Cannot Refuel/Fuel Odor From The Fuel Filler Opening Is Strong While Refueling. 1

CHECK EVAP CANISTER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 2.

NG

䊳

GO TO 3.

EC-1210

NGEC1072S0202

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

2

CHECK IF EVAP CANISTER SATURATED WITH WATER

Does water drain from the EVAP canister?

GI MA EM LC SEF596U

Yes or No Yes

䊳

GO TO 3.

No

䊳

GO TO 6.

FE CL

3

REPLACE EVAP CANISTER

Replace EVAP canister with a new one. 䊳

4 1. 2. 3. 4.

MT

GO TO 4.

AT

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

TF PD AX SU BR SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator.

ST RS

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace water separator.

5

BT HA

DETECT MALFUNCTIONING PART

Check the EVAP hose between EVAP canister and water separator for clogging or poor connection. 䊳

Repair or replace EVAP hose.

SC EL

EC-1211

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

6

CHECK VENT HOSES AND VENT TUBES

Check hoses and tubes between EVAP canister and refueling control valve for clogging, kink, looseness and improper connection. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair or replace hoses and tubes.

7

CHECK FILLER NECK TUBE

Check signal line and recirculation line for clogging, dents and cracks. OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace filler neck tube.

8

CHECK REFUELING CONTROL VALVE

1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage.

SEF706Z

OK or NG OK (With CONSULT-II)

䊳

GO TO 9.

OK (Without CONSULTII)

䊳

GO TO 10.

NG

䊳

Replace refueling control valve with fuel tank.

EC-1212

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

9 1. 2. a. b. c. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE With CONSULT-II Remove fuel tank. Refer to FE-5, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel feed hose located on the fuel level sensor unit retainer. Connect a spare fuel hose, one side to fuel level sensor unit retainer where the hose was removed and the other side to a fuel container. Drain fuel using “FUEL PUMP RELAY” in “ACTIVE TEST” mode with CONSULT-II. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel level sensor unit retainer with fuel level sensor unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel level sensor unit retainer remaining open and check that the pressure is applicable.

GI MA EM LC

FE CL MT AT TF PD AX

SEF707Z

SU

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

BR ST RS BT HA SC EL

EC-1213

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

10 1. 2. a. b. 3. 4. a. b. c. d.

CHECK REFUELING EVAP VAPOR CUT VALVE Without CONSULT-II Remove fuel tank. Refer to FE-5, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel level sensor unit retainer. Drain fuel from the tank using a hand pump into a fuel container. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel level sensor unit retainer with fuel level sensor unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel level sensor unit retainer remaining open and check that the pressure is applicable.

SEF707Z

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace refueling EVAP vapor cut valve with fuel tank.

11

CHECK FUEL FILLER TUBE

Check filler neck tube and hose connected to the fuel tank for clogging, dents and cracks. OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace fuel filler tube.

12

CHECK ONE-WAY FUEL VALVE-I

Check one-way valve for clogging. OK or NG OK

䊳

GO TO 13.

NG

䊳

Repair or replace one-way fuel valve with fuel tank.

EC-1214

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

On Board Refueling Vapor Recovery (ORVR) (Cont’d)

13

CHECK ONE-WAY FUEL VALVE-II

1. Make sure that fuel is drained from the tank. 2. Remove fuel filler tube and hose. 3. Check one-way fuel valve for operation as follows. When a stick is inserted, the valve should open, when removing stick it should close.

GI MA EM LC

SEF665U

FE

Do not drop any material into the tank. OK or NG OK

䊳

INSPECTION END

NG

䊳

Replace fuel filler tube or replace one-way fuel valve with fuel tank.

CL MT

Positive Crankcase Ventilation DESCRIPTION

SEC297C

AT NGEC1073

This system returns blow-by gas to the intake manifold. The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection in the reverse direction. On vehicles with an excessively high blow-by, the valve does not meet the requirement. This is because some of the flow will go through the hose connection to the air inlet tubes under all conditions.

TF PD AX SU BR ST RS

SEF559A

INSPECTION PCV (Positive Crankcase Ventilation) Valve

NGEC1074

BT

NGEC1074S01

With engine running at idle, remove PCV valve from rocker cover; if the valve is working properly, 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.

HA SC EL

SEC137A

EC-1215

IDX

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

VG33ER

Positive Crankcase Ventilation (Cont’d)

PCV Valve Ventilation Hose 1. 2.

NGEC1074S02

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-1216

BASIC SERVICE PROCEDURE

VG33ER Fuel Pressure Release

Fuel Pressure Release

NGEC1075

Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.

WITH CONSULT-II 1. 2. 3. 4. SEF163X

5.

NGEC1075S01

Turn ignition switch ON. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode with CONSULT-II. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF.

GI MA EM LC

FE CL MT

SEF214Y

WITHOUT CONSULT-II 1. 2. 3. 4. 5.

NGEC1075S02

Remove fuel pump fuse located in fuse box. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. Reinstall fuel pump fuse after servicing fuel system.

AT TF PD AX

SEF164X

Fuel Pressure Check 쐌 쐌

1. 2.

3. 4. 5.

NGEC1076

Use Fuel Pressure Gauge J-44321 to check fuel pressure. Do not perform fuel pressure check with electrical systems operating (i.e. lights, rear defog., A/C ect.). Fuel pressure gauge may indicate false readings due to varying engine loads and changes in manifold vacuum. Release fuel pressure to zero. Install the inline fuel quick disconnect fitting between the connection of the fuel feed hose (from tank) and the fuel hose (to engine). Connect the fuel pressure test gauge (quick connect adapter hose) to quick disconnect fitting. Start engine and check for fuel leakage. Read the indication of fuel pressure gauge. At idling: With vacuum hose connected Approximately 235 kPa (2.4 kg/cm2, 34 psi) With vacuum hose disconnected Approximately 294 kPa (3.0 kg/cm2, 43 psi)

SU BR ST RS BT HA SC EL

WEC875

EC-1217

IDX

BASIC SERVICE PROCEDURE

VG33ER

Fuel Pressure Regulator Check

If results are unsatisfactory, perform Fuel Pressure Regulator Check.

Fuel Pressure Regulator Check 1. 2. 3.

NGEC1077

Stop engine and disconnect fuel pressure regulator vacuum hose from intake manifold. Plug intake manifold with a blind cap. Connect variable vacuum source to fuel pressure regulator.

LEC763

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.

SEF718BA

Injector REMOVAL AND INSTALLATION 1. 2. 3. 쐌 쐌 쐌 쐌 쐌

NGEC1078

Release fuel pressure to zero. Refer to EC-1217. Remove supercharger. Refer to EM-109, “SUPERCHARGER”. Remove injector fuel tube assembly. The following parts should be disconnected or removed. Fuel feed and return hose All injectors harness connectors Push injector tail piece. Do not pull on connector. Do not extract injector by pinching.

EC-1218

BASIC SERVICE PROCEDURE

VG33ER Injector (Cont’d)

4. 5. 쐌 쐌 6.

Push out any malfunctioning injector from injector fuel tube. Replace or clean injector as necessary. Always replace O-rings with new ones. Lubricate O-rings with engine oil. Install injector to injector fuel tube assembly.

GI MA EM LC

SEF927X

7.

Install injectors with fuel tube assembly to intake manifold. Tighten in numerical order shown in the figure. a. First, tighten all bolts to 4.9 to 6.0 N·m (0.5 to 0.61 kg-m, 3.6 to 4.4 ft-lb). b. Then, tighten all bolts to 10.8 to 14.7 N·m (1.1 to 1.5 kg-m, 8 to 11 ft-lb). 8. Reinstall any part removed in reverse order of removal. CAUTION: After properly connecting fuel hose to injector and fuel tube, check connection for fuel leakage. SEF867W

Fast Idle Cam (FIC) INSPECTION AND ADJUSTMENT With CONSULT-II 1. 2. 3.

FE CL MT AT

NGEC1079 NGEC1079S01

Turn ignition switch ON. See “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. When engine coolant temperature is 20 to 30°C (68 to 86°F), make sure that the center of mark A is aligned with mark B as shown in the figure.

TF PD AX

SEF013Y

쐌

If NG, adjust by turning adjusting screw. Lock nut: : 0.98 - 1.96 N·m (10 - 20 kg-cm, 8.7 - 17.4 in-lb)

SU BR ST RS

SEF970R

4. 5. 쐌 쐌 쐌

Start engine and warm it up. When engine coolant temperature is 75 to 85°C (167 to 185°F), check the following. The center of mark A is aligned with mark C. The cam follower lever’s roller is not touching the fast idle cam. If NG, replace thermo-element and perform the above inspection and adjustment again.

BT HA SC EL

SEF971R

EC-1219

IDX

BASIC SERVICE PROCEDURE

VG33ER

Fast Idle Cam (FIC) (Cont’d)

Without CONSULT-II 1. 2. 3.

NGEC1079S02

Turn ignition switch ON. Check voltage between ECM terminal 59 (Engine coolant temperature sensor signal) and ground. When the voltage is between 3.12 to 3.52V, make sure that the center of mark A is aligned with mark B as shown in the figure.

SEF774U

쐌

If NG, adjust by turning adjusting screw. Lock nut: : 0.98 - 1.96 N·m (10 - 20 kg-cm, 8.7 - 17.4 in-lb)

4. 5.

Start engine and warm it up. When the voltage is between 1.10 to 1.36V, check the following. The center of mark A is aligned with mark C. The cam follower lever’s roller is not touching the fast idle cam. If NG, replace thermo-element and perform the above inspection and adjustment again.

SEF970R

쐌 쐌 쐌

SEF971R

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment

NGEC1080

PREPARATION 1) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 2) 3) 4) 5)

NGEC1080S01

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 Evaporative emission system On air conditioner equipped models, checks should be carried out while the air conditioner is OFF. On automatic transmission equipped models, when checking idle rpm, ignition timing and mixture ratio, checks should be carried out while shift lever is in “N” position. When measuring “CO” percentage, insert probe more than 40 cm (15.7 in) into tail pipe. Turn off headlamps, heater blower, rear defogger.

EC-1220

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

6) Keep front wheels pointed straight ahead. 7) Make the check after the cooling fan has stopped.

Overall Inspection Sequence

GI NGEC1080S0101

MA EM LC

FE CL MT AT TF PD AX SU BR ST RS SEF554YA

BT NOTE: If a vehicle contains a part which is operating outside of design specifications with no MIL 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.

HA SC EL

EC-1221

IDX

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

INSPECTION PROCEDURE 1

=NGEC1080S02

INSPECTION START

1. Visually check the following: 쐌 Air cleaner clogging 쐌 Hoses and ducts for leaks 쐌 Electrical connectors 쐌 Gasket 쐌 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 stays below 1,000 rpm.

SEF976U

3. Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load.

SEF977U

4. Make sure that no DTC is displayed with CONSULT-II or GST. OK or NG OK

䊳

GO TO 2.

NG

䊳

1. Repair or replace components as necessary. 2. GO TO 2.

EC-1222

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

2

CHECK IGNITION TIMING

1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed.

GI MA EM LC SEF978U

3. Turn off engine and disconnect throttle position sensor harness connector.

FE CL MT SEF975R

4. Start and rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run at idle speed. 5. Check ignition timing with a timing light.

AT TF PD AX SU

SEF927Z

M/T: 10°±1° BTDC A/T: 10°±1° BTDC (in “P” or “N” position) OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

BR ST RS BT HA SC EL

EC-1223

IDX

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

3

ADJUST IGNITION TIMING

1. Adjust ignition timing by turning distributor after loosening securing bolts. 2. Turn off engine and connect throttle position sensor harness connector to throttle position sensor.

SEF972R

䊳

4

GO TO 2.

CHECK BASE IDLE SPEED

With CONSULT-II 1. Read idle speed in “DATA MONITOR” mode with CONSULT-II.

SEF058Y

M/T: 700±50 rpm A/T: 700±50 rpm (in “P” or “N” position) Without CONSULT-II 1. Check idle speed. M/T: 700±50 rpm A/T: 700±50 rpm (in “P” or “N” position) OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

EC-1224

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

5

ADJUST BASE IDLE SPEED

1. Rev engine (2,000 to 3,000 rpm) 2 or 3 times under no-load then run engine at idle speed. 2. Adjust idle speed by turning idle speed adjusting screw.

GI MA EM LC

LEC513

M/T: 700±50 rpm A/T: 700±50 rpm (in “P” or “N” position) 䊳

6

FE

GO TO 6.

CL

CHECK TARGET IDLE SPEED

MT

With CONSULT-II 1. Turn off engine and connect throttle position sensor harness connector. 2. Start and rev engine (2,000 to 3,000 rpm) 2 or 3 times under no-load then run at idle speed. 3. Read idle speed in “DATA MONITOR” mode with CONSULT-II.

AT TF PD AX SEF058Y

M/T: 750±50 rpm A/T: 750±50 rpm (in “P” or “N” position)

SU BR

Without CONSULT-II 1. Turn off engine and connect throttle position sensor harness connector. 2. Start and rev engine (2,000 to 3,000 rpm) 2 or 3 times under no-load then run at idle speed. 3. Check idle speed. M/T: 750±50 rpm A/T: 750±50 rpm (in “P” or “N” position)

ST RS

OK or NG OK (With CONSULT-II)

䊳

GO TO 8.

OK (Without CONSULTII)

䊳

GO TO 9.

NG

䊳

GO TO 7.

BT HA SC EL

EC-1225

IDX

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

7

DETECT MALFUNCTIONING PART

Check the following. 1. Check IACV-AAC valve and replace if necessary. Refer to EC-1586. 2. Check IACV-AAC valve harness and repair if necessary. Refer to EC-1586. 3. Check ECM function by substituting another known-good ECM. (ECM may be the cause of a problem, but this is rarely the case.) With CONSULT-II

䊳

GO TO 8.

Without CONSULT-II

䊳

GO TO 9.

8

CHECK HEATED OXYGEN SENSOR 1 (BANK 2) SIGNAL

With CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. See “HO2S1 MNTR (B2)” in “DATA MONITOR” mode. 3. Running 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 5 times during 10 seconds.

SEF999Z

OK or NG OK

䊳

GO TO 12.

NG (Monitor does not fluctuate.)

䊳

GO TO 17.

NG (Monitor fluctuates less than 5 times.)

䊳

GO TO 10.

9

CHECK HEATED OXYGEN SENSOR 1 (BANK 2) SIGNAL

Without CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Set voltmeter probe between ECM terminal 62 and ground. 3. Make sure that the voltage fluctuates between 0 - 0.3V and 0.6 - 1.0V more than 5 times during 10 seconds at 2,000 rpm. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V OK or NG OK

䊳

GO TO 12.

NG (Voltage does not fluctuate.)

䊳

GO TO 17.

NG (Voltage fluctuates less than 5 times.)

䊳

GO TO 10.

EC-1226

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

10 1. 2. 3. 4. 5. 6.

1. 2. 3. 4. 5. 6.

CHECK HEATED OXYGEN SENSOR 1 (BANK 2) SIGNAL With CONSULT-II Stop engine. Replace heated oxygen sensor 1 (bank 2). Start engine and warm it up to normal operating temperature. Run engine at approx. 2,000 rpm for approx. 2 minutes under no-load. See “HO2S1 MNTR (B2)” in “DATA MONITOR” mode. Running 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 5 times during 10 seconds. 1 time: RICH → LEAN → RICH 2 times: RICH → LEAN → RICH → LEAN → RICH Without CONSULT-II Stop engine. Replace heated oxygen sensor 1 (bank 2). Start engine and warm it up to normal operating temperature. Run engine at approx. 2,000 rpm for approx. 2 minutes under no-load. Set voltmeter probe between ECM terminal 62 and ground. Make sure that the voltage fluctuates between 0 - 0.3V and 0.6 - 1.0V more than 5 times during 10 seconds at 2,000 rpm. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V OK or NG

OK (With CONSULT-II)

䊳

GO TO 12.

OK (Without CONSULTII)

䊳

GO TO 13.

NG

䊳

GO TO 11.

GI MA EM LC

FE CL MT AT TF

11

DETECT MALFUNCTIONING PART

Check the following. 1. Check fuel pressure regulator. Refer to EC-1218. 2. Check mass air flow sensor and its circuit. Refer to EC-1334. 3. Check injector and its circuit. Refer to EC-1725. Clean or replace if necessary. 4. Check engine coolant temperature sensor and its circuit. Refer to EC-1366. 5. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.) 䊳

PD AX SU

GO TO 2.

BR ST RS BT HA SC EL

EC-1227

IDX

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

12

CHECK HEATED OXYGEN SENSOR 1 (BANK 1) SIGNAL

With CONSULT-II 1. See “HO2S1 (B1)” in “DATA MONITOR” mode. 2. Maintaining 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 5 times during 10 seconds.

SEF999Z

OK or NG OK

䊳

INSPECTION END

NG (Monitor does not fluctuate.)

䊳

GO TO 16.

NG (Monitor fluctuates less than 5 times.)

䊳

GO TO 14.

13

CHECK HEATED OXYGEN SENSOR 1 (BANK 1) SIGNAL

Without CONSULT-II 1. Set voltmeter probe between ECM terminal 63 and ground. 2. Make sure that the voltage fluctuates between 0 - 0.3V and 0.6 - 1.0V more than 5 times during 10 seconds at 2,000 rpm. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V OK or NG OK

䊳

INSPECTION END

NG (Voltage does not fluctuate.)

䊳

GO TO 16.

NG (Voltage fluctuates less than 5 times.)

䊳

GO TO 14.

EC-1228

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

14 1. 2. 3. 4. 5. 6.

1. 2. 3. 4. 5. 6.

CHECK HEATED OXYGEN SENSOR 1 (BANK 1) SIGNAL With CONSULT-II Stop engine. Replace heated oxygen sensor 1 (bank 1). Start engine and warm it up to normal operating temperature. Run engine at approx. 2,000 rpm for approx. 2 minutes under no-load. See “HO2S1 MNTR (B1)” in “DATA MONITOR” mode. Maintaining 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 5 times during 10 seconds. 1 time: RICH → LEAN → RICH 2 times: RICH → LEAN → RICH → LEAN → RICH Without CONSULT-II Stop engine. Replace heated oxygen sensor 1 (bank 1). Start engine and warm it up to normal operating temperature. Run engine at approx. 2,000 rpm for approx. 2 minutes under no-load. Set voltmeter probe between ECM terminal 63 and ground. Make sure that the voltage fluctuates between 0 - 0.3V and 0.6 - 1.0V more than 5 times during 10 seconds at 2,000 rpm. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V OK or NG

OK

䊳

INSPECTION END

NG

䊳

GO TO 15.

15

MA EM LC

FE CL MT AT

DETECT MALFUNCTIONING PART

Check the following. 1. Check fuel pressure regulator. Refer to EC-1218. 2. Check mass air flow sensor and its circuit. Refer to EC-1334. 3. Check injector and its circuit. Refer to EC-1725. Clean or replace if necessary. 4. Check engine coolant temperature sensor and its circuit. Refer to EC-1366. 5. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.) 䊳

16 1. 2. 3. 4.

GI

GO TO 2.

TF PD AX SU

CHECK HEATED OXYGEN SENSOR 1 (BANK 1) HARNESS Turn off engine and disconnect battery ground cable. Disconnect ECM harness connector. Disconnect heated oxygen sensor 1 (bank 1) harness connector. Check harness continuity between ECM terminal 50 and heated oxygen sensor 1 (bank 1) harness connector. Continuity should exist. OK or NG

OK

䊳

1. Connect ECM harness connector. 2. GO TO 18.

NG

䊳

1. Repair or replace harness. 2. GO TO 8. (With CONSULT-II) GO TO 9. (Without CONSULT-II)

BR ST RS BT HA SC EL

EC-1229

IDX

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

17 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 1 (BANK 2) HARNESS Turn off engine and disconnect battery ground cable. Disconnect ECM harness connector. Disconnect heated oxygen sensor 1 (bank 2) harness connector. Check harness continuity between ECM terminal 51 and heated oxygen sensor 1 (bank 2) harness connector. Continuity should exist. OK or NG

OK

䊳

1. Connect ECM harness connector. 2. GO TO 18.

NG

䊳

1. Repair or replace harness. 2. GO TO 8. (With CONSULT-II) GO TO 9. (Without CONSULT-II)

18

PREPARATION FOR “CO” % CHECK

With CONSULT-II 1. Select “ENG COOLANT TEMP” in “ACTIVE TEST” mode. 2. Set “ENG COOLANT TEMP” to 5°C (41°F) by touching “DWN” and “Qd”.

SEF172Y

Without CONSULT-II 1. Disconnect engine coolant temperature sensor harness connector. 2. Connect a resistor (4.4 kΩ) between terminals of engine coolant temperature sensor harness connector.

AEC036B

䊳

GO TO 19.

EC-1230

BASIC SERVICE PROCEDURE

VG33ER

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

19

CHECK “CO” %

1. Start engine and warm it up until engine coolant temperature indicator points to the middle of gauge.

GI MA EM LC SEF976U

2. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed.

FE CL SEF978U

3. Check “CO” %. Idle CO: 1.5 - 9.5% 4. Without CONSULT-II After checking CO%, a. Disconnect the resistor from terminals of engine coolant temperature sensor. b. Connect engine coolant temperature sensor harness connector to engine coolant temperature sensor.

MT AT TF

OK or NG OK

䊳

GO TO 10.

NG

䊳

GO TO 20.

PD AX

20

DETECT MALFUNCTIONING PART

Check the following. 1. Connect heated oxygen sensor 1 harness connectors to heated oxygen sensors 1. 2. Check fuel pressure regulator. Refer to EC-1218. 3. Check mass air flow sensor and its circuit. Refer to EC-1334. 4. Check injector and its circuit. Refer to EC-1725. Clean or replace if necessary. 5. Check engine coolant temperature sensor and its circuit. Refer to EC-1366. 6. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.) 䊳

SU BR ST RS

GO TO 2.

BT HA SC EL

EC-1231

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Introduction

Introduction

NGEC1081

The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including: Emission-related diagnostic information

SAE Mode

Diagnostic Trouble Code (DTC)

Mode 3 of SAE J1979

Freeze Frame data

Mode 2 of SAE J1979

System Readiness Test (SRT) code

Mode 1 of SAE J1979

1st Trip Diagnostic Trouble Code (1st Trip DTC)

Mode 7 of SAE J1979

1st Trip Freeze Frame data Test values and Test limits

Mode 6 of SAE J1979

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

CONSULT-II

X

X

X

X

X

—

GST

X

X*1

X

—

X

X

*1: 1st trip DTCs for self-diagnoses concerning SRT items cannot be shown on the GST display.

The malfunction indicator lamp (MIL) 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-1289.)

Two Trip Detection Logic

NGEC1082

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 MIL 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 MIL lights up. The MIL 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 MIL, and store DTC and Freeze Frame data, even in the 1st trip, as shown below. X: Applicable MIL Items

DTC

1st trip

—: Not applicable 1st trip DTC

2nd trip

1st trip 2nd trip 1st trip 2nd trip Lighting up displaying displaying displaying displaying

Blinking

Lighting up

Blinking

Coolant overtemperature enrichment protection — DTC: P0217

—

X

—

—

X

—

X

—

Misfire (Possible three way catalyst damage) — DTC: P0300 P0306 is being detected

X

—

—

—

—

—

X

—

Misfire (Possible three way catalyst damage) — DTC: P0300 P0306 is being detected

—

—

X

—

—

X

—

—

Closed loop control — DTC: P1148, P1168

—

X

—

—

X

—

X

—

Fail-safe items (Refer to EC-1289.)

—

X

—

—

X*1

—

X*1

—

Except above

—

—

—

X

—

X

X

—

*1: Except “ECM”

EC-1232

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information

Emission-related Diagnostic Information DTC AND 1ST TRIP DTC

NGEC1083 NGEC1083S01

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 MIL 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 MIL lights up. In other words, the DTC is stored in the ECM memory and the MIL 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 MIL 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”, EC-1246. For malfunctions in which 1st trip DTCs are displayed, refer to EC-1242. 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 SAE J1979. 1st trip DTC detection occurs without lighting up the MIL 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 EC-1271. 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

GI MA EM LC

FE CL MT AT

NGEC1083S0101

DTC and 1st trip DTC can be read by the following methods. With CONSULT-II With GST CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P0705, P0750, etc. These DTCs are prescribed by SAE J2012. (CONSULT-II also displays the malfunctioning component or system.) 쐌 1st trip DTC No. is the same as DTC No. 쐌 Output of a DTC indicates a malfunction. However, 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 and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. If the DTC is being detected currently, the time data will be “0”. If a 1st trip DTC is stored in the ECM, the time data will be “[1t]”.

TF PD AX SU BR ST RS BT HA

SEC652C

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA

SC NGEC1083S02

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 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.

EC-1233

EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d)

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-1258. 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/MIL on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data. Priority 1 2 3

Items Freeze frame data

Misfire — DTC: P0300 - P0306 Fuel Injection System Function — DTC: P0171, P0172, P0174, P0175 Except the above items (Includes A/T related items)

1st trip freeze frame data

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”, EC-1246.

SYSTEM READINESS TEST (SRT) CODE

NGEC1083S03

System Readiness Test (SRT) code is specified in Mode 1 of SAE J1979. As part of enhanced emissions test for Inspection and Maintenance (I/M), certain states require that the status of srt be used to indicate whether the ECM has completed self-diagnosis of major emission systems and components. Completion must be verified in order for the emissions inspection to proceed. If a vehicle is rejected for a State emissions inspection due to one or more SRT items indicating “INCMP”, use the information in this service manual to set the SRT to “CMPLT”. In most cases, the ECM will automatically complete its self-diagnosis cycle during normal usage and the SRT status will indicate “CMPLT” for each application system. Once set as “CMPLT”, the SRT status remains “CMPLT” until the self-diagnosis memory is erased. Occasionally, certain portions of the self-diagnostic test may not be completed as a result of the customer’s normal driving pattern and the SRT will indicate “INCMP” for these items. NOTE: The SRT will also indicate “INCMP” if the self-diagnosis memory is erased for any reason or if the ECM memory power supply is interrupted for several hours. If, during the state emissions inspection, the SRT indicates “CMPLT” for all test items, the inspector will continue with the emissions test. However, if the SRT indicates “INCMP” for one or more of the SRT items, the vehicle is returned to the customer untested. NOTE: If MIL is “ON” during the state emissions inspection, the vehicle is also returned to the customer untested even though the SRT indicates “CMPLT” for all test items. Therefore, it is important to check SRT (“CMPLT”) and DTC (No DTCs) before the inspection.

EC-1234

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d)

SRT Item

=NGEC1083S0301

The following table shows required self-diagnostic items to set the SRT to “CMPLT”. SRT item Perfor(CONSULT-II indication) mance Priority *

Required self-diagnostic items to set the SRT to ″CMPLT″

Corresponding DTC No.

CATALYST

3

Three way catalyst function

P0420, P0430

EVAP SYSTEM

2

EVAP control system (small leak) (negative pressure)

P0442

3

EVAP control system (very small leak) (negative pressure)/ (positive pressure)

P0456, P1456

3

EVAP control system purge flow monitoring

P0441

3

Heated oxygen sensor 1 (circuit)

P0134, P0154

Heated oxygen sensor 1 (lean shift monitoring)

P1143, P1163

Heated oxygen sensor 1 (rich shift monitoring)

P1144, P1164

Heated oxygen sensor 1 (response monitoring)

P0133, P0153

Heated oxygen sensor 1 (high voltage)

P0132, P0152

Heated oxygen sensor 2 (min. voltage monitoring)

P1146, P1166

Heated oxygen sensor 2 (max. voltage monitoring)

P1147, P1167

Heated oxygen sensor 2 (response monitoring)

P0139, P0159

Heated oxygen sensor 2 (high voltage)

P0138, P0158

Heated oxygen sensor 1 heater

P0031, P0032, P0051, P0052

Heated oxygen sensor 2 heater

P0037, P0038, P0057, P0058

HO2S

HO2S HEATER

3

GI MA EM LC

FE CL MT AT

*: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure) one by one based on the priority for models with CONSULT-II.

SRT Set Timing

NGEC1083S0302

SRT is set as “CMPLT” after self-diagnosis has been performed one or more times. Completion of SRT will occur if the result is OK or NG. The set timing is different between them and is shown in the following table.

TF PD AX SU BR ST RS BT HA SC EL

EC-1235

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d) Self-diagnosis result

Example Ignition OFF – ON – OFF

Diagnosis All OK

Ignition OFF – ON – OFF

Ignition OFF – ON – OFF

Ignition OFF – ON – OFF

P0400

OK (1)

– (1)

OK (2)

– (2)

P0402

OK (1)

– (1)

– (1)

OK (2)

P1402

OK (1)

OK (2)

– (2)

– (2)

“CMPLT”

“CMPLT”

“CMPLT”

“CMPLT”

P0400

OK (1)

– (1)

– (1)

– (1)

P0402

– (0)

– (0)

OK (1)

– (1)

P1402

OK (1)

OK (2)

– (2)

– (2)

“INCMP”

“INCMP”

“CMPLT”

“CMPLT”

P0400

OK

OK

–

–

P0402

–

–

–

–

NG

–

NG

NG (Consecutive NG)

1st trip DTC

–

1st trip DTC

DTC (=MIL “ON”)

“INCMP”

“INCMP”

“INCMP”

“CMPLT”

Case 1 SRT of EGR

Case 2 SRT of EGR NG exists

Case 3

P1402 (1st trip) DTC SRT of EGR

OK: Self-diagnosis is carried out and the result is OK. NG: Self-diagnosis is carried out and the result is OK. –: Self-diagnosis is not carried out.

When all SRT related self-diagnoses showed OK results in a same cycle (Ignition OFF – ON – OFF), the SRT will indicate “CMPLT”. , Case 1 above When all SRT related self-diagnoses show OK results through several different cycles, the SRT will indicate “CMPLT” at the time the respective self-diagnoses have at least one OK result. , Case 2 above If one or more SRT related self-diagnoses showed NG results in 2 consecutive cycles, the SRT will also indicate “CMPLT”. , Case 3 above The previous table shows that the minimum number of cycles for setting SRT as “INCMP” is one (1) for each self-diagnosis (Case 1 and 2) or two (2) for one self-diagnosis (Case 3). However, in preparation for the State emissions inspection, it is unnecessary of each self-diagnosis to be executed twice (Case 3) because of the following reasons; 쐌 The SRT will indicate “CMPLT” at the time the respective self-diagnoses have one (1) OK result. 쐌 The emissions inspection requires “CMPLT” of the SRT only with OK self-diagnosis result. 쐌 When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to “CMPLT” of SRT, the self-diagnosis memory must be erased from ECM after repair. 쐌 If the 1st trip DTC is erased, all the SRT will indicate “INCMP”. NOTE: SRT can be set as “CMPLT” together with the DTC(s). Therefore, DTC check must always be carried out prior to the State emission inspection even though the SRT indicates “CMPLT”.

SRT Service Procedure

NGEC1083S0303

If a vehicle has been rejected for the State emissions inspection due to one or more SRT items indicating “INCMP”, review the following flowchart diagnostic sequence on the next page.

EC-1236

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST SEF170Z

*1

EC-1233

*2

EC-1237

*3

RS

EC-1238

BT

How to Display SRT Code

NGEC1083S0304

1.

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. 2. With GST Selecting Mode 1 with GST (Generic Scan Tool) A sample of CONSULT-II display for SRT code is shown below. “INCMP” means the self-diagnosis is incomplete and SRT is not set. “CMPLT” means the self-diagnosis is complete and SRT is set.

EC-1237

HA SC EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d)

SEF949Z

How to Set SRT Code

NGEC1083S0305

To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each diagnosis may require a long period of actual driving under various conditions. With CONSULT-II Perform corresponding DTC confirmation procedure one by one based on “Performance Priority” in the table on EC-1233. Without CONSULT-II The most efficient driving pattern in which SRT codes can be properly set is explained on EC-1239. The driving pattern should be performed one or more times to set all SRT codes.

EC-1238

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d)

Driving Pattern

NGEC1083S0306

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEF947YA

EC-1239

EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d)

쐌

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: 쐌 The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F) (where the voltage between the ECM terminal 59 and ground is 3.0 - 4.3V). 쐌 The engine must be operated at idle speed until the engine coolant temperature is greater than 70°C (158°F) (where the voltage between the ECM terminal 59 and ground is lower than 1.4V). 쐌 The engine is started at the tank fuel temperature of warmer than 0°C (32°F) (where the voltage between the ECM terminal 60 and ground is less than 4.1V). Pattern 2: 쐌 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. Pattern 3: 쐌 The driving pattern outlined in *2 must be repeated at least 3 times. Pattern 4: 쐌 Tests are performed after the engine has been operated for at least 17 minutes. 쐌 The accelerator pedal must be held very steady during steady-state driving. 쐌 If the accelerator pedal is moved, the test must be conducted all over again. *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: Operate the vehicle in the following driving pattern. 1) Decelerate vehicle to 0 km/h (0 MPH) and let engine idle. 2) Repeat driving pattern shown below at least 10 times. 쐌 During acceleration, hold the accelerator pedal as steady as possible.

SEF414S

*3: Checking the vehicle speed with CONSULT-II or GST is advised. Suggested Transmission Gear Position for A/T Models Set the selector lever in the “D” position with the overdrive switch turned ON. 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.

EC-1240

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d) For normal acceleration in low altitude areas For quick acceleration in low altitude areas [less than 1,219 m (4,000 ft)]: and high altitude areas [over 1,219 m (4,000 ft)]: ACCEL shift point km/h (MPH)

km/h (MPH)

1st to 2nd

24 (15)

24 (15)

2nd to 3rd

40 (25)

40 (25)

3rd to 4th

64 (40)

64 (40)

4th to 5th

72 (45)

72 (45)

Gear change

MA EM LC

Suggested Maximum Speed in Each Gear Downshift to a lower gear if the engine is not running smoothly, or if you need to accelerate. Do not exceed the maximum suggested speed (shown below) in any gear. For level road driving, use the highest gear suggested for that speed. Always observe posted speed limits and drive according to the road conditions to ensure safe operation. Do not over-rev the engine when shifting to a lower gear as it may cause engine damage or loss of vehicle control. Gear

km/h (MPH) 2WD (AUTO mode)

1st

50 (30)

2nd

95 (60)

GI

FE CL MT

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)

NGEC1083S04

The following is the information specified in Mode 6 of SAE J1979. 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 (30 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.

AT TF PD

—: Not applicable

AX

Test limit

Application

SU BR

X: Applicable Test value (GST display) SRT item

Self-diagnostic test item TID

CID

Three way catalyst function (Right bank)

01H

01H

Max.

X

Three way catalyst function (Left bank)

03H

02H

Max.

X

EVAP control system (Small leak)

05H

03H

Max.

X

EVAP control system purge flow monitoring

06H

83H

Min.

X

CATALYST

ST

EVAP SYSTEM

RS BT HA SC EL

EC-1241

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d) Test value (GST display) SRT item

Self-diagnostic test item

Test limit

Application

04H

Max.

X

0AH

84H

Min.

X

0BH

04H

Max.

X

0CH

04H

Max.

X

0DH

04H

Max.

X

11H

05H

Max.

X

12H

85H

Min.

X

13H

05H

Max.

X

14H

05H

Max.

X

15H

05H

Max.

X

19H

86H

Min.

X

1AH

86H

Min.

X

1BH

06H

Max.

X

1CH

06H

Max.

X

21H

87H

Min.

X

22H

87H

Min.

X

23H

07H

Max.

X

24H

07H

Max.

X

29H

08H

Max.

X

2AH

88H

Min.

X

2BH

09H

Max.

X

2CH

89H

Min.

X

Heated oxygen sensor 2 (bank 1)

2DH

0AH

Max.

X

2EH

8AH

Min.

X

Heated oxygen sensor 2 (bank 2)

2FH

0BH

Max.

X

30H

8BH

Min.

X

Heated oxygen sensor 1 (bank 1)

Heated oxygen sensor 1 (bank 2)

TID

CID

09H

HO2S

Heated oxygen sensor 2 (bank 1)

Heated oxygen sensor 2 (bank 2)

Heated oxygen sensor 1 (bank 1) Heated oxygen sensor 1 (bank 2) HO2S HEATER

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS

NGEC1083S05

X: Applicable DTC*1*2

—: Not applicable

CONSULT-II GST

SRT code

Test value/ Test limit (GST only)

1st trip DTC*1

Reference page

NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED.

P0000

—

—

—

—

HO2S1 HTR (B1)

P0031

X

X

X*5

EC-1319

HO2S1 HTR (B1)

P0032

X

X

X*5

EC-1319

HO2S2 HTR (B1)

P0037

X

X

X*5

EC-1326

HO2S2 HTR (B1)

P0038

X

X

X*5

EC-1326

Items (CONSULT-II screen terms)

EC-1242

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d) DTC*1*2 CONSULT-II GST

SRT code

Test value/ Test limit (GST only)

1st trip DTC*1

Reference page

HO2S1 HTR (B2)

P0051

X

X

X*5

EC-1319

HO2S1 HTR (B2)

P0052

X

X

X*5

EC-1319

HO2S2 HTR (B2)

P0057

X

X

X*5

EC-1326

HO2S2 HTR (B2)

P0058

X

X

X*5

EC-1326

MAF SEN/CIRCUIT

P0101

—

—

X

EC-1330

MAF SEN/CIRCUIT

P0102*3

—

—

—

EC-1330

MAF SEN/CIRCUIT

P0103*3

—

—

—

EC-1330

IAT SEN/CIRCUIT

P0112

—

—

—

EC-1343

IAT SEN/CIRCUIT

P0113

—

—

—

EC-1343

ECT SEN/CIRCUIT

P0117*3

—

—

—

EC-1348

ECT SEN/CIRCUIT

P0118*3

—

—

—

EC-1348

TP SEN/CIRCUIT

P0121

—

—

X

EC-1353

TP SEN/CIRCUIT

P0122*3

—

—

—

EC-1353

TP SEN/CIRCUIT

P0123*3

—

—

—

EC-1353

ECT SENSOR

P0125

—

—

X

EC-1366

IAT SENSOR

P0127

—

—

X

EC-1343

THERMSTAT FNCTN

P0128

—

—

X

EC-1372

HO2S1 (B1)

P0132

X

X

X*5

EC-1374

HO2S1 (B1)

P0133

X

X

X*5

EC-1382

HO2S1 (B1)

P0134

X

X

X*5

EC-1396

HO2S2 (B1)

P0138

X

X

X*5

EC-1407

HO2S2 (B1)

P0139

X

X

X*5

EC-1417

HO2S1 (B2)

P0152

X

X

X*5

EC-1374

HO2S1 (B2)

P0153

X

X

X*5

EC-1382

HO2S1 (B2)

P0154

X

X

X*5

EC-1396

HO2S2 (B2)

P0158

X

X

X*5

EC-1407

HO2S2 (B2)

P0159

X

X

X*5

EC-1417

FUEL SYS-LEAN-B1

P0171

—

—

X

EC-1427

FUEL SYS-RICH-B1

P0172

—

—

X

EC-1436

FUEL SYS-LEAN-B2

P0174

—

—

X

EC-1427

FUEL SYS-RICH-B2

P0175

—

—

X

EC-1436

FTT SENSOR

P0181

—

—

X

EC-1444

FTT SEN/CIRCUIT

P0182

—

—

X

EC-1444

FTT SEN/CIRCUIT

P0183

—

—

X

EC-1444

ENG OVER TEMP

P0217

—

—

X

EC-1449

SCB/V CONT SOL/V

P0245

—

—

X

EC-1456

Items (CONSULT-II screen terms)

EC-1243

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d) DTC*1*2 CONSULT-II GST

SRT code

Test value/ Test limit (GST only)

1st trip DTC*1

Reference page

MULTI CYL MISFIRE

P0300

—

—

X

EC-1462

CYL1 MISFIRE

P0301

—

—

X

EC-1462

CYL2 MISFIRE

P0302

—

—

X

EC-1462

CYL3 MISFIRE

P0303

—

—

X

EC-1462

CYL4 MISFIRE

P0304

—

—

X

EC-1462

CYL5 MISFIRE

P0305

—

—

X

EC-1462

CYL6 MISFIRE

P0306

—

—

X

EC-1462

KNOCK SEN/CIRC-B1

P0327

—

—

—

EC-1471

KNOCK SEN/CIRC-B1

P0328

—

—

—

EC-1471

CKP SEN/CIRCUIT

P0335

—

—

X

EC-1475

CMP SEN/CIRCUIT

P0340

—

—

X

EC-1481

TW CATALYST SYS-B1

P0420

X

X

X*5

EC-1488

TW CATALYST SYS-B2

P0430

X

X

X*5

EC-1488

EVAP PURG FLOW/MON

P0441

X

X

X*5

EC-1493

EVAP SMALL LEAK

P0442

X

X

X*5

EC-1505

PURG VOLUME CONT/V

P0444

—

—

X

EC-1519

PURG VOLUME CONT/V

P0445

—

—

X

EC-1519

VENT CONTROL VALVE

P0447

—

—

X

EC-1526

EVAP SYS PRES SEN

P0452

—

—

X

EC-1532

EVAP SYS PRES SEN

P0453

—

—

X

EC-1532

EVAP GROSS LEAK

P0455

X

X

X*5

EC-1543

EVAP VERY SML LEAK

P0456

X*4

X

X*5

EC-1556

FUEL LEV SEN SLOSH

P0460

—

—

X

EC-1570

FUEL LEVEL SENSOR

P0461

—

—

X

EC-1575

FUEL LEVL SEN/CIRC

P0462

—

—

X

EC-1577

FUEL LEVL SEN/CIRC

P0463

—

—

X

EC-1577

VEH SPEED SEN/CIRC

P0500*5

—

—

X

EC-1582

ISC SYSTEM/CIRC

P0505

—

—

X

EC-1586

CLOSED TP SW/CIRC

P0510

—

—

X

EC-1592

P0600*4

—

—

—

EC-1599

ECM

P0605

—

—

X

EC-1604

PNP SW/CIRC

P0705

—

—

X

AT-104

ATF TEMP SEN/CIRC

P0710

—

—

X

AT-110

VEH SPD SEN/CIR AT

P0720

—

—

X

AT-116

ENGINE SPEED SIG

P0725

—

—

X

AT-121

A/T 1ST GR FNCTN

P0731

—

—

X

AT-125

Items (CONSULT-II screen terms)

A/T COMM LINE

EC-1244

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d) DTC*1*2 CONSULT-II GST

SRT code

Test value/ Test limit (GST only)

1st trip DTC*1

A/T 2ND GR FNCTN

P0732

—

—

X

AT-131

A/T 3RD GR FNCTN

P0733

—

—

X

AT-137

A/T 4TH GR FNCTN

P0734

—

—

X

AT-143

TCC SOLENOID/CIRC

P0740

—

—

X

AT-152

A/T TCC S/V FNCTN

P0744

—

—

X

AT-157

L/PRESS SOL/CIRC

P0745

—

—

X

AT-164

SFT SOL A/CIRC

P0750*3

—

—

X

AT-169

SFT SOL B/CIRC

P0755*3

—

—

X

AT-174

HO2S1 (B1)

P1143

X

X

X*5

EC-1606

HO2S1 (B1)

P1144

X

X

X*5

EC-1615

HO2S2 (B1)

P1146

X

X

X*5

EC-1624

HO2S2 (B1)

P1147

X

X

X*5

EC-1634

CLOSED LOOP-B1

P1148

—

—

X*5

EC-1644

HO2S1 (B2)

P1163

X

X

X*5

EC-1606

HO2S1 (B2)

P1164

X

X

X*5

EC-1615

HO2S2 (B2)

P1166

X

X

X*5

EC-1624

HO2S2 (B2)

P1167

X

X

X*5

EC-1634

CLOSED LOOP-B2

P1168

—

—

X

EC-1644

ENG OVER TEMP

P1217

—

—

X

EC-1646

CKP SENSOR (COG)

P1336

—

—

X

EC-1651

EVAP SMALL LEAK

P1442

X

X

X*5

EC-1658

PURG VOLUME CONT/V

P1444

—

—

X

EC-1660

VENT CONTROL VALVE

P1446

—

—

X

EC-1672

VENT CONTROL VALVE

P1448

—

—

X

EC-1679

EVAP VERY SML LEAK

P1456

X*4

X

X*5

EC-1556

FUEL LEVEL SEN/CIRC

P1464

—

—

X

EC-1687

VC/V BYPASS/V

P1490

—

—

X

EC-1691

VC CUT/V BYPASS/V

P1491

—

—

X

EC-1697

A/T DIAG COMM LINE

P1605

—

—

X

EC-1706

P1705*5

—

—

X

AT-179

P-N POS SW/CIRCUIT

P1706

—

—

X

EC-1709

O/R CLTCH SOL/CIRC

P1760

—

—

X

AT-188

Items (CONSULT-II screen terms)

TP SEN/CIRC A/T

*1: 1st trip DTC No. 1 is the same as DTC No. *2: These numbers are prescribed by SAE J2012. *3: When the fail-safe operation occurs, the MIL illuminates. *4: SRT code will not be set if the self-diagnostic result is NG. *5: These are not displayed with GST. NOTE: Regarding D22 models, “B1” indicates bank 1, “B2” indicates bank 2.

EC-1245

Reference page

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d)

HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC ( With CONSULT-II)

NGEC1083S06 NGEC1083S0601

NOTE: If the DTC is not for A/T related items (see EC-1174), 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 5 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.) 쐌 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).

SEF823YD

The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFDIAG RESULTS” mode with CONSULT-II.

How to Erase DTC (

With GST)

NGEC1083S0602

NOTE: If the DTC is not for A/T related items (see EC-1174), skip step 2. 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 “SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II)” in AT section titled “TROUBLE

EC-1246

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Emission-related Diagnostic Information (Cont’d)

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 in the ECM can be erased by selecting Mode 4 with GST. 쐌 If the battery is disconnected, the emission-related diagnostic information will be lost after approx. 24 hours. 쐌 Erasing the emission-related diagnostic information using CONSULT-II or GST is easier and quicker than switching the mode selector on the ECM. 쐌 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) 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.

GI MA EM LC

FE CL

Malfunction Indicator Lamp (MIL) DESCRIPTION

NGEC1084

MT AT TF PD AX

SEF217U

The MIL is located on the instrument panel. 1. The MIL will light up when the ignition switch is turned ON without the engine running. This is a bulb check. 쐌 If the MIL does not light up, refer to EL section (“WARNING LAMPS”) or see EC-1751. 2. When the engine is started, the MIL should go OFF. If the MIL remains on, the on board diagnostic system has detected an engine system malfunction.

On Board Diagnostic System Function

NGEC1084S01

The on board diagnostic system has the following two functions.

SU BR ST RS BT HA SC EL

EC-1247

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Malfunction Indicator Lamp (MIL) (Cont’d) Diagnostic Test Mode

KEY and ENG. Status

Function

Explanation of Function

Mode I

Ignition switch in ON position

BULB CHECK

This function checks the MIL bulb for damage (blown, open circuit, etc.). If the MIL does not come on, check MIL circuit. (See EC-1751.)

MALFUNCTION WARNING

This is a usual driving condition. When a malfunction is detected twice in two consecutive driving cycles (two trip detection logic), the MIL will light up to inform the driver that a malfunction has been detected. The following malfunctions will light up or blink the MIL in the 1st trip. 쐌 Coolant overtemperature enrichment protection 쐌 “Misfire (Possible three way catalyst damage)” 쐌 “Closed loop control” 쐌 Fail-safe mode

Engine stopped

Engine running

Diagnostic Test Mode I — Bulb Check

NGEC1084S02

In this mode, the MIL on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to EL-94, “WARNING LAMPS” or see EC-1751.

Diagnostic Test Mode I — Malfunction Warning MIL

NGEC1084S03

Condition

ON

When the malfunction is detected or the ECM’s CPU is malfunctioning.

OFF

No malfunction.

OBD System Operation Chart

NGEC1085

RELATIONSHIP BETWEEN MIL, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS 쐌 쐌 쐌 쐌

쐌

NGEC1085S01

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 MIL will come on. For details, refer to “Two Trip Detection Logic” on EC-1232. The MIL 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 MIL (goes off) DTC, Freeze Frame Data (no display) 1st Trip DTC (clear)

NGEC1085S02

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)

EC-1248

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

OBD System Operation Chart (Cont’d) Items 1st Trip Freeze Frame Data (clear)

Fuel Injection System

Misfire

Other

*1, *2

*1, *2

1 (pattern B)

For details about patterns “B” and “C” under “Fuel Injection System” and “Misfire”, see EC-1251. For details about patterns “A” and “B” under “Other”, see EC-1253. *1: Clear timing is at the moment OK is detected. *2: Clear timing is when the same malfunction is detected in the 2nd trip.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1249

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

OBD System Operation Chart (Cont’d)

RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE” , “FUEL INJECTION SYSTEM”

=NGEC1085S03

SEF392S

*1: When the same malfunction is detected in two consecutive trips, MIL will light up. *2: MIL 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-1250

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

VG33ER

OBD System Operation Chart (Cont’d)

EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”

NGEC1085S04

Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. 쐌 The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. 쐌 The B counter will be counted up when driving pattern B is satisfied without any malfunction. 쐌 The MIL will go off when the B counter reaches 3. (*2 in “OBD SYSTEM OPERATION CHART”)



GI

NGEC1085S0401

NGEC1085S0402

Driving pattern C means the vehicle operation as follows: 1) The following conditions should be satisfied at the same time: Engine speed: (Engine speed in the freeze frame data) ±375 rpm Calculated load value: (Calculated load value in the freeze frame data) x (1±0.1) [%] Engine coolant temperature (T) condition: 쐌 When the freeze frame data shows lower than 70°C (158°F), “T” should be lower than 70°C (158°F). 쐌 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) 쐌 The C counter will be cleared when the malfunction is detected regardless of (1). 쐌 The C counter will be counted up when (1) is satisfied without the same malfunction. 쐌 The DTC will not be displayed after C counter reaches 80. 쐌 The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC is stored in ECM.

MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1251

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

OBD System Operation Chart (Cont’d)

RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”NGEC1085S05

SEF393S

*1: When the same malfunction is detected in two consecutive trips, MIL will light up. *2: MIL 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-1252

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

VG33ER

OBD System Operation Chart (Cont’d)

EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” NGEC1085S06 GI NGEC1085S0601

MA EM LC

FE CL AEC574

쐌 쐌 쐌

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.



MT AT TF

NGEC1085S0602

Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. 쐌 The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. 쐌 The B counter will be counted up when driving pattern B is satisfied without any malfunctions. 쐌 The MIL will go off when the B counter reaches 3 (*2 in “OBD SYSTEM OPERATION CHART”).

PD AX SU BR ST RS BT HA SC EL

EC-1253

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

CONSULT-II

CONSULT-II CONSULT-II INSPECTION PROCEDURE

=NGEC1086 NGEC1086S01

1. 2.

Turn ignition switch OFF. Connect “CONSULT-II” to data link connector which is located under LH dash panel near the fuse box cover.

3. 4.

Turn ignition switch ON. Touch “START”.

5.

Touch “ENGINE”.

SEF163X

PBR455D

SEF948Y

6.

Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual.

SEF949Y

EC-1254

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER CONSULT-II (Cont’d)

ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION NGEC1086S02

GI

DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS

INPUT

ENGINE CONTROL COMPONENT PARTS

Item

WORK SUPPORT

DATA MONITOR

DATA MONITOR (SPEC)

X

X

X

X

X

X

DTC & SRT CONFIRMATION ACTIVE TEST

DTC*1

Camshaft position sensor

X

X

Mass air flow sensor

X

Engine coolant temperature sensor

X

Heated oxygen sensor 1

X

X

X

X

X

Heated oxygen sensor 2

X

X

X

X

X

Vehicle speed sensor

X

X

X

Throttle position sensor

X

X

X

Fuel tank temperature sensor

X

X

X

EVAP control system pressure sensor

X

X

X

Intake air temperature sensor

X

X

X

Crankshaft position sensor (OBD)

X

Knock sensor

X

X

X

Ignition switch (start signal)

X

X

X

Closed throttle position switch (throttle position sensor signal)

X

X

Air conditioner switch

X

X

X

X

Park/neutral position (PNP) switch

X

X

EM LC

X

FE CL

X

MT AT TF

X

Closed throttle position switch

SRT STATUS

DTC WORK SUPPORT

FREEZE FRAME DATA*2

MA

PD AX SU BR

Power steering oil pressure switch

X

X

Battery voltage

X

X

Ambient air temperature switch

X

X

ST RS BT HA SC EL

EC-1255

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

CONSULT-II (Cont’d) DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS DATA MONITOR

DATA MONITOR (SPEC)

ACTIVE TEST

Injectors

X

X

X

Power transistor (Ignition timing)

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

Item

IACV-AAC valve

WORK SUPPORT

X

EVAP canister purge volume control solenoid valve

DTC*1

FREEZE FRAME DATA*2

Air conditioner relay OUTPUT

ENGINE CONTROL COMPONENT PARTS

DTC & SRT CONFIRMATION

Fuel pump relay

X

SRT STATUS

X

Cooling fan

X

X

X

Heated oxygen sensor 1 heater

X

X

X

X

Heated oxygen sensor 2 heater

X

X

X

X

EVAP canister vent control valve

X

X

X

X

Vacuum cut valve bypass valve

X

X

X

X

SCB valve control solenoid valve

X

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-1233.

EC-1256

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER CONSULT-II (Cont’d)

FUNCTION Diagnostic test mode

=NGEC1086S03

Function

GI

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.

EM

Data monitor (SPEC)

Input/Output specification of the basic fuel schedule, AFM, A/F feedback control value and the other data monitor items can be read.

LC

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 number can be read.

FE

*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) Others

CL MT AT

WORK SUPPORT MODE WORK ITEM

CONDITION

MA

NGEC1086S04

USAGE

TP SW/TP SEN IDLE POSI ADJ

쐌 FOLLOW THE BASIC INSPECTION INSTRUCTION IN When adjusting the idle throttle THE SERVICE MANUAL. position

IGNITION TIMING ADJ

쐌 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 target ignition timing After adjustment, confirm target ignition timing with a timing light by turning the distributor.

FUEL PRESSURE RELEASE

쐌 FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure from fuel line

SELF-LEARNING CONT

쐌 THE COEFFICIENT OF SELF-LEARNING CONTROL MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT.

When clean the coefficient of selflearning control valve

TF PD AX SU BR ST RS BT HA SC EL

EC-1257

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

CONSULT-II (Cont’d) WORK ITEM

CONDITION

USAGE

EVAP SYSTEM CLOSE

OPEN THE VACUUM CUT VALVE BYPASS VALVE AND CLOSE THE EVAP CANISTER VENT CONTROL VALVE IN ORDER TO MAKE EVAP SYSTEM CLOSE UNDER THE FOLLOWING CONDITIONS. 쐌 IGN SW ON 쐌 ENGINE NOT RUNNING 쐌 AMBIENT TEMPERATURE IS ABOVE 0°C (32°F). 쐌 NO VACUUM AND NO HIGH PRESSURE IN EVAP SYSTEM 쐌 FUEL TANK TEMP. IS MORE THAN 0°C (32°F). 쐌 WITHIN 10 MINUTES AFTER STARTING “EVAP SYSTEM CLOSE” 쐌 WHEN TRYING TO EXECUTE “EVAP SYSTEM CLOSE” UNDER THE CONDITION EXCEPT ABOVE, CONSULT-II WILL DISCONTINUE IT AND DISPLAY APPROPRIATE INSTRUCTION. NOTE: WHEN STARTING ENGINE, CONSULT-II MAY DISPLAY “BATTERY VOLTAGE IS LOW. CHARGE BATTERY”, EVEN IN USING CHARGED BATTERY.

When detecting EVAP vapor leak point of EVAP system

TARGET IDLE RPM ADJ*

SET ENGINE SPEED AT THE SPECIFIED VALUE UNDER THE FOLLOWING CONDITIONS. 쐌 ENGINE WARMED UP 쐌 NO-LOAD

When adjusting initial ignition timing and idle speed

*: This function is not necessary in the usual service procedure.

SELF-DIAGNOSTIC MODE DTC and 1st Trip DTC

NGEC1086S05 NGEC1086S0501

Regarding items of “DTC and 1st trip DTC”, refer to “TROUBLE DIAGNOSIS — INDEX” (See EC-1174.)

Freeze Frame Data and 1st Trip Freeze Frame Data NGEC1086S0502 Freeze frame data item *1 DIAG TROUBLE CODE [PXXXX] FUEL SYS-B1 *2

FUEL SYS-B2 *2 CAL/LD VALUE [%]

Description 쐌 The engine control component part/control system has a trouble code, it is displayed as “PXXXX”. (Refer to “TROUBLE DIAGNOSIS — INDEX”, EC-1174.) 쐌 “Fuel injection system status” at the moment a malfunction is detected is displayed. 쐌 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 쐌 The calculated load value at the moment a malfunction is detected is displayed.

COOLANT TEMP [°C] 쐌 The engine coolant temperature at the moment a malfunction is detected is displayed. or [°F] S-FUEL TRIM-B1 [%] S-FUEL TRIM-B2 [%]

쐌 “Short-term fuel trim” at the moment a malfunction is detected is displayed. 쐌 The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule.

L-FUEL TRIM-B2 [%]

쐌 “Long-term fuel trim” at the moment a malfunction is detected is displayed. 쐌 The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim.

ENGINE SPEED [rpm]

쐌 The engine speed at the moment a malfunction is detected is displayed.

L-FUEL TRIM-B1 [%]

EC-1258

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER CONSULT-II (Cont’d)

Freeze frame data item *1

Description

GI

VHCL SPEED [km/h] or [mph]

쐌 The vehicle speed at the moment a malfunction is detected is displayed.

ABSOL TH·P/S [%]

쐌 The throttle valve opening angle at the moment a malfunction is detected is displayed.

B/FUEL SCHDL [msec]

쐌 The base fuel schedule at the moment a malfunction is detected is displayed.

INT/A TEMP SE [°C] or [°F]

쐌 The intake air temperature at the moment a malfunction is detected is displayed.

MA EM LC

*1: The items are the same as those of 1st trip freeze frame data. *2: Regarding D22 model, “-B1” indicates right bank and “-B2” indicates left bank.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1259

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

CONSULT-II (Cont’d)

DATA MONITOR MODE ECM input signals

Main signals

Description

ENG SPEED [rpm]

쎻

쎻

쐌 Indicates the engine speed computed from the REF signal (120° signal) of the camshaft position sensor.

MAS A/F SE-B1 [V]

쎻

쎻

쐌 The signal voltage of the mass air flow sensor is displayed.

B/FUEL SCHDL [msec]

쎻

쐌 “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction.

A/F ALPHA-B1 [%]

쎻

A/F ALPHA-B2 [%]

쎻

Monitored item [Unit]

COOLAN TEMP/S [°C] or [°F]

쎻

쎻

HO2S1 (B1) [V]

쎻

쎻

HO2S1 (B2) [V]

쎻

쎻

HO2S2 (B1) [V]

쎻

쎻

HO2S2 (B2) [V]

쎻

쎻

HO2S1 MNTR (B1) [RICH/LEAN]

쎻

HO2S1 MNTR (B2) [RICH/LEAN]

쎻

HO2S2 MNTR (B1) [RICH/LEAN]

쎻

=NGEC1086S06

Remarks

쐌 When the engine is stopped, a certain value is indicated.

쐌 The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.

쐌 When the engine is stopped, a certain value is indicated. 쐌 This data also includes the data for the air-fuel ratio learning control.

쐌 The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed.

쐌 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.

쐌 The signal voltage of the heated oxygen sensor 1 (front) is displayed. 쐌 The signal voltage of the heated oxygen sensor 2 (rear) is displayed. 쐌 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.

쐌 After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. 쐌 When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously.

쐌 Display of heated oxygen sensor 2 (rear) signal: RICH ... means the amount of oxygen after three way catalyst is relatively small. LEAN ... means the amount of oxygen after three way catalyst is relatively large.

쐌 When the engine is stopped, a certain value is indicated.

HO2S2 MNTR (B2) [RICH/LEAN]

쎻

VHCL SPEED SE [km/h] or [mph]

쎻

쎻

쐌 The vehicle speed computed from the vehicle speed sensor signal is displayed.

BATTERY VOLT [V]

쎻

쎻

쐌 The power supply voltage of ECM is displayed.

THRTL POS SEN [V]

쎻

쎻

쐌 The throttle position sensor signal voltage is displayed.

FUEL T/TMP SE [°C] or [°F]

쎻

쐌 The fuel temperature judged from the fuel tank temperature sensor signal voltage is displayed.

EC-1260

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER CONSULT-II (Cont’d)

Monitored item [Unit]

INT/A TEMP SE [°C] or [°F]

ECM input signals

Main signals

쎻

쎻

EVAP SYS PRES [V]

Description

MA

쐌 The signal voltage of EVAP control system pressure sensor is displayed.

EM

쐌 The signal voltage of the fuel level sensor is displayed.

START SIGNAL [ON/OFF]

쎻

쎻

쐌 Indicates [ON/OFF] condition from the starter signal.

CLSD THL POS [ON/OFF]

쎻

쎻

쐌 Indicates idle position [ON/OFF] computed by ECM according to the throttle position sensor signal.

쎻

AIR COND SIG [ON/OFF]

쎻

쎻

쐌 Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal.

P/N POSI SW [ON/OFF]

쎻

쎻

쐌 Indicates [ON/OFF] condition from the park/neutral position (PNP) switch signal.

쎻

쐌 [ON/OFF] condition of the power steering oil pressure switch determined by the power steering oil pressure signal is indicated.

쎻

AMB TEMP SW [ON/OFF]

쎻

쐌 Indicates [ON/OFF] condition from the ambient air temperature switch signal.

IGNITION SW [ON/OFF]

쎻

쐌 Indicates [ON/OFF] condition from ignition switch.

INJ PULSE-B1 [msec]

쎻

INJ PULSE-B2 [msec] IGN TIMING [BTDC]

LC 쐌 After starting the engine, [OFF] is displayed regardless of the starter signal.

FE

쐌 Indicates mechanical contact [ON/OFF] condition of the closed throttle position switch.

CLSD THL/P SW [ON/OFF]

PW/ST SIGNAL [ON/OFF]

쎻

GI

쐌 The intake air temperature determined by the signal voltage of the intake air temperature sensor is indicated.

쎻

FUEL LEVEL SE [V]

Remarks

CL MT AT TF PD AX

쐌 Indicates the actual fuel injection pulse width compensated by ECM according to the input signals.

쐌 When the engine is stopped, a certain computed value is indicated.

쐌 Indicates the ignition timing computed by ECM according to the input signals.

쐌 When the engine is stopped, a certain value is indicated.

SU BR

쐌 “Calculated load value” indicates the value of the current airflow divided by peak airflow.

ST

CAL/LD VALUE [%]

RS

ABSOL TH·P/S [%]

쐌 “Absolute throttle position sensor” indicates the throttle opening computed by ECM according to the signal voltage of the throttle position sensor. 쐌 Indicates the mass airflow computed by ECM according to the signal voltage of the mass airflow sensor.

MASS AIRFLOW [g·m/s]

IACV-AAC/V [%]

쎻

쐌 Indicates the IACV-AAC valve control value computed by ECM according to the input signals.

BT HA SC EL

EC-1261

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

CONSULT-II (Cont’d)

Monitored item [Unit]

ECM input signals

Main signals

Description 쐌 Indicates the EVAP canister purge volume control solenoid valve control value computed by the ECM according to the input signals. 쐌 The opening becomes larger as the value increases.

PURG VOL C/V [%]

AIR COND RLY [ON/OFF]

쎻

쐌 The air conditioner relay control condition (determined by ECM according to the input signal) is indicated.

FUEL PUMP RLY [ON/OFF]

쎻

쐌 Indicates the fuel pump relay control condition determined by ECM according to the input signals.

VENT CONT/V [ON/OFF]

쐌 The control condition of the EVAP canister vent control valve (determined by ECM according to the input signal) is indicated. 쐌 ON ... Closed OFF ... Open

VC/V BYPASS/V [ON/OFF]

쐌 The control condition of the vacuum cut valve bypass valve (determined by ECM according to the input signal) is indicated. 쐌 ON ... Open OFF ... Closed

COOLING FAN [ON/OFF]

쐌 Indicates the control condition of the cooling fan (determined by ECM according to the input signal). ON ... Operation OFF ... Stop

HO2S1 HTR (B1) [ON/OFF] HO2S1 HTR (B1) [ON/OFF] HO2S2 HTR (B1) [ON/OFF] HO2S2 HTR (B2) [ON/OFF]

쎻

쐌 Indicates [ON/OFF] condition of front heated oxygen sensor heater determined by ECM according to the input signals. 쐌 Indicates [ON/OFF] condition of rear heated oxygen sensor heater determined by ECM according to the input signals.

SCB/V CON S/V

쐌 The control condition of the SCB valve control solenoid valve (determined by ECM according to the input signals) is indicated. 쐌 ON ... SCB valve is closed. OFF ... SCB valve is opened.

VOLTAGE [V]

쐌 Voltage measured by the voltage probe.

FREQUENCY [msec] or [Hz] or [%]

Remarks

쐌 Pulse width, frequency or duty cycle measured by the pulse probe.

쐌 Only “#” is displayed if item is unable to be measured. 쐌 Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured.

NOTE: 쐌 Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. 쐌 Regarding D22 model, “-B1” indicates right bank and “-B2” indicates left bank.

EC-1262

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER CONSULT-II (Cont’d)

DATA MONITOR (SPEC) MODE

NGEC1086S07

ECM input signals

Main signals

쎻

쎻

쐌 The signal voltage of the mass air flow sen- 쐌 When the engine is running, specifisor specification is displayed. cation range is indicated.

MA

B/FUEL SCHDL [msec]

쎻

쐌 “Base fuel schedule” indicates the fuel injec쐌 When the engine is running, specifition pulse width programmed into ECM, cation range is indicated. prior to any learned on board correction.

EM

A/F ALPHA-B1 [%]

쎻

LC

A/F ALPHA-B2 [%]

쎻

쐌 When the engine is running, specifi쐌 Indicates the mean value of the air-fuel ratio cation range is indicated. feedback correction factor per cycle. 쐌 This data also includes the data for the air-fuel ratio learning control.

Monitored item [Unit]

MAS A/F SE-B1 [V]

Description

GI

Remarks

NOTE: 쐌 Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. 쐌 Regarding D22 model, “B1” indicates bank 1 and “B2” indicates bank 2.

ACTIVE TEST MODE TEST ITEM

CONDITION

FE NGEC1086S08

JUDGEMENT

CHECK ITEM (REMEDY)

쐌 Engine: Return to the original 쐌 Harness and connector trouble condition If trouble symptom disappears, see FUEL INJECTION 쐌 Fuel injectors 쐌 Change the amount of fuel injec- CHECK ITEM. 쐌 Front heated oxygen sensor tion using CONSULT-II. 쐌 Engine: Return to the original trouble condition IGNITION TIMING 쐌 Timing light: Set 쐌 Retard the ignition timing using CONSULT-II.

IACV-AAC/V OPENING

쐌 Engine: After warming up, idle the engine. 쐌 Change the IACV-AAC valve opening percent using CONSULT-II.

If trouble symptom disappears, see 쐌 Adjust initial ignition timing CHECK ITEM.

CL MT AT TF PD

Engine speed changes according to the opening percent.

쐌 Harness and connector 쐌 IACV-AAC valve

POWER BALANCE

쐌 Engine: After warming up, idle the engine. 쐌 A/C switch “OFF” 쐌 Shift lever “N” 쐌 Cut off each injector signal one at a time using CONSULT-II.

Engine runs rough or dies.

쐌 쐌 쐌 쐌 쐌 쐌

COOLING FAN

쐌 Ignition switch: ON 쐌 Turn the cooling fan “ON” and “OFF” using CONSULT-II.

Cooling fan moves and stops.

쐌 Engine: Return to the original trouble condition 쐌 Change the engine coolant temperature using CONSULT-II.

쐌 Harness and connector If trouble symptom disappears, see 쐌 Engine coolant temperature senCHECK ITEM. sor 쐌 Fuel injectors

RS

ENG COOLANT TEMP

FUEL PUMP RELAY

쐌 Ignition switch: ON (Engine stopped) 쐌 Turn the fuel pump relay “ON” and “OFF” using CONSULT-II and listen to operating sound.

Fuel pump relay makes the operat- 쐌 Harness and connector ing sound. 쐌 Fuel pump relay

HA

Harness and connector Compression Injectors Power transistor Spark plugs Ignition coils

쐌 Harness and connector 쐌 Cooling fan motor 쐌 Cooling fan relay

AX SU BR ST

BT

SC EL

EC-1263

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

CONSULT-II (Cont’d) TEST ITEM

CONDITION

JUDGEMENT

CHECK ITEM (REMEDY)

PURG VOL CONT/V

쐌 Engine: After warming up, run engine at 1,500 rpm. 쐌 Change the EVAP canister purge Engine speed changes according volume control solenoid valve to the opening percent. opening percent using CONSULT-II.

FUEL/T TEMP SEN

쐌 Change the fuel tank temperature using CONSULT-II.

VENT CONTROL/V

쐌 Ignition switch: ON (Engine stopped) 쐌 Turn solenoid valve “ON” and “OFF” with the CONSULT-II and listen to operating sound.

Solenoid valve makes an operating 쐌 Harness and connector sound. 쐌 Solenoid valve

VC/V BYPASS/V

쐌 Ignition switch: ON (Engine stopped) 쐌 Turn solenoid valve “ON” and “OFF” with the CONSULT-II and listen to operating sound.

Solenoid valve makes an operating 쐌 Harness and connector sound. 쐌 Solenoid valve

DTC CONFIRMATION MODE SRT STATUS Mode

쐌 Harness and connector 쐌 Solenoid valve

NGEC1086S09 NGEC1086S0901

For details, refer to “SYSTEM READINESS TEST (SRT) CODE”, EC-1234.

SRT WORK SUPPORT Mode

NGEC1086S0902

SRT status and some of the data monitor item can be read.

EC-1264

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER CONSULT-II (Cont’d)

DTC Work Support Mode Test mode

Test item

Condition

NGEC1086S0903

Reference page

EVAP SML LEAK P0442/P1442

EC-1505

EVAP V/S LEAK P0456/P1456

EC-1556

EVAPORATIVE SYSTEM PURG VOL CN/V P1444

GI MA

EC-1660

PURGE FLOW P1441

EC-1493

VC CUT/V BP/V P1491

EC-1697

HO2S1 (B1) P0134

EC-1396

HO2S1 (B1) P1143

EC-1606

HO2S1 (B1) P1144

EC-1615

HO2S1 (B1) P0133

Refer to corresponding trouble diagnosis for DTC.

HO2S1 HO2S1 (B2) P0154 HO2S1 (B2) P1163

EM LC

EC-1382 EC-1396 EC-1606

HO2S1 (B2) P1164

EC-1615

HO2S1 (B2) P0153

EC-1382

HO2S2 (B1) P1146

EC-1624

HO2S2 (B1) P1147

EC-1634

HO2S2 (B1) P0139

EC-1417

HO2S2 (B2) P1166

EC-1624

HO2S2 (B2) P1167

EC-1634

HO2S2 (B2) P0159

EC-1417

FE CL MT AT

HO2S2

TF PD AX

REAL TIME DIAGNOSIS IN DATA MONITOR MODE SU (RECORDING VEHICLE DATA) NGEC1086S10

SEF705Y

CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1) “AUTO TRIG” (Automatic trigger): 쐌 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%”, “REAL-TIME DIAG” screen is also displayed. The recording time after the malfunction detection and the recording speed can be changed by “TRIGGER POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL. 2) “MANU TRIG” (Manual trigger): 쐌 DTC/1st trip DTC and malfunction item will not be displayed

BR ST RS BT HA SC EL

SEF707X

EC-1265

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

CONSULT-II (Cont’d)

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” 쐌 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. 쐌 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-23, “Incident Simulation Tests”. 2) “MANU TRIG” 쐌 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-1266

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Generic Scan Tool (GST)

Generic Scan Tool (GST) DESCRIPTION

=NGEC1087 NGEC1087S01

Generic Scan Tool (OBDII scan tool) complying with SAE J1978 has 7 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.

GI MA EM LC

SEF139P

GST INSPECTION PROCEDURE 1. 2.

NGEC1087S02

Turn ignition switch OFF. Connect “GST” to data link connector for GST which is located under LH dash panel near the fuse box cover.

FE CL MT

SEF163X

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.)

AT TF PD AX

AEC059B

5.

Perform each diagnostic mode according to each service procedure. For further information, see the GST Operation Manual of the tool maker.

SU BR ST RS

AEC060B

BT HA SC EL

EC-1267

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

VG33ER

Generic Scan Tool (GST) (Cont’d)

FUNCTION Diagnostic test mode

NGEC1087S03

Function

MODE 1

READINESS TESTS

This mode gains access to current emission-related data values, including analog inputs and outputs, digital inputs and outputs, 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-1258).]

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: 쐌 Clear number of diagnostic trouble codes (MODE 1) 쐌 Clear diagnostic trouble codes (MODE 3) 쐌 Clear trouble code for freeze frame data (MODE 1) 쐌 Clear freeze frame data (MODE 2) 쐌 Reset status of system monitoring test (MODE 1) 쐌 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 can close EVAP system in ignition switch “ON” position (Engine stopped). When this mode is performed, the following parts can be opened or closed. 쐌 EVAP canister vent control valve open 쐌 Vacuum cut valve bypass valve closed In the following conditions, this mode cannot function. 쐌 Low ambient temperature 쐌 Low battery voltage 쐌 Engine running 쐌 Ignition switch OFF 쐌 Low fuel temperature 쐌 Too much pressure is applied to EVAP system This mode is to enable the off-board to request vehicle specific vehicle information such as Vehicle Identification Number (VIN) and calibration IDs.

EC-1268

TROUBLE DIAGNOSIS — INTRODUCTION

VG33ER Introduction

Introduction

MEF036D

SEF233G

NGEC1088

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-1271. 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.

GI MA EM LC

FE CL MT AT TF PD AX

SEF234G

DIAGNOSTIC WORKSHEET

SEF907L

NGEC1088S01

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 MIL to come on steady or blink and DTC to be detected. Examples: 쐌 Vehicle ran out of fuel, which caused the engine to misfire. 쐌 Fuel filler cap was left off or incorrectly screwed on, allowing fuel to evaporate into the atmosphere [for the models with EVAP (SMALL LEAK) diagnosis].

SU BR ST RS BT HA SC EL

EC-1269

IDX

TROUBLE DIAGNOSIS — INTRODUCTION

VG33ER

Introduction (Cont’d)

Worksheet Sample

NGEC1088S0101

MTBL0017

EC-1270

TROUBLE DIAGNOSIS — INTRODUCTION

VG33ER Work Flow

Work Flow

NGEC1089

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST SEF510ZF

*1 *2

*3

EC-1289 If time data of “SELF-DIAG RESULTS” is other than “0” or “[1t]”, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312.

*4

*5

If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to “TROUBLE DIAGNOSIS FOR POWER SUPPLY”, EC-1313. If malfunctioning part cannot be

*6 *7

detected, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. EC-1239 EC-1308

RS BT HA SC EL

EC-1271

IDX

TROUBLE DIAGNOSIS — INTRODUCTION

VG33ER

Work Flow (Cont’d)

DESCRIPTION FOR WORK FLOW STEP

NGEC1089S01

DESCRIPTION

STEP I

Get detailed information about the conditions and the environment when the incident/symptom occurred using the “DIAGNOSTIC WORK SHEET”, EC-1270.

STEP II

Before confirming the concern, check and write down (print out using CONSULT-II or GST) the (1st trip) DTC and the (1st trip) freeze frame data, then erase the DTC and the data. (Refer to EC-1246.) The (1st trip) DTC and the (1st trip) freeze frame data can be used when duplicating the incident at STEP III & IV. If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 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-1290.) 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 “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. If the malfunction code is detected, skip STEP IV and perform STEP V.

STEP IV

Try to detect the (1st trip) DTC by driving in (or performing) the “DTC Confirmation Procedure”. Check and read the (1st trip) DTC and (1st trip) freeze frame data by using CONSULT-II or GST. 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 “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. In case the “DTC 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-1273.) If CONSULT-II is available, perform “DATA MONITOR (SPEC)” mode with CONSULT-II and proceed to the “TROUBLE DIAGNOSIS — SPECIFICATION VALUE”, EC-1308. (If malfunction is detected, proceed to “REPAIR/REPLACE”.) Then perform inspections according to the Symptom Matrix Chart. (Refer to EC-1290.)

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-1294, EC-1299. 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-25, “Circuit Inspection”. Repair or replace the malfunction parts. If malfunctioning part cannot be detected, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312.

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 “DTC Confirmation Procedure” and confirm the normal code [DTC No. P0000 or 0505] 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 and TCM (Transmission control module). (Refer to EC-1246.)

EC-1272

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER Basic Inspection

Basic Inspection

NGEC1090

Precaution: Perform Basic Inspection without electrical or mechanical loads applied; 쐌 Headlamp switch is OFF, 쐌 Air conditioner switch is OFF, 쐌 Rear window defogger switch is OFF, 쐌 Steering wheel is in the straight-ahead position, etc. 1

GI MA EM

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: 쐌 Harness connectors for improper connections 쐌 Vacuum hoses for splits, kinks, or improper connections 쐌 Wiring for improper connections, pinches, or cuts

LC

FE CL MT

SEF983U

Models with CONSULT-II

䊳

GO TO 2.

Models with GST

䊳

GO TO 2.

Models with No Tools

䊳

GO TO 15.

2

AT TF PD AX

CONNECT CONSULT-II OR GST TO THE VEHICLE

With CONSULT-II Connect “CONSULT-II” to the data link connector for CONSULT-II and select “ENGINE” from the menu. Refer to EC-1254.

SU BR

With GST Connect “GST” to the data link connector for GST. Refer to EC-1267. Models with CONSULT-II

䊳

GO TO 3.

ST

Models with GST

䊳

GO TO 14.

RS BT HA SC EL

EC-1273

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER

Basic Inspection (Cont’d)

3

CHECK FI CAM FUNCTION

With CONSULT-II 1. Turn ignition switch ON. 2. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. 3. Start engine and warm it up.

SEF013Y

4. When engine coolant temperature is 75 to 85°C (167 to 185°F), check the following. 쐌 The center of mark A is aligned with mark C. 쐌 The cam follower lever’s roller is not touching the fast idle cam.

SEF971R

OK or NG OK

䊳

GO TO 4.

NG

䊳

1. Check FI cam. Refer to “Fast Idle Cam (FIC)”, EC-1219. 2. GO TO 4.

EC-1274

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER Basic Inspection (Cont’d)

4

CHECK IGNITION TIMING

With CONSULT-II 1. Warm up engine to normal operating temperature. 2. Select “IGNITION TIMING ADJ” in “WORK SUPPORT” mode and touch “START”.

GI MA EM LC

FE PEF546N

3. Check ignition timing at idle using a timing light.

CL MT AT TF

SEF984U

PD

Ignition timing: 10°±2° BTDC OK or NG OK

䊳

GO TO 5.

AX

NG

䊳

1. Adjust ignition timing by turning distributor. Refer to “Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment”, EC-1220. 2. GO TO 5.

SU BR ST RS BT HA SC EL

EC-1275

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER

Basic Inspection (Cont’d)

5

CHECK BASE IDLE SPEED

With CONSULT-II 1. Select “IGNITION TIMING ADJ” in “WORK SUPPORT” mode and touch “START”.

PEF546N

2. Check idle speed. 700±50 rpm (in “P” or “N” position) OK or NG OK

䊳

GO TO 6.

NG

䊳

1. Adjust engine speed by turning idle speed adjusting screw. Refer to “Idle Speed/ Ignition Timing/Idle Mixture Ratio Adjustment”, EC-1220. 2. GO TO 6.

6

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION-I

With CONSULT-II NOTE: Always check ignition timing and base idle speed before performing the following. 1. Warm up engine to normal operating temperature. 2. Check FI cam, refer to procedure 3. 3. Stop engine. 䊳

GO TO 7.

EC-1276

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER Basic Inspection (Cont’d)

7

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION-II

1. Turn ignition switch ON. 2. Select “TP SW/TP SEN IDLE POSI ADJ” in “WORK SUPPORT” mode. 3. Read “CLSD THL/P SW” signal under the following conditions. 쐌 Insert a 0.3 mm (0.012 in) and 0.4 mm (0.016 in) feeler gauge alternately between the throttle adjust screw (TAS) and throttle drum as shown in the figure and check the signal.

GI MA EM LC

FE CL LEC656

MT AT TF PD SEF715Y

“CLSD THL/P SW” signal should remain “ON” while inserting 0.3 mm (0.012 in) feeler gauge. “CLSD THL/P SW” signal should remain “OFF” while inserting 0.4 mm (0.016 in) feeler gauge.

AX

OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 8.

SU BR

8

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION

With CONSULT-II NOTE: 쐌 Never adjust throttle adjust screw (TAS). 쐌 Do not touch throttle drum when checking “CLSD THL/P SW” signal, doing so may cause an incorrect adjustment. 1. Warm up engine to normal operating temperature. 2. Check FI cam. Refer to procedure 3. 3. Stop engine. 4. Loosen throttle position sensor fixing bolts. 䊳

GO TO 9.

ST RS BT HA SC EL

EC-1277

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER

Basic Inspection (Cont’d)

9

ADJUSTMENT CLOSED THROTTLE POSITION SWITCH IDLE POSITION-II

1. Turn ignition switch ON. 2. Select “TP SW/TP SEN IDLE POSI ADJ” in “WORK SUPPORT” mode. 3. Insert 0.35 mm (0.0138 in) feeler gauge between throttle adjust screw and throttle drum as shown in the figure.

LEC656

4. Open throttle valve and then close. 5. Check “CLSD THL/P SW” signal.

SEF715Y

“CLSD THL/P SW” signal should remain “OFF” when the throttle valve is closed. OK or NG OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

10

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION-III

With CONSULT-II Turn throttle position sensor body counterclockwise until “CLSD THL/P SW” signal switches to “OFF”.

SEF689W

䊳

GO TO 11.

EC-1278

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER Basic Inspection (Cont’d)

11

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION-IV

With CONSULT-II 1. Remove 0.35 mm (0.0138 in) feeler gauge then insert 0.3 mm (0.012 in) feeler gauge. 2. Temporarily tighten sensor body fixing bolts as follows. 쐌 Gradually move the sensor body clockwise and stop it when “CLSD THL/P SW” signal switches from “OFF” to “ON”, then temporarily tighten sensor body fixing bolts.

GI MA EM LC

SEF689W

3. 4. 5. 6. 7.

Make sure two or three times that the signal is “ON” when the throttle valve is closed and “OFF” when it is opened. Remove 0.3 mm (0.012 in) feeler gauge then insert 0.4 mm (0.016 in) feeler gauge. Make sure two or three times that the signal remains “OFF” when the throttle valve is closed. Tighten throttle position sensor. Check the “CLSD THL/P SW” signal again. The signal remains “OFF” while closing throttle valve.

FE CL MT

OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 8.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1279

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER

Basic Inspection (Cont’d)

12

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. Remove feeler gauge. 2. Start engine. 3. Warm up engine to normal operating temperature. 4. Select “TP SW/TP SEN IDLE POSI ADJ” in “WORK SUPPORT” mode. 5. Stop engine. (Turn ignition switch OFF.) 6. Turn ignition switch ON and wait at least 5 seconds.

SEF864V

7. Turn ignition switch OFF and wait at least 5 seconds. 8. Repeat steps 5 and 6 until “CLSD THL POS” signal changes to “ON”.

SEF715Y

䊳

13

GO TO 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. 3. Check idle speed. 750±50 rpm (in “P” or “N” position) OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Adjust idle speed. Refer to “Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment”, EC-1220. 2. GO TO 27.

EC-1280

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER Basic Inspection (Cont’d)

14

CHECK FI CAM FUNCTION

With GST 1. Turn ignition switch ON. 2. Select “MODE 1” with GST. 3. Start engine and warm it up. 4. When engine coolant temperature is 75 to 85°C (167 to 185°F), check the following. 쐌 The center of mark A is aligned with mark C. 쐌 The cam follower lever’s roller is not touching the fast idle cam.

GI MA EM LC

FE SEF971R

CL

OK or NG OK

䊳

GO TO 16.

NG

䊳

1. Check FI cam. Refer to “Fast Idle Cam (FIC)”, EC-1219. 2. GO TO 16.

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1281

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER

Basic Inspection (Cont’d)

15

CHECK FI CAM FUNCTION

No Tools 1. Set the voltmeter between ECM terminal 59 (Engine coolant temperature sensor signal) and ground. 2. Start engine and warm it up.

SEF119W

3. When the voltage is between 1.10 to 1.36V, check the following. 쐌 The center of mark A is aligned with mark C. 쐌 The cam follower lever’s roller is not touching the fast idle cam.

SEF971R

OK or NG OK

䊳

GO TO 16.

NG

䊳

1. Check FI cam. Refer to “Fast Idle Cam (FIC)”, EC-1219. 2. GO TO 16.

EC-1282

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER Basic Inspection (Cont’d)

16

CHECK IGNITION TIMING

Without CONSULT-II 1. Warm up engine to normal operating temperature. 2. Stop engine and disconnect throttle position sensor harness connector.

GI MA EM LC

SEF975R

FE

3. Start engine. 4. Check ignition timing at idle using a timing light.

CL MT AT SEF984U

Ignition timing: 10°±2° BTDC

TF

OK or NG OK

䊳

GO TO 17.

PD

NG

䊳

1. Adjust ignition timing by turning distributor. Refer to “Idle Speed/Ignition Timing/ Idle Mixture Ratio Adjustment”, EC-1220. 2. GO TO 17.

AX

17

SU

CHECK BASE IDLE SPEED

Without CONSULT-II 1. Make sure that throttle position sensor harness connector remain disconnected. 2. Does engine speed fall to the following speed? 700±50 rpm (in “P” or “N” position) OK or NG OK

䊳

GO TO 18.

NG

䊳

1. Adjust engine speed by turning idle speed adjusting screw. Refer to “Idle Speed/ Ignition Timing/ Idle Mixture Ratio Adjustment”, EC-1220. 2. GO TO 18.

BR ST RS BT

18

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION

Without CONSULT-II NOTE: Always check ignition timing and base idle speed before performing the following. 1. Warm up engine to normal operating temperature. 2. Check FI cam, refer to procedure 14 or 15. 3. Stop engine. 䊳

HA SC EL

GO TO 19.

EC-1283

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER

Basic Inspection (Cont’d)

19

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION-I

1. Disconnect closed throttle position switch harness connector. 2. Check continuity between closed throttle position switch terminals 4 and 5 under the following conditions.

SEC298C

쐌 Insert the 0.3 mm (0.012 in) and 0.4 mm (0.016 in) feeler gauge alternately between the throttle adjust screw (TAS) and throttle drum as shown in the figure.

LEC656

“Continuity should exist” while inserting 0.3 mm (0.012 in) feeler gauge. “Continuity should not exist” while inserting 0.4 mm (0.016 in) feeler gauge. OK or NG OK

䊳

GO TO 24.

NG

䊳

GO TO 20.

20

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION

Without CONSULT-II NOTE: 쐌 Never adjust throttle adjust screw (TAS). 쐌 Do not touch throttle drum when checking “continuity”, doing so may cause an incorrect adjustment. 1. Warm up engine to normal operating temperature. 2. Check FI cam. Refer to procedure 12 or 13. 3. Stop engine. 4. Loosen throttle position sensor fixing bolts. 䊳

GO TO 21.

EC-1284

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER Basic Inspection (Cont’d)

21

ADJUSTMENT CLOSED THROTTLE POSITION SWITCH IDLE POSITION-II

1. Disconnect closed throttle position switch harness connector. 2. Insert 0.35 mm (0.0138 in) feeler gauge between the throttle adjust screw and throttle drum as shown in the figure.

GI MA EM LC

FE LEC656

3. Open throttle valve then close. 4. Check continuity between closed throttle position switch terminals 4 and 5.

CL MT AT TF SEC298C

Continuity should not exist while closing the throttle position sensor. OK or NG OK

䊳

GO TO 23.

NG

䊳

GO TO 22.

22

PD AX SU

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION-III

BR

Without CONSULT-II Turn throttle position sensor body counterclockwise until continuity does not exist.

ST RS BT HA SEF689W

䊳

GO TO 23.

SC EL

EC-1285

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER

Basic Inspection (Cont’d)

23

ADJUSTMENT THROTTLE POSITION SWITCH IDLE POSITION-IV

Without CONSULT-II 1. Remove 0.35 mm (0.0138 in) feeler gauge then insert 0.3 mm (0.012 in) feeler gauge. 2. Temporarily tighten sensor body fixing bolts as follows. 쐌 Gradually move the sensor body clockwise and stop it when the continuity comes to exist, then temporarily tighten sensor body fixing bolts.

SEF689W

3. Make sure two or three times that the continuity exists when the throttle valve is closed and continuity does not exist when it is opened. 4. Remove 0.3 mm (0.012 in) feeler gauge then insert 0.4 mm (0.016 in) feeler gauge. 5. Make sure two or three times that the continuity does not exist when the throttle valve is closed. 6. Tighten throttle position sensor. 7. Check the continuity again. Continuity does not exist while closing the throttle valve. OK or NG OK

䊳

GO TO 24.

NG

䊳

GO TO 20.

24

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. Remove feeler gauge. 2. Start engine. 3. Warm up engine to normal operating temperature. 4. Stop engine. (Turn ignition switch OFF.) 5. Turn ignition switch ON and wait at least 5 seconds.

SEF864V

6. Turn ignition switch OFF and wait at least 5 seconds. 7. Repeat steps 4 and 5, 20 times. 䊳

GO TO 25.

EC-1286

TROUBLE DIAGNOSIS — BASIC INSPECTION

VG33ER Basic Inspection (Cont’d)

25

REINSTALLATION

Without CONSULT-II 1. Reconnect throttle position sensor harness connector and closed throttle position switch harness connector. 2. Start engine and rev it (2,000 to 3,000 rpm) two or three times under no-load and then run engine at idle speed. 䊳

26

GI MA

GO TO 26.

EM

CHECK TARGET IDLE SPEED

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm (in “P” or “N” position)

LC

OK or NG OK

䊳

GO TO 27.

NG

䊳

1. Adjust idle speed. Refer to “Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment”, EC-1220. 2. GO TO 27.

FE CL

27

ERASE UNNECESSARY DTC

After this inspection, unnecessary DTC No. might be displayed. Erase the stored memory in ECM and TCM (Transmission control module). Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-1246 and AT-35, “HOW TO ERASE DTC”. 䊳

MT AT

INSPECTION END

TF PD AX SU BR ST RS BT HA SC EL

EC-1287

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

DTC Inspection Priority Chart

DTC Inspection Priority Chart

NGEC1091

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

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

P0101, P0102, P0103 Mass air flow sensor P0112, P0113, P0127 Intake air temperature sensor P0117, P0118, P0125 Engine coolant temperature sensor P0121, P0122, P0123 Throttle position sensor P0181, P0182, P0183 Fuel tank temperature sensor P0327, P0328 Knock sensor P0335 P1336 Crankshaft position sensor (OBD) P0340 Camshaft position sensor P0460 P0461 P1464 Fuel level sensor P0500 Vehicle speed sensor P0600 A/T communication line P0605 ECM P1605 A/T diagnosis communication line P1706 Park/Neutral position (PNP) switch

2

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

P0132-P0134, P1143, P1144/P0152-P0154, P1163, P1164 Heated oxygen sensor 1 P0131, P0032/P0051, P0052 Heated oxygen sensor 1 heater P0138, P0139, P1146, P1147/P0158, P0159, P1166, P1167 Heated oxygen sensor 2 P0037, P0038/P0057, P0058 Heated oxygen sensor 2 heater P0217 Engine coolant overtemperature enrichment protection P0444, P0445, P1444 EVAP canister purge volume control solenoid valve P0447 P1446 P1448 EVAP canister vent control valve P0452, P0453 EVAP control system pressure sensor P0510 Closed throttle position switch P0705-P0755 P1705 P1760 A/T related sensors, solenoid valves and switches P0456, P1456 EVAP control system (VERY SMALL LEAK) P1447 EVAP control system purge flow monitoring P1490 P1491 Vacuum cut valve bypass valve

3

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

P0171 P0172 P0174 P0175 Fuel injection system function P0306 - P0300 Misfire P0420 P0430 Three way catalyst function P0442/P1442 EVAP control system (SMALL LEAK) P0455 EVAP control system (GROSS LEAK) P0505 IACV-AAC valve P0731-P0734 P0744 A/T function P1148 P1168 Closed loop control

EC-1288

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER Fail-safe Chart

Fail-safe Chart

=NGEC1092

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 MIL illuminates.

GI

DTC No. Detected items

CONSULT-II GST

Engine operating condition in fail-safe mode

P0101 P0102 P0103

Mass air flow sensor circuit

Engine speed will not rise more than 2,400 rpm due to the fuel cut.

P0117 P0118

Engine coolant temperature sensor circuit

Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON or START. CONSULT-II displays the engine coolant temperature decided by ECM.

Throttle position sensor circuit

LC

Engine coolant temperature decided (CONSULT-II display)

Just as ignition switch is turned ON or Start

40°C (104°F)

More than approx. 4 minutes after ignition ON or Start

80°C (176°F)

CL

40 - 80°C (104 - 176°F) (Depends on the time)

MT

FE

Throttle position will be determined based on the injected fuel amount and the engine speed. Therefore, acceleration will be poor. Condition

Driving condition

When engine is idling When accelerating Unable to ECM access ECM

EM

Condition

Except as shown above P0121 P0122 P0123

MA

Poor acceleration

PD AX SU

ECM fail-safe operation

BR

Engine speed will not rise more than 3,000 rpm

ST

Fuel injection

Simultaneous multiport fuel injection system

Ignition timing

Ignition timing is fixed at the preset value Fuel pump relay is “ON” when engine is running and “OFF” when engine stalls

Fuel pump

TF

Normal

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 MIL 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.

Engine speed

AT

IACV-AAC valve Replace ECM, if ECM fail-safe condition is confirmed.

RS BT

Full open

HA SC EL

EC-1289

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

Symptom Matrix Chart

Symptom Matrix Chart

NGEC1093

SYSTEM — BASIC ENGINE CONTROL SYSTEM

NGEC1093S01

BATTERY DEAD (UNDER CHARGE)

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEATS/WATER TEMPERATURE HIGH

SLOW/NO RETURN TO IDLE

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

AH

AJ AK AL AM HA

2

3

HIGH IDLE/LOW IDLE

AA AB AC AD AE AF AG

ENGINE STALL

IDLING VIBRATION

Fuel

ROUGH IDLE/HUNTING

Warranty symptom code

HESITATION/SURGING/FLAT SPOT

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Fuel pump circuit

3 1

1

2

3

2

Injector circuit

1

2

Air

EC-1218 4

4

4

4

4

4

3

3

EC-1199

4 1

3

IACV-AAC valve circuit

3 1

2 IACV-FICD solenoid valve circuit Ignition

4

Positive crankcase ventilation system Incorrect idle speed adjustment

EC-1733 EC-1725

Fuel pressure regulator system Evaporative emission system

Reference page

3

3

1

1

2

2

3

2

3

1

1

1

2

2

3

EC-1215 EC-1220 1

3

EC-1586 EC-1746

Incorrect ignition timing adjustment

3

3

1

1

1

1

1

1

EC-1220

Ignition circuit

1

1

2

2

2

2

2

2

EC-1718

2

3

3

3

3

2

Main power supply and ground circuit Air conditioner circuit

1

1

2

3

1 - 6: The numbers refer to the order of inspection. (continued on next page)

EC-1290

EC-1313 3

2

1 HA-26

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

Symptom Matrix Chart (Cont’d)

BATTERY DEAD (UNDER CHARGE)

EXCESSIVE OIL CONSUMPTION

GI EXCESSIVE FUEL CONSUMPTION

2

OVERHEATS/WATER TEMPERATURE HIGH

2

Camshaft position sensor circuit

SLOW/NO RETURN TO IDLE

AH

HIGH IDLE/LOW IDLE

IDLING VIBRATION

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

AA AB AC AD AE AF AG

ENGINE STALL

ROUGH IDLE/HUNTING

Warranty symptom code

HESITATION/SURGING/FLAT SPOT

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

MA EM Reference page

LC

FE

AJ AK AL AM HA EC-1481

CL

1 Mass air flow sensor circuit

1

2

Heated oxygen sensor 1 (front) circuit Engine coolant temperature sensor circuit

2

2

3 1

2

3

EC-1396

MT

3

EC-1348, 1366

AT

2

EC-1353

1

EC-1273

2 3

3 2

Throttle position sensor circuit

1

2

2

2

Incorrect throttle position sensor adjustment

3

1

1

1

Vehicle speed sensor circuit

2

Knock sensor circuit ECM Start signal circuit

1

1

3

3

3 2

TF

EC-1582 3

2

3

3

2

2

EC-1471 EC-1604, 1289

1

1

PD AX

EC-1730

Park/neutral position (PNP) switch circuit

3

3

3 3

Power steering oil pressure switch circuit

1

EC-1334

2

EC-1709

2

SU

EC-1741

BR

1 - 6: The numbers refer to the order of inspection. (continued on next page)

ST RS BT HA SC EL

EC-1291

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

Symptom Matrix Chart (Cont’d)

SYSTEM — ENGINE MECHANICAL & OTHER

NGEC1093S02

Fuel

BATTERY DEAD (UNDER CHARGE)

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEATS/WATER TEMPERATURE HIGH

SLOW/NO RETURN TO IDLE

AH

HIGH IDLE/LOW IDLE

IDLING VIBRATION

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

AA AB AC AD AE AF AG

ENGINE STALL

ROUGH IDLE/HUNTING

Warranty symptom code

HESITATION/SURGING/FLAT SPOT

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Reference section

AJ AK AL AM HA

Fuel tank

FE-4 5

Fuel piping Vapor lock

5

5

5

5

4

5

5

5

5

5

4

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

4

5

Air leakage from intake manifold/ Collector/Gasket Cranking

5

5 4

FE-3

5

—

Battery 1

1

1

Generator circuit

1

1

1

1 SC-4

1 Starter circuit Park/neutral position (PNP) switch Drive plate/Flywheel

AT-104 6

EM-124

1 - 6: The numbers refer to the order of inspection. (continued on next page)

EC-1292

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

Symptom Matrix Chart (Cont’d)

BATTERY DEAD (UNDER CHARGE)

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEATS/WATER TEMPERATURE HIGH

SLOW/NO RETURN TO IDLE

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

AH

AJ AK AL AM HA

5

5

HIGH IDLE/LOW IDLE

AA AB AC AD AE AF AG

ENGINE STALL

IDLING VIBRATION

Engine

GI

ROUGH IDLE/HUNTING

Warranty symptom code

HESITATION/SURGING/FLAT SPOT

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

MA EM Reference section

LC

FE CL

Cylinder head 5

5

5

5

5

5

Cylinder head gasket

2

2

MT

Cylinder block Piston

3

AT

Piston ring 6

6

6

6

6

6

6

6

Connecting rod EM-92, EM-82 and EM-115

Bearing Crankshaft

TF PD

Valve Timing chain mechanism Camshaft

AX

6 Intake valve

6

6

6

6

6

6

6 2

Exhaust valve

SU

Hydraulic lash adjuster Exhaust

Exhaust manifold/Tube/Muffler/ Gasket

BR 6

6

6

6

6

6

6

6

FE-9

6

MA-32, EM-79 and LC-20

Three way catalyst Lubrication

Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery

6

6

6

6

6

6

6

Oil level (Low/Filthy) oil Cooling

2

MA-32

ST RS

Radiator/Hose/Radiator filler cap Thermostat

5

BT

5

Water pump Water gallery

LC-27 6

6

6

6

6

Cooling fan

6 5

6

2

HA

6

5

SC

Coolant level (low)/Contaminated coolant

MA-28

EL

1 - 6: The numbers refer to the order of inspection.

EC-1293

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NGEC1094

Remarks: 쐌 Specification data are reference values. 쐌 Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data in spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the ECM according to the signals input from the camshaft position sensor and other ignition timing related sensors. 쐌 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

쐌 Tachometer: Connect 쐌 Run engine and compare tachometer indication with the CONSULT-II value.

MAS A/F SE-B1

쐌 쐌 쐌 쐌

COOLAN TEMP/S

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2)

Almost the same speed as the CONSULT-II value.

Idle

1.0 - 1.7V

2,500 rpm

1.7 - 2.3V

쐌 Engine: After warming up

More than 70°C (158°F) 0 - 0.3V +, Approx. 0.6 1.0V

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

SPECIFICATION

쐌 Engine: After warming up

쐌 Engine: After warming up

Maintaining engine speed at 2,000 rpm

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds. 0 - 0.3V +, Approx. 0.6 1.0V LEAN +, RICH

VHCL SPEED SE

쐌 Turn drive wheels and compare speedometer indication with the CONSULT-II value

Almost the same speed as the CONSULT-II value

BATTERY VOLT

쐌 Ignition switch: ON (Engine stopped)

11 - 14V

쐌 Engine: After warming up, idle the engine

Throttle valve: fully closed (a)

0.15 - 0.85V

Throttle valve: Partially open

Between (a) and (b)

Throttle valve: fully open (b)

3.5 - 4.7V

THRTL POS SEN

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

START SIGNAL

쐌 Ignition switch: ON , START , ON

CLSD THL POS CLSD THL/P SW

쐌 Engine: After warming up, idle the engine

AIR COND SIG

쐌 Engine: After warming up, idle the engine

P/N POSI SW

PW/ST SIGNAL

쐌 Ignition switch: ON

쐌 Engine: After warming up, idle the engine

OFF , ON , OFF

Throttle valve: Idle position

ON

Throttle valve: Slightly open

OFF

Air conditioner switch: OFF

OFF

Air conditioner 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 turned

ON

EC-1294

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM AMB TEMP SW

CONDITION 쐌 Ignition switch: ON 쐌 Compare ambient air temperature with the following:

SPECIFICATION

Below 19°C (66°F)

OFF

Above 25°C (77°F)

ON

IGNITION SW

쐌 Ignition switch: ON , OFF , ON

INJ PULSE-B1 INJ PULSE-B2

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

2.4 - 3.7 msec

2,000 rpm

1.9 - 3.3 msec

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

1.0 - 1.6 msec

B/FUEL SCHDL

쐌 쐌 쐌 쐌

2,000 rpm

0.7 - 1.4 msec

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

10°±2° BTDC

2,000 rpm

More than 25° BTDC

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

10 - 20%

2,000 rpm

—

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

0%

2,000 rpm

—

Maintaining engine speed at 2,000 rpm

54 - 155%

IGN TIMING

IACV-AAC/V

PURG VOL C/V

ON , OFF , ON

EVAP SYS PRES

쐌 Ignition switch: ON

Approx. 1.8 - 4.8V

AIR COND RLY

쐌 Air conditioner switch: OFF , ON

OFF , ON

쐌 Ignition switch is turned to ON (Operates for 5 seconds) 쐌 Engine running and cranking

ON

FUEL PUMP RLY

Except as shown above

OFF Engine coolant temperature is 94°C (201°F) or less

쐌 After warming up engine, idle the Engine coolant temperature is engine. between 95°C (203°F) and 100°C 쐌 Air conditioner switch: OFF (212°F) Engine coolant temperature is 100°C (212°F) or more

HO2S1 HTR (B1) HO2S1 HTR (B2)

HO2S2 HTR (B1) HO2S2 HTR (B2)

SCB/V CON S/V VC/V BYPASS/V

EM LC

CL MT AT

쐌 Engine: After warming up

VENT CONT/V

MA

FE

A/F ALPHA-B1 A/F ALPHA-B2

COOLING FAN

GI

PD AX SU

OFF

BR LOW

ST HIGH

쐌 Ignition switch: ON

OFF

쐌 Engine speed: Below 2,800 rpm

ON

쐌 Engine speed: Above 2,800 rpm

OFF

쐌 Ignition switch: ON (Engine stopped) 쐌 Engine speed: Above 2,800 rpm

OFF

쐌 Engine speed: Below 2,800 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]

ON

쐌 More than 5 seconds after turning ignition switch ON (Engine stopped)

OFF

쐌 Engine speed: Idle

ON

Ignition switch: ON

OFF

EC-1295

TF

RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM

CAL/LD VALUE

ABSOL TH·P/S

MASS AIRFLOW

CONDITION 쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

SPECIFICATION

Idle

18.5 - 26.0%

2,500 rpm

18.0 - 21.0%

쐌 Engine: After warming up 쐌 Ignition switch: ON

Throttle valve: fully closed

0.0%

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

Throttle valve: fully open

Approx. 80%

Idle

3.3 - 4.8 g·m/s

2,500 rpm

12.0 - 14.9 g·m/s

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Major Sensor Reference Graph in Data Monitor Mode

NGEC1095

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

NGEC1095S01

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”.

SEF306Y

ENG SPEED, MAS A/F SE-B1, THRTL POS SEN, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1 NGEC1095S02 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 sufficiently. Each value is for reference, the exact value may vary.

EC-1296

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

Major Sensor Reference Graph in Data Monitor Mode (Cont’d)

GI MA EM LC

FE SEF241Y

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1297

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

Major Sensor Reference Graph in Data Monitor Mode (Cont’d)

SEF242YD

EC-1298

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

ECM Terminals and Reference Value

ECM Terminals and Reference Value PREPARATION 1. 쐌

NGEC1096 NGEC1096S01

ECM is located behind the instrument lower cover. For this inspection: Remove instrument lower cover.

GI MA EM LC

SEF324V

2.

Remove ECM harness protector.

FE CL MT

AEC913

3. 쐌 쐌 쐌

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.

AT TF PD AX

MEC486B

ECM HARNESS CONNECTOR TERMINAL LAYOUTNGEC1096S02

SU BR ST RS

SEF533P

ECM INSPECTION TABLE

NGEC1096S03

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 the ECM terminals, such as the ground.

EC-1299

BT HA SC EL IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) Approximately 0.7V

[Engine is running] 쐌 Idle speed

SEF988U

1

PU/W

Ignition signal 1.1 - 1.5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

SEF989U

1 - 2V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

SEF992U

3

P/L

Tachometer 3 - 5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

SEF993U

4

OR/B

ECM relay (Self shutoff)

[Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

0 - 1.5V

[Ignition switch OFF] 쐌 A few seconds passed after turning ignition switch OFF

BATTERY VOLTAGE (11 - 14V)

EC-1300

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

GI MA

[Engine is running] 쐌 Idle speed

EM LC

5

R/Y

EVAP canister purge volume control solenoid valve

SEF994U

BATTERY VOLTAGE (11 - 14V)

FE

[Engine is running] 쐌 Engine speed is 2,000 rpm (More than 100 seconds after starting engine)

CL SEF995U

6

G/W

[Ignition switch ON] SCB valve control sole- 쐌 Engine stopped noid valve [Engine is running] 쐌 Idle speed

7

9

10

11

12

Y/G

B/Y

B/R

W/R

P

A/T check signal

Ambient air temperature switch

ECM ground

Approximately 0V

[Ignition switch ON] [Engine is running]

0 - 3.0V

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is above 25°C (77°F) 쐌 Air conditioner is operating

0V

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is below 19°C (66°F) 쐌 Air conditioner is operating

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is below 19°C (66°F) 쐌 Air conditioner is not operating

Approximately 5V

[Engine is running] 쐌 Idle speed

Engine ground

[Ignition switch ON] 쐌 For 5 seconds after turning ignition switch ON [Engine is running]

0 - 1V

[Ignition switch ON] 쐌 More than 5 seconds after turning ignition switch ON

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Both A/C switch and blower switch are ON*

0 - 1V

[Engine is running] 쐌 A/C switch is OFF

BATTERY VOLTAGE (11 - 14V)

AT TF PD AX SU BR ST RS

Fuel pump relay

Air conditioner relay

MT

BATTERY VOLTAGE (11 - 14V)

BT HA SC EL

EC-1301

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

18

R/W

Malfunction indicator lamp

19

B/R

ECM ground

20

L/OR

Start signal

21

22

23

24

G/R

L/B

L

W/L

Air conditioner switch

Park/neutral position (PNP) switch

CONDITION

DATA (DC Voltage)

[Ignition switch ON]

0 - 1V

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed

Engine ground

[Ignition switch ON]

Approximately 0V

[Ignition switch START]

9 - 12V

[Engine is running] 쐌 Both A/C switch and blower switch are ON (Compressor operates)*

Approximately 0V

[Engine is running] 쐌 A/C switch is OFF

BATTERY VOLTAGE (11 - 14V)

[Ignition switch ON] 쐌 Gear position is “N” or “P”

Approximately 0V

[Ignition switch ON] 쐌 Except the above gear position

Approximately 5V

[Engine is running] 쐌 Warm-up condition 쐌 More than -40.0 kpa (-300 mmHg, -11.81 inHg) of vacuum is applied to the throttle opener with Throttle position sensor a hand vacuum pump. 쐌 Accelerator pedal fully released

0.15 - 0.85V

[Ignition switch ON] 쐌 Accelerator pedal fully depressed

3.5 - 4.7V

[Ignition switch OFF]

0V

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

Ignition switch

25

B/Y

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

26

PU/W

A/T signal No. 1

[Engine is running] 쐌 Idle speed

Approximately 0 - 1.0V

27

P/B

A/T signal No. 2

[Engine is running] 쐌 Idle speed

Approximately 0 - 1.0V

[Engine is running] 쐌 Warm-up condition 쐌 More than -40.0 kpa (-300 mmHg, -11.81 inHg) of vacuum is applied to the throttle opener with a hand vacuum pump. 쐌 Accelerator pedal fully released

BATTERY VOLTAGE (11 - 14V)

[Ignition switch ON] 쐌 Accelerator pedal depressed

Approximately 0V

28

BR/W

Throttle position switch (Closed position)

EC-1302

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

GI

2 - 3V

MA 29

G/B

Vehicle speed sensor

[Engine is running] 쐌 Lift up the vehicle. 쐌 In 2nd gear position 쐌 Vehicle speed is 40 km/h (25 MPH)

EM SEF996U

32

B/Y

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

33

W/G

A/T signal No. 4

[Engine is running] 쐌 Idle speed

Approximately 0 - 1.0V Approximately 8V Approximately 0 - 1.0V

34

R/Y

A/T signal No. 5

[Engine is running] 쐌 Idle speed

35

G/R

A/T signal No. 3

[Engine is running] 쐌 Idle speed

39

GY/R

LC

FE CL Approximately 0V

MT

쐌 Steering wheel is not being turned

Approximately 5V

AT

[Engine is running] Power steering oil pres- 쐌 Steering wheel is being turned sure switch [Engine is running]

42

B/W

Sensors’ power supply

[Ignition switch ON]

Approximately 5V

43

BR

Sensors’ ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

TF PD 0.3 - 0.5V

AX [Engine is running] 쐌 Idle speed

44

PU

SU SEF997U

Camshaft position sensor (Reference signal)

BR

0.3 - 0.5V

ST [Engine is running] 쐌 Engine speed is 2,000 rpm

RS SEF998U

46

OR/B

Fuel level sensor

[Ignition switch ON]

Approximately 0 - 4.8V Output voltage varies with fuel level.

BT HA SC EL

EC-1303

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 1 - 2V (AC range)

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

47

L

SEF690W

Crankshaft position sensor (OBD)

3 - 4V (AC range)

[Engine is running] 쐌 Engine speed is 2,000 rpm

SEF691W

Approximately 2.5V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

49

LG

SEF999U

Camshaft position sensor (Position signal)

Approximately 2.5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

SEF001V

0 - Approximately 1.0V

50

B

Heated oxygen sensor 1 (bank 1)

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

SEF002V

0 - Approximately 1.0V

51

G

Heated oxygen sensor 1 (bank 2)

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

SEF002V

EC-1304

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

54

WIRE COLOR

R

ITEM

Mass air flow sensor

CONDITION

DATA (DC Voltage)

GI

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

1.0 - 1.7V

MA

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm

1.7 - 2.3V

EM

55

G

Mass air flow sensor ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

56

OR

Heated oxygen sensor 2 (bank 1)

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

0 - Approximately 1.0V

Y

Heated oxygen sensor 2 (bank 2)

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

0 - Approximately 1.0V

Engine coolant temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with engine coolant temperature

MT AT

57

59

LG/R

LC

FE CL

60

Y/B

Fuel tank temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with fuel temperature

61

PU/R

Intake air temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with intake air temperature.

TF

62

Y

EVAP control system pressure sensor

[Ignition switch ON]

Approximately 1.8 - 4.8V

PD

64

W

Knock sensor

[Engine is running] 쐌 Idle speed

Approximately 2.5V

66

B

Fuel level sensor ground

[Engine is running] 쐌 Idle speed

Approximately 0V

67

B/P

Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V) 6 - 10V

AX SU BR

69

LG/R

Data link connector

[Engine is running] 쐌 Idle speed (CONSULT-II or GST is disconnected)

72

B/P

Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

80

SB

Power supply (Backup)

[Ignition switch OFF]

BATTERY VOLTAGE (11 - 14V)

ST RS BT HA SC EL

EC-1305

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 8 - 11V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

SEF005V

101

OR/L

IACV-AAC valve 7 - 10V

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 3,000 rpm

SEF692W

BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 102 104 106 109 111 113

W/B W/R W/G W/L W/PU W

Injector Injector Injector Injector Injector Injector

No. No. No. No. No. No.

1 3 5 2 4 6

SEF007V

BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

SEF008V

108

R/G

EVAP canister vent control valve

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

116

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

117

B/P

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 2,800 rpm

Approximately 0.4V

BR/Y

Heated oxygen sensor 1 heater (front) (bank 1)

[Engine is running] 쐌 Engine speed is above 2,800 rpm

BATTERY VOLTAGE (11 - 14V)

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 2,800 rpm

Approximately 0.4V

[Engine is running] 쐌 Engine speed is above 2,800 rpm

BATTERY VOLTAGE (11 - 14V)

119

120

121

P/B

Vacuum cut valve bypass valve

BR

Heated oxygen sensor 1 heater (front) (bank 2)

EC-1306

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

VG33ER

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

122

123

124

WIRE COLOR

R/B

R/Y

B/R

ITEM

Heated oxygen sensor 2 heater (bank 1)

Heated oxygen sensor 2 heater (bank 2)

ECM ground

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Engine speed is below 2,800 rpm 쐌 After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more.

Approximately 0.4V

[Ignition switch ON] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 2,800 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 2,800 rpm 쐌 After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more.

Approximately 0.4V

[Ignition switch ON] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 2,800 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed

Engine ground

GI MA EM LC

FE CL MT

*: Any mode except OFF, ambient air temperature is above 25°C (77°F).

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1307

IDX

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

VG33ER

Description

Description

NGEC1097

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: 쐌 B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction) 쐌 A/F ALPHA-B1/B2 (The mean value of air-fuel ratio feedback correction factor per cycle) 쐌 MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)

Testing Condition

NGEC1098

쐌 Vehicle driven distance: More than 5,000 km (3,107 miles) 쐌 Barometric pressure: 101.3 kPa (760.0 mmHg, 29.92 inHg)±3 kPa (22.5 mmHg, 0.89 inHg) 쐌 Atmospheric temperature: 20 - 30°C (68 - 86°F) 쐌 Engine coolant temperature: 75 - 95°C (167 - 203°F) 쐌 Transmission: Warmed-up*1 쐌 Electrical load: Not applied*2 쐌 Engine speed: Idle *1: For A/T models, after the engine is warmed up to normal operating temperature, drive vehicle until “FLUID TEMP SE” (A/T fluid temperature sensor signal) indicates less than 0.9V. For M/T models, drive vehicle for 5 minutes after the engine is warmed up to normal operating temperature. *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

NGEC1099

NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform “Basic Inspection”, EC-1273. 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1”, “A/F ALPHA-B2” 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-1309.

EC-1308

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

VG33ER Diagnostic Procedure

Diagnostic Procedure

NGEC1100

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEF613ZC

EC-1309

EL IDX

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

VG33ER

Diagnostic Procedure (Cont’d)

SEF768Z

EC-1310

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

VG33ER

Diagnostic Procedure (Cont’d)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEC653C

EL

EC-1311

IDX

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT

VG33ER

Description

Description

NGEC1101

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 (1st trip) DTC 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

NGEC1101S01

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 does not appear during the DTC Confirmation Procedure.

VI

The Diagnostic Procedure 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-1246. 䊳

2

GO TO 2.

CHECK GROUND TERMINALS

Check ground terminals for corroding or loose connection. Refer to “Circuit Inspection”, “GROUND INSPECTION”, GI-28. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace.

3

SEARCH FOR ELECTRICAL INCIDENT

Perform “Incident Simulation Tests”, GI-23. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace.

4

CHECK CONNECTOR TERMINALS

Refer to “How to Check Enlarged Contact Spring of Terminal”, GI-20. OK or NG OK

䊳

INSPECTION END

NG

䊳

Repair or replace connector.

EC-1312

NGEC1102

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33ER

Main Power Supply and Ground Circuit

Main Power Supply and Ground Circuit WIRING DIAGRAM

NGEC1103

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC163A

EC-1313

IDX

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33ER

Main Power Supply and Ground Circuit (Cont’d)

ECM TERMINALS AND REFERENCE VALUE

NGEC1104

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 the ECM terminals, such as the ground. TERMINAL NO.

4

WIRE COLOR

OR/B

ITEM

ECM relay (Self-shutoff)

CONDITION [Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

DATA (DC Voltage)

0 - 1.5V

[Ignition switch OFF] BATTERY VOLTAGE 쐌 A few seconds passed after turning ignition switch (11 - 14V) OFF 10

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

19

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

[Ignition switch OFF]

0V

24

W/L

Ignition switch [Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

25

B/Y

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

32

B/Y

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

67

B/P Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

72

B/P

80

SB

Power supply (Back-up)

[Ignition switch OFF]

BATTERY VOLTAGE (11 - 14V)

116

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

117

B/P

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

124

B/R

ECM ground

[Engine is running] 쐌 Idle speed

Engine ground

DIAGNOSTIC PROCEDURE 1

INSPECTION START

Start engine. Is engine running? Yes or No Yes

䊳

GO TO 6.

No

䊳

GO TO 2.

EC-1314

NGEC1105

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33ER

Main Power Supply and Ground Circuit (Cont’d)

2

CHECK ECM POWER SUPPLY CIRCUIT-I

1. Turn ignition switch OFF and then ON. 2. Check voltage between ECM terminal 24 and ground with CONSULT-II or tester.

GI MA EM LC SEF674U

Voltage: Battery voltage OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

FE CL

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E74, M82 쐌 Harness connectors M58, F28 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between ECM and fuse 䊳

4

MT AT

Repair harness or connectors.

CHECK ECM GROUND CIRCUIT-I FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 10, 19, 25, 32, 116, 124 and engine ground. Refer to WIRING DIAGRAM. Continuity should exist. 4. Also check harness for short to power.

TF PD AX SU

OK or NG OK

䊳

GO TO 15.

NG

䊳

GO TO 5.

BR ST

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-2 (if equipped) 쐌 Harness for open between ECM and engine ground 䊳

RS

Repair open circuit or short to power in harness or connectors.

BT HA SC EL

EC-1315

IDX

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33ER

Main Power Supply and Ground Circuit (Cont’d)

6

CHECK ECM POWER SUPPLY CIRCUIT-II

1. Stop engine. 2. Check voltage between ECM terminal 80 and ground with CONSULT-II or tester.

SEF678U

Voltage: Battery voltage OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M59, F27 쐌 Fuse block (J/B) connector M27 쐌 10A fuse 쐌 Harness for open or short between ECM and fuse 䊳

8

Repair harness or connectors.

CHECK ECM POWER SUPPLY CIRCUIT-III

1. Turn ignition switch ON and then OFF. 2. Check voltage between ECM terminals 67, 72, 117 and ground with CONSULT-II or tester.

SEF679U

Voltage: After turning ignition switch OFF, battery voltage will exist for a few seconds, then drop to approximately 0V. OK or NG OK

䊳

GO TO 14.

NG (Battery voltage does not exist.)

䊳

GO TO 9.

NG (Battery voltage exists for more than a few seconds.)

䊳

GO TO 13.

EC-1316

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33ER

Main Power Supply and Ground Circuit (Cont’d)

9

CHECK ECM POWER SUPPLY CIRCUIT-IV

1. Disconnect ECM relay.

GI MA EM LC AEC927A

2. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.

FE CL MT SEF625W

AT

Voltage: Battery voltage OK or NG OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

TF PD

10

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between ECM relay and harness connectors M59, F27 䊳

AX

Repair open circuit or short to ground or short to power in harness or connectors.

SU 11

CHECK ECM OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 4 and ECM 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

䊳

GO TO 12.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

12

BR ST RS BT

CHECK HARNESS CONTINUITY BETWEEN ECM RELAY AND ECM FOR OPEN AND SHORT

1. Check harness continuity between ECM terminals 67, 72, 117 and ECM relay terminal 3. Refer to WIRING DIAGRAM. Continuity should exist. 2. Also check harness for short to ground and short to power.

HA SC

OK or NG

EL

OK

䊳

GO TO 13.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1317

IDX

TROUBLE DIAGNOSIS FOR POWER SUPPLY

VG33ER

Main Power Supply and Ground Circuit (Cont’d)

13

CHECK ECM RELAY

1. Apply 12V direct current between relay terminals 1 and 2. 2. Check continuity between relay terminals 3 and 5.

SEF039W

12V (1 - 2) applied: Continuity exists. No voltage applied: No continuity OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace ECM relay.

14

CHECK ECM GROUND CIRCUIT-II FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 10, 19, 25, 32, 116, 124 and engine ground. Refer to WIRING DIAGRAM. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 15.

NG

䊳

GO TO 5.

15

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1318

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33ER Description

Description

NGEC1177

SYSTEM DESCRIPTION

NGEC1177S01

Sensor

ECM function

Input Signal to ECM

Camshaft position sensor

Actuator

Heated oxygen Heated oxygen sensor 1 heatsensor 1 ers heater control

Engine speed

GI

The ECM performs ON/OFF control of the heated oxygen sensor 1 heaters corresponding to the engine speed.

OPERATION

MA EM LC

NGEC1177S02

Engine speed

rpm

Heated oxygen sensor 1 heaters

Above 2,800

OFF

Below 2,800

ON

FE

CONSULT-II Reference Value in Data Monitor Mode

CL

NGEC1178

Specification data are reference values. MONITOR ITEM HO2S1 HTR (B1) HO2S1 HTR (B2)

MT CONDITION

SPECIFICATION

쐌 Engine speed: Below 2,800 rpm

ON

쐌 Engine speed: Above 2,800 rpm

OFF

AT TF

ECM Terminals and Reference Value

NGEC1179

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

119 (B1)

BR/Y

121 (B2)

ITEM

AX

DATA (DC Voltage)

SU Heated oxygen sensor 1 heater

BR

CONDITION

PD

[Engine is running] 쐌 Engine speed is below 2,800 rpm

Approximately 0.4V

[Engine is running] 쐌 Engine speed is above 2,800 rpm

BATTERY VOLTAGE (11 - 14V)

BR ST RS

On Board Diagnosis Logic

NGEC1180

Malfunction is detected when the current amperage in the heated oxygen sensor 1 heater circuit is out of the normal range. [An excessively low (P0031) (B1)/(P0051) (B1) or high (P0032) (B2)/(P0052) (B2) voltage signal is sent to ECM through the heated oxygen sensor 1 heater.]

POSSIBLE CAUSE 쐌 쐌

HA SC

NGEC1180S01

Harness or connectors [The heated oxygen sensor 1 heater circuit is open or shorted.] Heated oxygen sensor 1 heater

EC-1319

BT

EL IDX

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF058Y

NGEC1181

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is 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 run it for at least 6 seconds at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1323. With GST 1) Start engine and run it for at least 6 seconds at idle speed. 2) Turn ignition switch OFF, wait at least 5 seconds and then turn ON. 3) Start engine and run it for at 6 seconds at idle speed. 4) Select “MODE 3” with GST. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1323. 쐌 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-1320

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33ER Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1182 NGEC1182S01

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC164A

EC-1321

IDX

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33ER

Wiring Diagram (Cont’d)

LEFT BANK

NGEC1182S02

WEC165A

EC-1322

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1183

CHECK HO2S1 POWER SUPPLY CIRCUIT

GI

1. Turn ignition switch OFF. 2. Check heated oxygen sensor 1 harness protector.

MA EM LC

SEF505YB

FE

3. Disconnect corresponding heated oxygen sensor 1 harness connector.

CL MT AT LEC658

4. Turn ignition switch ON. 5. Check voltage between HO2S1 terminal 1 and ground with CONSULT-II or tester.

TF PD AX SU

SEF633W

BR

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

RS

DETECT MALFUNCTIONING PART

BT

Check the following. 쐌 Harness connectors M59, F27 쐌 Fuse block (J/B) connector M26 쐌 10A fuse 쐌 Harness for open or short between heated oxygen sensor 1 and fuse 䊳

ST

Repair harness or connectors.

HA SC EL

EC-1323

IDX

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK HO2S1 HEATER OUTPUT CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

SEC658C

Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

4

CHECK HEATED OXYGEN SENSOR 1 HEATER

Check resistance between HO2S1 terminals 3 and 1.

AEC158A

Resistance: 2.3 - 4.3Ω at 25°C (77°F) Check continuity between HO2S1 terminals 2 and 1, 3 and 2. Continuity should not exist. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

EC-1324

DTC P0031, P0032, P0051, P0052 HO2S1 HEATER

VG33ER

Diagnostic Procedure (Cont’d)

5

REPLACE HEATED OXYGEN SENSOR 1

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

GI MA EM LC SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

6

Replace malfunctioning heated oxygen sensor 1.

CHECK INTERMITTENT INCIDENT

FE CL MT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1325

IDX

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33ER

Description

Description

NGEC1216

SYSTEM DESCRIPTION

NGEC1216S01

Sensor

ECM function

Input Signal to ECM

Camshaft position sensor

Actuator

Heated oxygen Heated oxygen sensor 2 heatsensor 2 ers heater control

Engine speed

The ECM performs ON/OFF control of the heated oxygen sensor 2 heaters corresponding to the engine speed.

OPERATION

NGEC1216S02

Engine speed rpm

Heated oxygen sensor 2 heaters

Above 2,800

OFF

Below 2,800

ON

CONSULT-II Reference Value in Data Monitor Mode

NGEC1217

Specification data are reference values. MONITOR ITEM

HO2S2 HTR (B1) HO2S2 HTR (B2)

CONDITION

SPECIFICATION

쐌 Ignition switch: ON (Engine stopped) 쐌 Engine is running above 2,800 rpm.

OFF

쐌 Engine is running below 2,800 rpm after driving for 2 minutes at a speed of 70 km/h (43 MPH) or more.

ON

ECM Terminals and Reference Value

NGEC1218

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 the ECM terminals, such as the ground. TERMINAL NO.

122

123

WIRE COLOR

R/B

R/Y

ITEM

Heated oxygen sensor 2 heater (bank 1)

Heated oxygen sensor 2 heater (bank 2)

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 2,800 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 2,800 rpm 쐌 After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more

Approximately 0.4V

[Ignition switch “ON”] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 2,800 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Engine speed is below 2,800 rpm 쐌 After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more

Approximately 0.4V

EC-1326

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1219

Malfunction is detected when the current amperage in the heated oxygen sensor 2 heater circuit is out of the normal range. [An excessively low (P0037) (B1)/(P0057) (B2) or high (P0038) (B1)/(P0058) (B2) voltage signal is sent to ECM through the heated oxygen sensor 2 heater.]

POSSIBLE CAUSE 쐌 쐌

DTC Confirmation Procedure

SEF058Y

NGEC1219S01

Harness or connectors (The heated oxygen sensor 2 heater circuit is open or shorted.) Heated oxygen sensor 2 heater

GI MA EM LC

NGEC1220

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is 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. 3) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 4) Stop vehicle and let engine idle for at least 6 seconds. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1330. With GST Follow the procedure “With CONSULT-II”.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1327

IDX

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33ER

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1221 NGEC1221S01

WEC166A

EC-1328

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33ER

Wiring Diagram (Cont’d)

LEFT BANK

NGEC1221S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC167A

EC-1329

EL IDX

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1222

CHECK HO2S2 POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 2 harness protector color.

SEC301CA

3. Disconnect corresponding heated oxygen sensor 2 harness connector.

LEC659

4. Turn ignition switch ON. 5. Check voltage between HO2S2 terminal 3 and ground.

SEF637W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M59, F27 쐌 Fuse block (J/B) connector M26 쐌 10A fuse 쐌 Harness for open or short between heated oxygen sensor 2 and fuse 䊳

Repair harness or connectors.

EC-1330

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK HO2S2 HEATER OUTPUT CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram.

GI MA EM LC

SEC665C

Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

CL MT

DETECT MALFUNCTIONING PART

AT

Check the following. 쐌 Joint connector-3 (if equipped) 쐌 Harness for open or short between heated oxygen sensor 2 and engine ground. 䊳

FE

TF

Repair open circuit or short to ground or short to power in harness or connectors.

PD AX SU BR ST RS BT HA SC EL

EC-1331

IDX

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33ER

Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 2 HEATER

Check the following. 1. Check resistance between HO2S2 terminals 2 and 3.

SEF716W

Resistance: 2.3 - 4.3Ω at 25°C (77°F) 2. Check continuity.

MTBL0233

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. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

EC-1332

DTC P0037, P0038, P0057, P0058 HO2S2 HEATER

VG33ER

Diagnostic Procedure (Cont’d)

6

REPLACE HEATED OXYGEN SENSOR 2

Check heated oxygen sensor 2 harness protector color.

GI MA EM LC SEC301CA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

FE

Replace malfunctioning heated oxygen sensor 2.

CL 7

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

MT

INSPECTION END

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1333

IDX

DTC P0101, P0102, P0103 MAF SENSOR

VG33ER

Component Description

Component Description

NGEC1106

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.

SEF030T

CONSULT-II Reference Value in Data Monitor Mode

NGEC1107

Specification data are reference values. MONITOR ITEM

MAS A/F SE-B1

CAL/LD VALUE

MASS AIRFLOW

CONDITION 쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

SPECIFICATION

Idle

1.0 - 1.7V

2,500 rpm

1.7 - 2.3V

Idle

18.5 - 26.0%

2,500 rpm

18.0 - 21.0%

Idle

3.3 - 4.8 g·m/s

2,500 rpm

12.0 - 14.9 g·m/s

ditto

ditto

ECM Terminals and Reference Value

NGEC1108

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

54

55

R

G

ITEM

Mass air flow sensor

Mass air flow sensor ground

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

1.0 - 1.7V

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm

1.7 - 2.3V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

On Board Diagnosis Logic

NGEC1109

Malfunction is detected when (Malfunction A, P0103) an excessively high voltage from the sensor is sent to ECM when engine is not running, (Malfunction B, P0102) an excessively low voltage from the sensor is sent to ECM when engine is running, (Malfunction C, P0101) a high voltage from the sensor is sent to ECM under light load driving condition, (Malfunction D, P0101) a low voltage from the sensor is sent to ECM under heavy load driving condition.

EC-1334

DTC P0101, P0102, P0103 MAF SENSOR

VG33ER

On Board Diagnosis Logic (Cont’d)

POSSIBLE CAUSE Malfunction A or C 쐌

NGEC1109S01 NGEC1109S0101

Harness or connectors (The sensor circuit is open or shorted.) Mass air flow sensor

쐌

Malfunction B or D 쐌

MA NGEC1109S0102

Harness or connectors (The sensor circuit is open or shorted.) Intake air leaks Mass air flow sensor

쐌 쐌

FAIL-SAFE MODE

GI

EM LC NGEC1109S02

When the malfunction B is detected, the ECM enters fail-safe mode and the MIL lights up. Detected items

Engine operating condition in fail-safe mode

Mass air flow sensor circuit

FE

Engine speed will not rise more than 2,400 rpm due to the fuel cut.

CL MT

DTC Confirmation Procedure

NGEC1110

Perform “PROCEDURE FOR MALFUNCTION A” first. If the 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. If there is no problem on “PROCEDURE FOR MALFUNCTION B”, perform “PROCEDURE FOR MALFUNCTION C”. If there is no problem on ”PROCEDURE FOR MALFUNCTION C”, perform “PROCEDURE FOR MALFUNCTION D”. 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.

AT TF PD AX SU BR ST RS

PROCEDURE FOR MALFUNCTION A 1) 2) 3) 4)

SEF058Y

5) 6)

NGEC1110S01

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 6 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1339. If 1st DTC is not detected, go to next step. Start engine and let it idle for at least 6 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1339.

EC-1335

BT HA SC EL IDX

DTC P0101, P0102, P0103 MAF SENSOR

VG33ER

DTC Confirmation Procedure (Cont’d)

With GST Follow the procedure “With CONSULT-II”.

PROCEDURE FOR MALFUNCTION B

NGEC1110S02

With CONSULT-II 1) Turn ignition switch ON. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and wait 5 seconds at most. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1339. With GST Follow the procedure “With CONSULT-II”. SEF058Y

PROCEDURE FOR MALFUNCTION C

SEF174Y

NGEC1110S03

NOTE: If engine will not start or stops soon, wait at least 10 seconds with engine stopped (Ignition switch ON) instead of running engine at idle speed. 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) Run engine for at least 10 seconds at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1339. With GST Follow the procedure “With CONSULT-II”.

EC-1336

DTC P0101, P0102, P0103 MAF SENSOR

VG33ER

DTC Confirmation Procedure (Cont’d)

PROCEDURE FOR MALFUNCTION D

NGEC1110S04

CAUTION: Always drive vehicle at a safe speed. With CONSULT-II 1) Turn ignition switch “ON”. 2) Start engine and warm it up to normal operating temperature. If engine cannot be started, go to “Diagnostic Procedure”, EC-1339. 3) Select “DATA MONITOR” mode with CONSULT-II. 4) Check the voltage of MAS AIR/FL SE with “DATA MONITOR”. 5) Increases engine speed to about 4,000 rpm. 6) Monitor the linear voltage rise in response to engine speed increases. If NG, go to “Diagnostic Procedure”, EC-1339. If OK, go to following step. 7) Maintain the following conditions for at least 10 consecutive seconds. ENG SPEED

More than 2,000 rpm

THRTL POS SEN

More than 3V

Selector lever

Suitable position

Driving location

Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test.

MA EM LC

FE CL MT

SEF243Y

8)

GI

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1339.

AT TF PD AX

SEF175Y

Overall Function Check PROCEDURE FOR MALFUNCTION D

SEF534P

NGEC1111

SU

NGEC1111S01

Use this procedure to check the overall function of the mass air flow sensor circuit. During this check, a 1st trip DTC might not be confirmed. With GST 1) Start engine and warm it up to normal operating temperature. 2) Select “MODE 1” with GST. 3) Check the mass air flow sensor signal with “MODE 1”. 4) Check for linear mass air flow sensor signal value rise in response to increases to about 4,000 rpm in engine speed. 5) If NG, go to “Diagnostic Procedure”, EC-1339.

BR ST RS BT HA SC EL

EC-1337

IDX

DTC P0101, P0102, P0103 MAF SENSOR

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1112

WEC168A

EC-1338

DTC P0101, P0102, P0103 MAF SENSOR

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1113

INSPECTION START

GI

Which malfunction (A, B, C or D) is duplicated?

MA MTBL0063

EM

Type I or Type II Type I

䊳

GO TO 3.

Type II

䊳

GO TO 2.

2

LC

CHECK INTAKE SYSTEM

Check the following for connection. 쐌 Air duct 쐌 Vacuum hoses 쐌 Intake air passage between air duct to intake manifold collector

FE CL

OK or NG OK

䊳

GO TO 3.

NG

䊳

Reconnect the parts.

3

MT AT

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

TF PD AX SU LEC657

䊳

GO TO 4.

BR ST RS BT HA SC EL

EC-1339

IDX

DTC P0101, P0102, P0103 MAF SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

4

CHECK MAFS POWER SUPPLY CIRCUIT

1. Disconnect mass air flow sensor harness connector.

AEC641A

2. Turn ignition switch ON. 3. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF627W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between ECM relay and mass air flow sensor 쐌 Harness for open or short between mass air flow sensor and ECM 䊳

6

Repair harness or connectors.

CHECK MAFS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between MAFS terminal 3 and ECM terminal 55. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1340

DTC P0101, P0102, P0103 MAF SENSOR

VG33ER Diagnostic Procedure (Cont’d)

7

CHECK MAFS INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between MAFS terminal 4 and ECM terminal 54. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power.

GI MA

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

8

EM LC

CHECK MASS AIR FLOW SENSOR

1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 54 (Mass air flow sensor signal) and ground.

FE CL MT AT SEF747U

TF PD AX SU LEC102A

4. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Then repeat above check. 5. If NG, remove mass air flow sensor from air duct. Check hot wire for damage or dust.

BR ST RS BT HA SEF030T

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace mass air flow sensor.

EC-1341

SC EL IDX

DTC P0101, P0102, P0103 MAF SENSOR Diagnostic Procedure (Cont’d)

9

CHECK MAFS SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector-2. 3. Check the following. 쐌 Continuity between joint connector-2 terminal 1 and ground Refer to Wiring Diagram. 쐌 Joint connector-2 (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-2. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1342

VG33ER

DTC P0112, P0113, P0127 IAT SENSOR

VG33ER Component Description

Component Description

NGEC1118

The intake air temperature sensor is mounted to the air duct housing. 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. Intake air temperature °C (°F)

Voltage*

(V)

Resistance

GI MA EM

kΩ

LC

LEC519

20 (68)

3.5

2.1 - 2.9

80 (176)

1.23

0.27 - 0.38

*: These data are reference values and are measured between ECM terminal 61 (Intake air temperature sensor) and ground.

CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than the ECM terminals, such as the ground.

FE CL MT

SEF012P

On Board Diagnosis Logic

NGEC1119

Malfunction is detected when (Malfunction A) an excessively low (P0112) or high (P0113) voltage from the sensor is sent to ECM, (Malfunction B, P0127) rationally incorrect voltage from the sensor is sent to ECM, compared with the voltage signal from engine coolant temperature sensor.

POSSIBLE CAUSE 쐌 쐌

AT TF PD

NGEC1119S01

Harness or connectors (The sensor circuit is open or shorted.) Intake air temperature sensor

AX SU BR ST RS

DTC Confirmation Procedure

NGEC1120

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 5 seconds before conducting the next test.

BT HA SC EL

EC-1343

IDX

DTC P0112, P0113, P0127 IAT SENSOR

VG33ER

DTC Confirmation Procedure (Cont’d)

PROCEDURE FOR MALFUNCTION A

NGEC1120S01

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”, EC-1346. With GST Follow the procedure “With CONSULT-II”. SEF058Y

PROCEDURE FOR MALFUNCTION B

SEF176Y

NGEC1120S02

CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: 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. With CONSULT-II 1) Wait until engine coolant temperature is less than 90°C (194°F). a) Turn ignition switch ON. b) Select “DATA MONITOR” mode with CONSULT-II. c) Check the engine coolant temperature. d) If the engine coolant temperature is not less than 90°C (194°F), turn ignition switch OFF and cool down engine. 쐌 Perform the following steps before engine coolant temperature is above 90°C (194°F). 2) Turn ignition switch ON. 3) Select “DATA MONITOR” mode with CONSULT-II. 4) Start engine. 5) Hold vehicle speed at more than 70 km/h (43 MPH) for 100 consecutive seconds. 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1346. With GST Follow the procedure “With CONSULT-II”.

EC-1344

DTC P0112, P0113, P0127 IAT SENSOR

VG33ER Wiring Diagram

Wiring Diagram

NGEC1121

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC169A

EC-1345

EL IDX

DTC P0112, P0113, P0127 IAT SENSOR

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1122

CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect intake air temperature sensor harness connector.

LEC519

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground.

SEF203W

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and intake air temperature sensor 䊳

3

Repair harness or connectors.

CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between intake air temperature sensor terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-1346

DTC P0112, P0113, P0127 IAT SENSOR

VG33ER Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M81, F36 쐌 Joint connector-4 (if equipped) 쐌 Harness for open or short between ECM and intake air temperature sensor 䊳

5

GI MA

Repair open circuit or short to power in harness or connectors.

EM

CHECK INTAKE AIR TEMPERATURE SENSOR

LC

Check resistance as shown in the figure.

FE CL SEF947Q

MT



AT TF MTBL0228

PD AX SU BR SEF012P

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace intake air temperature sensor.

6

CHECK INTERMITTENT INCIDENT

ST RS BT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

HA SC EL

EC-1347

IDX

DTC P0117, P0118 ECT SENSOR

VG33ER

Component Description

Component Description

NGEC1123

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)

SEF012P

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

*: These data are reference values and are measured between ECM terminal 59 (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 the ECM terminals, such as the ground.

On Board Diagnosis Logic

NGEC1124

Malfunction is detected when an excessively high (P0118) or low (P0117) voltage from the sensor is sent to ECM.

POSSIBLE CAUSE 쐌 쐌

NGEC1124S01

Harness or connectors (The sensor circuit is open or shorted.) Engine coolant temperature sensor

FAIL-SAFE MODE

NGEC1124S02

When this malfunction is detected, the ECM enters fail-safe mode and the MIL lights up.

EC-1348

DTC P0117, P0118 ECT SENSOR

VG33ER On Board Diagnosis Logic (Cont’d)

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)

GI MA EM LC

40 - 80°C (104 - 176°F) (Depends on the time)

Except as shown above

FE CL MT

DTC Confirmation Procedure

SEF058Y

NGEC1125

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. 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”, EC-1351. With GST Follow the procedure “With CONSULT-II”.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1349

IDX

DTC P0117, P0118 ECT SENSOR

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1126

WEC186A

EC-1350

DTC P0117, P0118 ECT SENSOR

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1127

CHECK ECTS POWER SUPPLY CIRCUIT

GI

1. Turn ignition switch OFF. 2. Disconnect engine coolant temperature sensor harness connector.

MA EM LC

AEC643A

3. Turn ignition switch ON. 4. Check voltage between ECTS terminal 1 and ground with CONSULT-II or tester.

FE CL MT AT

SEF206W

Voltage: Approximately 5V

TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

PD AX

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Harness for open or short between ECM and engine coolant temperature sensor 䊳

3

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK ECTS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between ECTS terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power.

SU BR ST RS BT

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

HA SC EL

EC-1351

IDX

DTC P0117, P0118 ECT SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Joint connector-4 (if equipped) 쐌 Harness for open or short between ECM and engine coolant temperature sensor 䊳

5

Repair open circuit or short to power in harness or connectors.

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

SEF152P



MTBL0229

SEF012P

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace engine coolant temperature sensor.

6

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1352

DTC P0121, P0122, P0123 TP SENSOR

VG33ER Description

Description

NGEC1128

NOTE: If DTC P0120 is displayed with DTC P0510, first perform the trouble diagnosis for DTC P0510. Refer to EC-1592.

GI

COMPONENT DESCRIPTION

MA

NGEC1128S01

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.

EM LC

FE CL MT AT TF PD SEC299C

CONSULT-II Reference Value in Data Monitor Mode

NGEC1129

Specification data are reference values. MONITOR ITEM

CONDITION 쐌 Engine: After warming up, idle the engine

THRTL POS SEN

ABSOL TH·P/S

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

AX SU

SPECIFICATION

BR Throttle valve: fully closed (a)

0.15 - 0.85V

Throttle valve: Partially open

Between (a) and (b)

Throttle valve: fully opened (b)

3.5 - 4.7V

ST RS

쐌 Engine: After warming up 쐌 Ignition switch: ON 쐌 More than -40.0 kpa (-300 mmHg, -11.81 inHg) of vacuum is applied to the throttle opener with a hand vacuum pump.

Throttle valve: fully closed

쐌 Engine: After warming up 쐌 Ignition switch: ON (Engine stopped)

Throttle valve: fully opened

0.0%

BT HA

Approx. 80%

SC EL

EC-1353

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33ER

ECM Terminals and Reference Value

ECM Terminals and Reference Value

=NGEC1130

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 the ECM terminals, such as the ground. TERMINAL NO.

23

WIRE COLOR

L

ITEM

Throttle position sensor

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Warm-up condition 쐌 Accelerator pedal fully released

0.15 - 0.85V

[Ignition switch ON] 쐌 Accelerator pedal fully depressed

3.5 - 4.7V

42

B/W

Sensors’ power supply

[Ignition switch ON]

Approximately 5V

43

BR

Sensors’ ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

On Board Diagnosis Logic

NGEC1131

Malfunction is detected when (Malfunction A) an excessively low (P0122) or high (P0123) voltage from the sensor is sent to ECM, (Malfunction B, P0121) a high voltage from the sensor is sent to ECM under light load driving conditions, (Malfunction C, P0121) a low voltage from the sensor is sent to ECM under heavy load driving conditions.

POSSIBLE CAUSE Malfunction A 쐌 쐌

Harness or connectors (The throttle position sensor circuit is open or shorted.) Throttle position sensor

Malfunction B 쐌 쐌 쐌 쐌 쐌

쐌 쐌

NGEC1131S0102

Harness or connectors (The throttle position sensor circuit is open or shorted.) Throttle position sensor Fuel injector Camshaft position sensor Mass air flow sensor

Malfunction C 쐌

NGEC1131S01 NGEC1131S0101

NGEC1131S0103

Harness or connectors (The throttle position sensor circuit is open or shorted.) Intake air leaks Throttle position sensor

FAIL-SAFE MODE

NGEC1131S02

When the malfunction A is detected, the ECM enters fail-safe mode and the MIL lights up.

EC-1354

DTC P0121, P0122, P0123 TP SENSOR

VG33ER

On Board Diagnosis Logic (Cont’d) Detected items

Engine operating condition in fail-safe mode

GI

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

MA

Normal

When accelerating

Poor acceleration

EM LC

DTC Confirmation Procedure

NGEC1132

NOTE: 쐌 Perform “PROCEDURE FOR MALFUNCTION A” first. If the 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. If there is no problem on “PROCEDURE FOR MALFUNCTION B”, perform “PROCEDURE FOR MALFUNCTION C”. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A

FE CL MT

NGEC1132S01

CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: 쐌 Before performing the following procedure, confirm that battery voltage is more than 10V at idle. 쐌 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.

AT TF PD AX

With CONSULT-II 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. 1)

Vehicle speed

More than 5 km/h (3 MPH)

Selector lever

Suitable position except “P” or “N” position

3) SEF065Y

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1359. With GST Follow the procedure “With CONSULT-II”.

SU BR ST RS BT HA SC EL

EC-1355

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33ER

DTC Confirmation Procedure (Cont’d)

PROCEDURE FOR MALFUNCTION B

NGEC1132S02

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 10 seconds. If idle speed is over 1,000 rpm, maintain the following conditions for at least 10 seconds to keep engine speed below 1,000 rpm.

SEF058Y

Selector lever

Suitable position except “P” or “N”

Brake pedal

Depressed

Vehicle speed

0 km/h (0 MPH)

4)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1359. With GST Follow the procedure “With CONSULT-II”.

PROCEDURE FOR MALFUNCTION C

SEF177Y

NGEC1132S03

CAUTION: Always drive vehicle at a safe speed. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode with CONSULT-II. 5) Select “THRTL POS SEN” and “ABSOL TH·P/S” in “DATA MONITOR” mode with CONSULT-II. 6) Press RECORD on CONSULT-II SCREEN at the same time accelerator pedal is depressed. 7) Print out the recorded graph and check the following: 쐌 The voltage rise is linear in response to accelerator pedal depression. 쐌 The voltage when accelerator pedal is fully depressed is approximately 4V. If NG, go to “Diagnostic Procedure”, EC-1359. If OK, go to following step.

EC-1356

DTC P0121, P0122, P0123 TP SENSOR

VG33ER

DTC Confirmation Procedure (Cont’d)

GI MA EM LC

FE SEF174Z

CL MT

8) 9)

SEF805Z

Select “AUTO TRIG” in “DATA MONITOR” mode with CONSULT-II. Maintain the following conditions for at least 10 consecutive seconds.

CMPS·RPM (REF)

More than 2,000 rpm

MAS AIR/FL SE

More than 3V

COOLAN TEMP/S

More than 70°C (158°F)

IACV-AAC/V

Less than 80%

Selector lever

Suitable position

Driving location

Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test.

10) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1359. With GST Follow the procedure “With CONSULT-II”.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1357

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1133

WEC171A

EC-1358

DTC P0121, P0122, P0123 TP SENSOR

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1134

INSPECTION START

GI

Which malfunction A, B or C is duplicated?

MA EM MTBL0066

Type A, B or C Type A or B

䊳

GO TO 4.

Type C

䊳

GO TO 2.

2

LC

ADJUST THROTTLE POSITION SENSOR

FE

Check the following items. Refer to “Basic Inspection”, EC-1273.

CL MT AT MTBL0576

䊳

3

GO TO 3.

TF

CHECK INTAKE SYSTEM.

PD

1. Turn ignition switch OFF. 2. Check the following for connection. 쐌 Air duct 쐌 Vacuum hoses 쐌 Intake air passage between air duct to intake manifold collector OK or NG OK

䊳

GO TO 4.

NG

䊳

Reconnect the parts.

AX SU BR ST RS BT HA SC EL

EC-1359

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

4

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC657

䊳

5

GO TO 5.

CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT

1. Disconnect throttle position sensor harness connector.

AEC638A

2. Turn ignition switch ON. 3. Check voltage between sensor terminal 3 and ground with CONSULT-II or tester.

SEF630W

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1360

DTC P0121, P0122, P0123 TP SENSOR

VG33ER Diagnostic Procedure (Cont’d)

6

CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between throttle position sensor terminal 1 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power.

GI MA

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

EM LC

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and throttle position sensor. 䊳

Repair open circuit or short to power in harness or connectors.

FE 8

CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 23 and throttle position sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

CL MT

OK or NG OK (With CONSULT-II)

䊳

GO TO 9.

OK (Without CONSULTII)

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

AT TF PD

9 1. 2. 3. 4. 5.

CHECK THROTTLE POSITION SENSOR With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine (ignition switch OFF). Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check voltage of “THRTL POS SEN” under the following conditions. Voltage measurement must be made with throttle position sensor installed in vehicle.

AX SU BR ST RS BT SEF062Y

HA

OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 11.

SC EL

EC-1361

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

10 1. 2. 3. 4.

CHECK 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 23 (Throttle position sensor signal) and ground. Voltage measurement must be made with throttle position sensor installed in vehicle.

MTBL0231

OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 11.

11

ADJUST CLOSED THROTTLE POSITION SWITCH

Adjust closed throttle position switch. Refer to “Basic Inspection”, EC-1273.

MTBL0576

OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace throttle position sensor. To adjust it, perform “Basic Inspection”, EC-1273.

EC-1362

DTC P0121, P0122, P0123 TP SENSOR

VG33ER Diagnostic Procedure (Cont’d)

12

CHECK MASS AIR FLOW SENSOR

1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 54 (Mass air flow sensor signal) and ground.

GI MA EM LC

SEF747U

FE CL MT AT LEC102A

4. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Then repeat above check. 5. If NG, remove mass air flow sensor from air duct. Check hot wire for damage or dust.

TF PD AX SU BR SEF030T

OK or NG OK

䊳

GO TO 13.

NG

䊳

Replace mass air flow sensor.

ST RS BT HA SC EL

EC-1363

IDX

DTC P0121, P0122, P0123 TP SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

13

CHECK CAMSHAFT POSITION SENSOR

1. Install any parts removed. 2. Start engine. 3. Check voltage between ECM terminals 44, 48 and ground, ECM terminal 49 and ground with DC range.

AEC072B

OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace distributor assembly with camshaft position sensor.

14

CHECK FUEL INJECTOR

1. Disconnect injector harness connector. 2. Check resistance between terminals as shown in the figure.

SEF625V

Resistance: 10 - 14Ω [at 25°C (77°F)] OK or NG OK

䊳

GO TO 15.

NG

䊳

Replace fuel injector.

EC-1364

DTC P0121, P0122, P0123 TP SENSOR

VG33ER Diagnostic Procedure (Cont’d)

15

CHECK THROTTLE POSITION SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector-2. 3. Check the following. 쐌 Continuity between joint connector-2 terminal 1 and ground 쐌 Joint connector-2 (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-2. OK or NG OK

䊳

GO TO 16.

NG

䊳

Repair open circuit or short to power in harness or connectors.

16

CHECK INTERMITTENT INCIDENT

GI MA EM LC

FE

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1365

IDX

DTC P0125 ECT SENSOR

VG33ER

Description

Description

NGEC1135

NOTE: If DTC P0125 is displayed with P0117, P0118, first perform the trouble diagnosis for DTC P0117, P0118. Refer to EC-1348.

COMPONENT DESCRIPTION

NGEC1135S01

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)

SEF012P

Voltage*

(V)

Resistance

(kΩ)

−10 (14)

4.4

9.2

20 (68)

3.5

2.1 - 2.9

50 (122)

2.2

0.68 - 1.00

90 (194)

0.9

0.236 - 0.260

*: These data are reference values and are measured between ECM terminal 59 (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 the ECM terminals, such as the ground.

On Board Diagnosis Logic

NGEC1136

Malfunction is detected when voltage sent to ECM from the sensor is not practical, even when some time has passed after starting the engine, or engine coolant temperature is insufficient for closed loop fuel control.

POSSIBLE CAUSE 쐌 쐌 쐌

Harness or connectors (High resistance in the circuit) Engine coolant temperature sensor Thermostat

EC-1366

NGEC1136S01

DTC P0125 ECT SENSOR

VG33ER DTC Confirmation Procedure

DTC Confirmation Procedure

SEF174Y

=NGEC1137

CAUTION: Be careful not to overheat engine. 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. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Check that “COOLAN TEMP/S” is above 10°C (50°F). If it is above 10°C (50°F), the test result will be OK. If it is below 10°C (50°F), go to following step. 4) Start engine and run it for 65 minutes at idle speed. If “COOLAN TEMP/S” increases to more than 10°C (50°F) within 65 minutes, stop engine because the test result will be OK. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1369. With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1367

IDX

DTC P0125 ECT SENSOR

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1138

WEC186A

EC-1368

DTC P0125 ECT SENSOR

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1139

CHECK ECTS POWER SUPPLY CIRCUIT

GI

1. Turn ignition switch OFF. 2. Disconnect engine coolant temperature sensor harness connector.

MA EM LC

AEC643A

3. Turn ignition switch ON. 4. Check voltage between ECTS terminal 1 and ground with CONSULT-II or tester.

FE CL MT AT

SEF206W

Voltage: Approximately 5V

TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

PD AX

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Harness for open or short between ECM and engine coolant temperature sensor 䊳

3

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK ECTS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between ECTS terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power.

SU BR ST RS BT

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

HA SC EL

EC-1369

IDX

DTC P0125 ECT SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Joint connector-4 (if equipped) 쐌 Harness for open or short between ECM and engine coolant temperature sensor 䊳

5

Repair open circuit or short to power in harness or connectors.

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

SEF152P



MTBL0229

SEF012P

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace engine coolant temperature sensor.

6

CHECK THERMOSTAT OPERATION

When the engine is cold [lower than 70°C (158°F)] condition, grasp lower radiator hose and confirm the engine coolant does not flow. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair or replace thermostat. Refer to LC-13, “Thermostat”.

EC-1370

DTC P0125 ECT SENSOR

VG33ER Diagnostic Procedure (Cont’d)

7

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

GI

INSPECTION END

MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1371

IDX

DTC P0128 THERMOSTAT FUNCTION

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1344

Engine coolant temperature has not risen enough to open the thermostat even though the engine has run long enough. This is due to a leak in the seal or the thermostat open stuck. Malfunction is detected when the engine coolant temperature does not reach to specified temperature even though the engine has run long enough.

POSSIBLE CAUSE 쐌 쐌 쐌

NGEC1344S01

Thermostat function Leakage from sealing portion of thermostat Engine coolant temperature sensor

DTC Confirmation Procedure

NGEC1345

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. TESTING CONDITION: 쐌 For best results, perform at ambient temperature of –10°C (14°F) or higher. 쐌 For best results, perform at engine coolant temperature of –10°C (14°F) to 70°C (158°F).

WITH CONSULT-II 1)

2) 3) 4)

5)

NGEC1345S01

Replace thermostat with new one. Refer to LC-13, “Thermostat”. Use only a genuine NISSAN thermostat as a replacement. If an incorrect thermostat is used, the MIL may come on. Turn ignition switch “ON”. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Check that the “COOLAN TEMP/S” is above 70°C (158°F). If it is below 70°C (158°F), go to following step. If it is above 70°C (158°F), stop engine and cool down the engine to less than 70°C (158°F), then retry from step 1. Drive vehicle for 10 consecutive minutes under the following conditions.

VHCL SPEED SE

80 - 120 km/h (50 - 75 MPH)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1373.

WITH GST 1)

Follow the prodedure “WITH CONSULT-II” above.

EC-1372

NGEC1345S02

DTC P0128 THERMOSTAT FUNCTION

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1346

CHECK ENGINE COOLANT TEMPERATURE SENSOR

GI

1. Turn ignition switch OFF. 2. Remove engine coolant temperature sensor. 3. Check resistance between engine coolant temperature sensor terminals under the following conditions.

MA EM LC

FE CL MT SEF304X

AT

OK or NG

TF

OK

䊳

INSPECTION END

NG

䊳

Replace engine coolant temperature sensor.

PD AX SU BR ST RS BT HA SC EL

EC-1373

IDX

DTC P0132, P0152 HO2S1

VG33ER

Component Description

Component Description

NGEC1170

The heated oxygen sensor 1 is placed into the front tube. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NGEC1171

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 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

NGEC1172

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1 (Bank 1) [Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

51

G

Heated oxygen sensor 1 (Bank 2) SEF002V

EC-1374

DTC P0132, P0152 HO2S1

VG33ER On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1173

To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high. Malfunction is detected when an excessively high voltage from the sensor is sent to ECM.

POSSIBLE CAUSE 쐌 쐌

MA

NGEC1173S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 1

EM LC

SEF301UA

DTC Confirmation Procedure

SEF174Y

GI

NGEC1174

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) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Restart engine and let it idle for 25 seconds. 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1378. With GST Follow the procedure “With CONSULT-II”. 쐌 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.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1375

IDX

DTC P0132, P0152 HO2S1

VG33ER

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1175 NGEC1175S01

WEC172A

EC-1376

DTC P0132, P0152 HO2S1

VG33ER Wiring Diagram (Cont’d)

LEFT BANK

NGEC1175S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC173A

EC-1377

EL IDX

DTC P0132, P0152 HO2S1

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1176

INSPECTION START

1. Turn ignition switch OFF. 2. Check heated oxygen sensor 1 harness protector.

SEF505YB

3. Disconnect corresponding heated oxygen sensor 1 harness connector.

LEC658

䊳

2

GO TO 2.

RETIGHTEN HEATED OXYGEN SENSOR 1

1. Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

GO TO 3.

EC-1378

DTC P0132, P0152 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

3

CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

GI MA EM LC

SEC656C

Continuity should exist. 3. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram.

FE CL MT AT TF SEC657C

Continuity should not exist. 4. Also check harness for short to power.

PD OK or NG

AX

OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

SU 4

CHECK FRONT HO2S1 CONNECTOR FOR WATER

1. Disconnect heated oxygen sensor 1 harness connector. 2. Check connectors for water. Water should not exist. OK or NG OK (With CONSULT-II)

䊳

GO TO 5.

OK (Without CONSULTII)

䊳

GO TO 6.

NG

䊳

Repair or replace harness or connectors.

BR ST RS BT HA SC EL

EC-1379

IDX

DTC P0132, P0152 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 1

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “MANU TRIG” in “DATA MONITOR” mode with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown left:

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

EC-1380

DTC P0132, P0152 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

6

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

GI MA EM LC

SEF796Z

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.

FE CL

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

MT

REPLACE HEATED OXYGEN SENSOR 1

AT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

TF

7

PD AX SU SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

BR ST

Replace malfunctioning heated oxygen sensor 1.

RS 8

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

BT

INSPECTION END

HA SC EL

EC-1381

IDX

DTC P0133, P0153 HO2S1

VG33ER

Component Description

Component Description

NGEC1162

The heated oxygen sensor 1 is placed into the front tube. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NGEC1163

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 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

NGEC1164

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1 (Bank 1) [Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

51

G

Heated oxygen sensor 1 (Bank 2) SEF002V

EC-1382

DTC P0133, P0153 HO2S1

VG33ER On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1165

To judge the malfunction of heated oxygen sensor 1, this diagnosis measures response time of heated oxygen sensor 1 signal. The time is compensated by engine operating (speed and load), fuel feedback control constant, and heated oxygen sensor 1 temperature index. Judgment is based on whether the compensated time (heated oxygen sensor 1 cycling time index) is inordinately long or not. Malfunction is detected when the response of the voltage signal from the sensor takes more than the specified time. SEF010V

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC1165S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 1 Heated oxygen sensor 1 heater Fuel pressure Injectors Intake air leaks Exhaust gas leaks PCV valve Mass air flow sensor

DTC Confirmation Procedure

GI MA EM LC

FE CL MT NGEC1166

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1383

IDX

DTC P0133, P0153 HO2S1

VG33ER

DTC Confirmation Procedure (Cont’d)

SEF338Z

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 5 seconds. 3) Turn ignition switch ON and select “HO2S1 (B1)/(B2) P0133/ P0153” 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 2,800 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 40 to 50 seconds.) ENG SPEED

1,700 - 2,800 rpm

Vehicle speed

More than 80 km/h (50 MPH)

B/FUEL SCHDL

2.0 - 14.0 msec

Selector lever

Suitable position

SEF339Z

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-1387.

SEF658Y

Overall Function Check

SEF919UA

NGEC1167

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 4) If NG, go to “Diagnostic Procedure”, EC-1387.

EC-1384

DTC P0133, P0153 HO2S1

VG33ER Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1168 NGEC1168S01

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC172A

EC-1385

IDX

DTC P0133, P0153 HO2S1

VG33ER

Wiring Diagram (Cont’d)

LEFT BANK

NGEC1168S02

WEC173A

EC-1386

DTC P0133, P0153 HO2S1

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1169

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

LEC657

䊳

FE

GO TO 2.

CL 2

RETIGHTEN HEATED OXYGEN SENSOR 1

MT

Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

AT

GO TO 3.

TF 3

CHECK FOR EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.

PD AX SU BR ST SEF099P

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace.

4

RS BT

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor.

HA

OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair or replace.

SC EL

EC-1387

IDX

DTC P0133, P0153 HO2S1

VG33ER

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 “CLEAR”.

SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-1246. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6.

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171, P0174 or P0172, P0175. Refer to EC-1427, 1436.

No

䊳

GO TO 6.

EC-1388

DTC P0133, P0153 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

6

CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check heated oxygen sensor 1 harness protector.

GI MA EM LC SEF505YB

3. Disconnect corresponding heated oxygen sensor 1 harness connector.

FE CL MT AT LEC658

4. Disconnect ECM harness connector. 5. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

TF PD AX MTBL0587

Continuity should exist. 6. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram.

SU BR ST

MTBL0588

RS

Continuity should not exist. 7. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

BT HA SC EL

EC-1389

IDX

DTC P0133, P0153 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK HEATED OXYGEN SENSOR 1 HEATER

Check resistance between HO2S1 terminals 3 and 1.

AEC158A

Resistance: 2.3 - 4.3Ω at 25°C (77°F) Check continuity between HO2S1 terminals 2 and 1, 3 and 2. Continuity should not exist. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 12.

EC-1390

DTC P0133, P0153 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

8

CHECK MASS AIR FLOW SENSOR

1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 54 (Mass air flow sensor signal) and ground.

GI MA EM LC

SEF747U

FE CL MT MTBL0227

4. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Then repeat above check. 5. If NG, remove mass air flow sensor from air duct. Check hot wire for damage or dust.

AT TF PD AX SU SEF030T

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace mass air flow sensor.

BR ST RS BT HA SC EL

EC-1391

IDX

DTC P0133, P0153 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

9

CHECK PCV VALVE

With engine running at idle, remove PCV valve from rocker cover; make sure that 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.

SEC137A

OK or NG OK (With CONSULT-II)

䊳

GO TO 10.

OK (Without CONSULTII)

䊳

GO TO 11.

NG

䊳

Replace PCV valve.

EC-1392

DTC P0133, P0153 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

10

CHECK FRONT HEATED OXYGEN SENSOR

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “MANU TRIG” in “DATA MONITOR” mode with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

GI MA EM LC

FE SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below.

CL MT AT TF PD

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

AX SU BR ST RS SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BT HA

OK or NG

SC

OK

䊳

GO TO 12.

NG

䊳

Replace malfunctioning heated oxygen sensor 1 (front).

EL

EC-1393

IDX

DTC P0133, P0153 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

11

CHECK FRONT HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

SEF796Z

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. OK or NG OK

䊳

GO TO 13.

NG

䊳

GO TO 12.

12

REPLACE HEATED OXYGEN SENSOR 1

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 1.

EC-1394

DTC P0133, P0153 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

13

CHECK HO2S1 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 14.

NG

䊳

Repair open circuit or short to power in harness or connectors.

14

CHECK INTERMITTENT INCIDENT

GI MA EM LC

FE

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1395

IDX

DTC P0134, P0154 HO2S1

VG33ER

Component Description

Component Description

NGEC1140

The heated oxygen sensor 1 is placed into the front tube. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NGEC1141

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 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

NGEC1142

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1 (bank 1) [Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

51

G

Heated oxygen sensor 1 (bank 2) SEF002V

EC-1396

DTC P0134, P0154 HO2S1

VG33ER On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1143

Under the condition in which the heated oxygen sensor 1 signal is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output voltage is within 200 to 400 mV range is monitored, and the diagnosis checks that this time is not inordinately long. Malfunction is detected when the voltage from the sensor is constantly approx. 0.3V.

POSSIBLE CAUSE SEF237U

쐌 쐌

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 1

GI MA EM

NGEC1143S01

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1397

IDX

DTC P0134, P0154 HO2S1

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

SEC701C

SEC702C

SEC703C

=NGEC1144

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 5 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “HO2S1 (B1)/(B2) P0134/P0154” 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 2,800 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

1,400 - 2,700 rpm

Vehicle speed

More than 65 km/h (40 MPH)

B/FUEL SCHDL

2.0 - 14.0 msec

Selector lever

Suitable position

6)

If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-1402. During this test, P1148 and P1168 may be stored in ECM.

EC-1398

DTC P0134, P0154 HO2S1

VG33ER Overall Function Check

Overall Function Check

SEF919UA

=NGEC1145

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. 쐌 The voltage does not remain in the range of 0.2 - 0.4V. 4) If NG, go to “Diagnostic Procedure”, EC-1402.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1399

IDX

DTC P0134, P0154 HO2S1

VG33ER

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1146 NGEC1146S01

WEC172A

EC-1400

DTC P0134, P0154 HO2S1

VG33ER Wiring Diagram (Cont’d)

LEFT BANK

NGEC1146S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC173A

EC-1401

EL IDX

DTC P0134, P0154 HO2S1

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1147

INSPECTION START

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC657

3. Make sure HO2S 1 harness protector color, and disconnect corresponding heated oxygen sensor 1 harness connector.

SEF505YB

LEC658

䊳

GO TO 2.

EC-1402

DTC P0134, P0154 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

2

CHECK HO2S 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

GI MA EM LC

SEC654C

Continuity should exist. 3. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram.

FE CL MT AT TF SEC655C

Continuity should not exist. 4. Also check harness for short to power.

PD OK or NG

AX

OK (With CONSULT-II)

䊳

GO TO 3.

OK (Without CONSULTII)

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

SU BR ST RS BT HA SC EL

EC-1403

IDX

DTC P0134, P0154 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK HEATED OXYGEN SENSOR 1

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “MANU TRIG” in “DATA MONITOR” mode with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below.

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace malfunctioning heated oxygen sensor 1.

EC-1404

DTC P0134, P0154 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

4

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

GI MA EM LC

SEF796Z

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.

FE CL

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

MT

REPLACE HEATED OXYGEN SENSOR 1

AT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

TF

5

PD AX SU SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

BR ST

Replace malfunctioning heated oxygen sensor 1.

RS BT HA SC EL

EC-1405

IDX

DTC P0134, P0154 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

6

CHECK HO2S 1 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector-2. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-2. OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

7

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1406

DTC P0138, P0158 HO2S2

VG33ER Component Description

Component Description

SEF327R

NGEC1208

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

GI MA EM LC

CONSULT-II Reference Value in Data Monitor Mode

NGEC1209

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2)

FE

0 - 0.3V +, Approx. 0.6 - 1.0V

CL

Revving engine from idle up to 2,000 rpm

쐌 Engine: After warming up

LEAN +, RICH

ECM Terminals and Reference Value

MT NGEC1210

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 the ECM terminals, such as the ground. TERMINAL NO. 56 57

WIRE COLOR

AT TF PD

ITEM

CONDITION

OR

Heated oxygen sensor 2 (bank 1)

Y

Heated oxygen sensor 2 (bank 2)

DATA (DC Voltage)

AX [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 2,000 rpm

0 - Approximately 1.0V

SU BR ST RS

On Board Diagnosis Logic

NGEC1211

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the voltage is unusually high during the various driving condition such as fuel-cut. Malfunction is detected when an excessively high voltage from the sensor is sent to ECM.

POSSIBLE CAUSE SEF305UA

쐌

Harness or connectors

EC-1407

BT HA SC EL

NGEC1211S01

IDX

DTC P0138, P0158 HO2S2

VG33ER

DTC Confirmation Procedure

쐌

(The sensor circuit is open or shorted.) Heated oxygen sensor 2

DTC Confirmation Procedure

SEF189Y

END SPEED

Less than 3,600 rpm

COOLAN TEMP/S

More than 70°C (158°F)

Selector lever

Suitable position

6)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1412.

Overall Function Check

SEF922UA

NGEC1212

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 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 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.

NGEC1213

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. 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 terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. 4) Check the voltage when racing up to 4,000 rpm under no load

EC-1408

DTC P0138, P0158 HO2S2

VG33ER Overall Function Check (Cont’d)

5)

at least 10 times. (depress and release accelerator pedal as soon as possible) The voltage should be below 1.4V during this procedure. If NG, go to “Diagnostic Procedure”, EC-1412.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1409

IDX

DTC P0138, P0158 HO2S2

VG33ER

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1214 NGEC1214S01

WEC174A

EC-1410

DTC P0138, P0158 HO2S2

VG33ER Wiring Diagram (Cont’d)

LEFT BANK

NGEC1214S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC175A

EC-1411

EL IDX

DTC P0138, P0158 HO2S2

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1215

INSPECTION START

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC657

3. Check heated oxygen sensor 2 harness protector color.

SEC301CA

4. Disconnect corresponding heated oxygen sensor 2 harness connector. 5. Disconnect ECM harness connector. 䊳

GO TO 2.

EC-1412

DTC P0138, P0158 HO2S2

VG33ER Diagnostic Procedure (Cont’d)

2

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram.

GI MA EM LC SEC663C

Continuity should exist. 2. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram.

FE CL MT AT SEC664C

Continuity should not exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

3

CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

PD AX SU BR ST RS

DETECT MALFUNCTIONING PART

BT

Check the following. 쐌 Joint connector-3 (if equipped) 쐌 Harness for open between heated oxygen sensor 2 and engine ground. 䊳

TF

HA

Repair open circuit to ground or short to power in harness or connectors.

SC EL

EC-1413

IDX

DTC P0138, P0158 HO2S2

VG33ER

Diagnostic Procedure (Cont’d)

5

CHECK HO2S2 CONNECTORS FOR WATER

Check heated oxygen sensor 2 connector and harness connector for water. Water should not exist. OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

Repair or replace harness or connectors.

6

CHECK HEATED OXYGEN SENSOR 2

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)/(B2)” as the monitor item with CONSULTII. 4. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

SEF989RD

“HO2S2 (B1)/(B2)” should be above 0.62V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

EC-1414

DTC P0138, P0158 HO2S2

VG33ER Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without 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. Set voltmeter probes between ECM terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (depress and release accelerator pedal as soon as possible)

GI MA EM LC

FE SEF797ZB

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 “O/D” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

CL MT AT TF

REPLACE HEATED OXYGEN SENSOR 2

PD

1. Stop vehicle and turn ignition switch OFF. 2. Check heated oxygen sensor 2 harness protector color.

AX SU BR ST SEC301CA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 2.

RS BT HA SC EL

EC-1415

IDX

DTC P0138, P0158 HO2S2 Diagnostic Procedure (Cont’d)

9

CHECK HO2S2 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1416

VG33ER

DTC P0139, P0159 HO2S2

VG33ER Component Description

Component Description

SEF327R

NGEC1200

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

GI MA EM LC

CONSULT-II Reference Value in Data Monitor Mode

NGEC1201

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2)

FE

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up

CL

Revving engine from idle up to 2,000 rpm LEAN +, RICH

ECM Terminals and Reference Value

MT NGEC1202

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 the ECM terminals, such as the ground. TERMINAL NO. 56 57

WIRE COLOR OR Y

AT TF PD

ITEM

CONDITION

Heated oxygen sensor 2 (bank 1) Heated oxygen sensor 2 (bank 2)

DATA (DC Voltage)

AX [Engine is running] 쐌 Revving engine from idle up to 2,000 rpm

0 - Approximately 1.0V

SU BR ST RS

On Board Diagnosis Logic

NGEC1203

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the switching response of the sensor’s voltage is faster than specified during the various driving condition such as fuel-cut. Malfunction is detected when it takes more time for the sensor to respond between rich and lean than the specified time.

BT HA SC EL

SEF302U

EC-1417

IDX

DTC P0139, P0159 HO2S2

VG33ER

On Board Diagnosis Logic (Cont’d)

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌

DTC Confirmation Procedure

SEF666Y

SEF667Y

NGEC1203S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 2 Fuel pressure Injectors Intake air leaks

NGEC1204

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. TESTING CONDITION: Open engine hood before conducting following procedure With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that “COOLANT TEMP/S” is more than 70°C (158°F). 6) Select “HO2S2 (B1)/(B2) P0139/P0159” of “HO2S2” in DTC WORK SUPPORT” mode with CONSULT-II. 7) Start engine and follow the instructions of CONSULT-II. 8) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If NG is displayed, refer to “DIAGNOSTIC PROCEDURE”, EC-1422. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. a) Stop engine and cool down “COOLANT TEMP/SE” to less than 70°C (158°F). b) Turn ignition switch ON. c) Select “DATA MONITOR” mode with CONSULT-II. d) Start engine. e) Perform from step 6) again when the “COOLANT TEMP/S” reaches to 70°C (158°F)

SEF668Y

EC-1418

DTC P0139, P0159 HO2S2

VG33ER Overall Function Check

Overall Function Check

SEF922UA

=NGEC1205

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. 4) Check the voltage when racing 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 “O/D” OFF (A/T). The voltage should change at more than 0.06V for 1 second during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-1422.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1419

IDX

DTC P0139, P0159 HO2S2

VG33ER

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1206 NGEC1206S01

WEC174A

EC-1420

DTC P0139, P0159 HO2S2

VG33ER Wiring Diagram (Cont’d)

LEFT BANK

NGEC1206S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC175A

EC-1421

EL IDX

DTC P0139, P0159 HO2S2

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1207

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC657

䊳

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-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.

SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-1246. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6.

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171, P0174 or P0172, P0175. Refer to EC-1427, 1436.

No

䊳

GO TO 3.

EC-1422

DTC P0139, P0159 HO2S2

VG33ER Diagnostic Procedure (Cont’d)

3

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 2 harness protector color.

GI MA EM LC SEC301CA

3. Disconnect corresponding heated oxygen sensor 2 harness connector.

FE CL MT AT LEC659

4. Disconnect ECM harness connector. 5. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram.

TF PD AX MTBL0591

Continuity should exist. 6. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram.

SU BR ST

MTBL0592

RS

Continuity should not exist. 7. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

BT HA SC EL

EC-1423

IDX

DTC P0139, P0159 HO2S2

VG33ER

Diagnostic Procedure (Cont’d)

4

CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-3 (if equipped) 쐌 Harness for open between heated oxygen sensor 2 and engine ground. 䊳

6

Repair open circuit or short to power in harness or connectors.

CHECK HEATED OXYGEN SENSOR 2 (REAR)

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)/(B2)” as the monitor item with CONSULTII. 4. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

SEF989RD

“HO2S2 (B1)/(B2)” should be above 0.62V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

EC-1424

DTC P0139, P0159 HO2S2

VG33ER Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without 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. Set voltmeter probes between ECM terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (depress and release accelerator pedal as soon as possible)

GI MA EM LC

FE SEF797ZB

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 “O/D” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

CL MT AT TF

REPLACE HEATED OXYGEN SENSOR 2

PD

1. Stop vehicle and turn ignition switch OFF. 2. Check heated oxygen sensor 2 harness protector color.

AX SU BR ST SEC301CA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 2.

RS BT HA SC EL

EC-1425

IDX

DTC P0139, P0159 HO2S2 Diagnostic Procedure (Cont’d)

9

CHECK HO2S2 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1426

VG33ER

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1223

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the ECM judges the condition as the fuel injection system malfunction and light up the MIL (2 trip detection logic). Sensor Heated oxygen sensors 1

Input Signal to ECM Density of oxygen in exhaust gas (Mixture ratio feedback signal)

ECM function Fuel injection control

GI MA EM LC

Actuator Injectors

Malfunction is detected when fuel injection system does not operate properly, the amount of mixture ratio compensation is too large. (The mixture ratio is too lean.)

FE

POSSIBLE CAUSE

CL

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

Intake air leaks Heated oxygen sensor 1 Injectors Exhaust gas leaks Incorrect fuel pressure Lack of fuel Mass air flow sensor PCV system (Loose or disconnected rubber tube)

NGEC1223S01

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1427

IDX

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF968Y

=NGEC1224

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) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 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 or P0174 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-1431. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-1431. If engine does not start, check exhaust and intake air leak visually. With GST Follow the procedure “With CONSULT-II”.

EC-1428

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33ER Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1225 NGEC1225S01

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC187A

EC-1429

IDX

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Wiring Diagram (Cont’d)

LEFT BANK

NGEC1225S02

WEC188A

EC-1430

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1226

CHECK EXHAUST AIR LEAK

GI

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.

MA EM LC

SEF099P

FE

OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair or replace.

2

CL MT

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace.

3

AT TF PD

CHECK FOR PCV HOSE

Check PCV hose for loose connection or disconnection. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace.

AX SU BR ST RS BT HA SC EL

EC-1431

IDX

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Diagnostic Procedure (Cont’d)

4 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT Turn ignition switch OFF. Disconnect corresponding heated oxygen sensor 1 harness connector. Disconnect ECM harness connector. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

SEF831Z

Continuity should exist. 5. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram.

SEF832Z

Continuity should not exist. 6. Also check harness for short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

5

CHECK FUEL PRESSURE

1. Release fuel pressure to zero. Refer to EC-1217. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (3.0 kg/cm2, 43 psi) OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

EC-1432

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Diagnostic Procedure (Cont’d)

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuel pump and circuit (Refer to EC-1733.) 쐌 Fuel pressure regulator (Refer to EC-1218.) 쐌 Fuel lines (Refer to “ENGINE MAINTENANCE”, MA-26.) 쐌 Fuel filter for clogging 䊳

7

Repair or replace.

GI MA EM

CHECK MASS AIR FLOW SENSOR

With CONSULT-II 1. Install all parts removed. 2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm With GST 1. Install all parts removed. 2. Check mass air flow sensor signal in MODE 1 with GST. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm OK or NG OK

䊳

GO TO 8.

NG

䊳

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-1334.

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1433

IDX

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Diagnostic Procedure (Cont’d)

8

CHECK FUNCTION OF INJECTORS

With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

SEF070Y

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

䊳

GO TO 9.

NG

䊳

Perform trouble diagnosis for “INJECTORS”, EC-1725.

EC-1434

DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Diagnostic Procedure (Cont’d)

9

CHECK INJECTOR

1. 2. 3. 4.

Confirm that the engine is cooled down and there are no fire hazards near the vehicle. Turn ignition switch OFF. Disconnect injector harness connectors on left bank (for DTC P0171), right bank (for DTC P0174). Remove injector gallery assembly. Refer to EC-1218. Keep fuel hose and all injectors connected to injector gallery. The injector harness connectors on right bank (for DTC P0171), left bank (for DTC P0174) should remain connected. 5. Disconnect all ignition coil harness connectors. 6. Prepare pans or saucers under each injector. 7. Crank engine for about 3 seconds. Make sure that fuel sprays out from injectors.

GI MA EM LC

FE CL SEF595Q

Fuel should be sprayed evenly for each injector.

MT

OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace injectors from which fuel does not spray out. Always replace O-ring with new ones.

10

AT TF

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

PD

INSPECTION END

AX SU BR ST RS BT HA SC EL

EC-1435

IDX

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1227

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the ECM judges the condition as the fuel injection system malfunction and light up the MIL (2 trip detection logic). Sensor Heated oxygen sensors 1

Input Signal to ECM Density of oxygen in exhaust gas (Mixture ratio feedback signal)

ECM function Fuel injection control

Actuator Injectors

Malfunction is detected when fuel injection system does not operate properly, the amount of mixture ratio compensation is too large. (The mixture ratio is too rich.)

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌

Heated oxygen sensor 1 Injectors Exhaust gas leaks Incorrect fuel pressure Mass air flow sensor

EC-1436

NGEC1227S01

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF968Y

=NGEC1228

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) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 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 P0172, P0175 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-1440. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-1440. If engine does not start, remove ignition plugs and check for fouling, etc. With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1437

IDX

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1229 NGEC1229S01

WEC187A

EC-1438

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Wiring Diagram (Cont’d)

LEFT BANK

NGEC1229S02

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC188A

EC-1439

EL IDX

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1230

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

䊳

GO TO 2.

NG

䊳

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

䊳

GO TO 3.

NG

䊳

Repair or replace.

EC-1440

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Diagnostic Procedure (Cont’d)

3 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT Turn ignition switch OFF. Disconnect corresponding heated oxygen sensor 1 harness connector. Disconnect ECM harness connector. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram.

GI MA EM LC

SEF833Z

Continuity should exist. 5. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram.

FE CL MT AT TF

SEF834Z

PD

Continuity should not exist. 6. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

4

1. Release fuel pressure to zero. Refer to EC-1217. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (3.0 kg/cm2, 43 psi) OK or NG 䊳

GO TO 6.

NG

䊳

GO TO 5.

SU BR

CHECK FUEL PRESSURE

OK

AX

ST RS BT HA SC EL

EC-1441

IDX

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Diagnostic Procedure (Cont’d)

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuel pump and circuit (Refer to EC-1733.) 쐌 Fuel pressure regulator (Refer to EC-1218.) 䊳

6

Repair or replace.

CHECK MASS AIR FLOW SENSOR

With CONSULT-II 1. Install all parts removed. 2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm With GST 1. Install all parts removed. 2. Check mass air flow sensor signal in MODE 1 with GST. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm OK or NG OK

䊳

GO TO 7.

NG

䊳

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-1334.

EC-1442

DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK FUNCTION OF INJECTORS

With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

GI MA EM LC

SEF070Y

3. Make sure that each circuit produces a momentary engine speed drop.

FE

Without CONSULT-II 1. Start engine. 2. Listen to each injector operating sound.

CL MT AT TF MEC703B

PD

Clicking noise should be heard. OK or NG

AX SU

OK

䊳

GO TO 8.

NG

䊳

Perform trouble diagnosis for “INJECTORS”, EC-1725.

8

CHECK INJECTOR

1. Remove injector assembly. Refer to EC-1218. Keep fuel hose and all injectors connected to injector gallery. 2. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 3. Disconnect injector harness connectors left bank (for DTC P0172), right bank (for P0175). The injector harness connectors on right bank (for P0172), left bank (for P0175) should remain connected. 4. Disconnect all ignition coil harness connectors. 5. Prepare pans or saucers under each injectors. 6. Crank engine for about 3 seconds. Make sure fuel does not drip from injector.

BR ST RS BT

OK or NG OK (Does not drip)

䊳

GO TO 9.

NG (Drips)

䊳

Replace the injectors from which fuel is dripping. Always replace O-ring with new one.

9

HA SC

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1443

EL IDX

DTC P0181, P0182, P0183 FTT SENSOR

VG33ER

Component Description

Component Description

NGEC1231

The fuel tank temperature sensor is used to detect the fuel temperature inside the fuel tank. 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.

LEC764

Fluid temperature °C (°F)

Voltage*

(V)

Resistance

(kΩ)

20 (68)

3.5

2.3 - 2.7

50 (122)

2.2

0.79 - 0.90

*: These data are reference values and are measured between ECM terminal 60 (Fuel tank 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 the ECM terminals, such as the ground.

On Board Diagnosis Logic

NGEC1232

Malfunction is detected when an excessively high (P0183) or low (P0182) voltage is sent to ECM, rationally incorrect voltage (P0181) from the sensor is sent to ECM, compared with the voltage signals from engine coolant temperature sensor and intake air temperature sensor.

POSSIBLE CAUSE 쐌 쐌

Harness or connectors (The sensor circuit is open or shorted.) Fuel tank temperature sensor

EC-1444

NGEC1232S01

DTC P0181, P0182, P0183 FTT SENSOR

VG33ER DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC1233

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.

GI MA EM LC

1) 2) 3)

4)

SEF174Y

5) 6) 7)

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 10 seconds. If the result is NG, go to “Diagnostic Procedure”, EC-1447. If the result is OK, go to following step. Check “COOLAN TEMP/S” value. If “COOLAN TEMP/S” is less than 60°C (140°F), the result will be OK. If “COOLAN TEMP/S” is above 60°C (140°F), go to the following step. Cool engine down until “COOLAN TEMP/S” is less than 60°C (140°F). Wait at least 10 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1447.

FE CL MT AT TF PD AX

With GST Follow the procedure “With CONSULT-II”.

SU BR ST RS BT HA SC EL

EC-1445

IDX

DTC P0181, P0182, P0183 FTT SENSOR

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1234

LEC503

EC-1446

DTC P0181, P0182, P0183 FTT SENSOR

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1235

CHECK FUEL TANK TEMPERATURE SENSOR POWER SUPPLY CIRCUIT

GI

1. Turn ignition switch OFF. 2. Disconnect fuel level sensor unit harness connector.

MA EM LC

LEC764

3. Turn ignition switch ON. 4. Check voltage between fuel level sensor unit terminal 1 and ground with CONSULT-II or tester.

FE CL MT AT

SEF639W

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

TF PD AX

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors B101, M67 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuel tank temperature sensor 䊳

SU BR

Repair harness or connector.

ST 3

CHECK FUEL TANK TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between fuel level sensor unit terminal 4 and body ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power.

RS BT

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

HA SC

DETECT MALFUNCTIONING PART

Check harness for open between fuel tank temperature sensor and body ground. 䊳

Repair open circuit or short to power in harness or connectors.

EC-1447

EL IDX

DTC P0181, P0182, P0183 FTT SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

5

CHECK FUEL TANK TEMPERATURE SENSOR

1. Remove fuel level sensor unit. 2. Check resistance fuel level sensor unit terminals T and E by heating with hot water or heat gun as shown in the figure.

SEC311C

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace fuel tank temperature sensor.

6

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1448

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1239

This diagnosis checks whether the engine coolant temperature is extraordinary high, even when the load is not heavy. When malfunction is detected, the malfunction indicator lamp (MIL) will light up even in the first trip. Malfunction is detected when engine coolant temperature is excessively high under normal engine speed.

GI MA EM LC

Possible Cause 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC1240

Cooling fan (Crankshaft driven) Thermostat Improper ignition timing Engine coolant temperature sensor Blocked radiator Blocked front end (Improper fitting of nose mask) Crushed vehicle frontal area (Vehicle frontal is collided but not repaired) 쐌 Blocked air passage by improper installation of front fog lamp or fog lamps. 쐌 Improper mixture ratio of coolant 쐌 Damaged bumper For more information, refer to “MAIN 12 CAUSES OF OVERHEATING”, EC-1455.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1449

IDX

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33ER

Overall Function Check

Overall Function Check

=NGEC1241

Use this procedure to check the overall function of the engine coolant over temperature enrichment protection 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.

WITH CONSULT-II 1.

쐌 쐌 SEF621W

a)

b)

2.

3.

4.

5.

6.

NGEC1241S01

Check the coolant level and mixture ratio (Using coolant tester) in the reservoir tank and radiator. Allow engine to cool before checking coolant level and mixture ratio. If the coolant level in the reservoir and/or the radiator is below the proper range, skip following steps and go to “Diagnostic Procedure”, EC-1452. If the coolant mixture ratio is out of range between 45 to 55%, replace the coolant. Refer to “Changing Engine Coolant”, MA-28. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pouring coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to “Anti-freeze Coolant Mixture Ratio”, MA-13. After refilling coolant, run engine to ensure that no water-flow noise is emitted. After checking or replacing coolant, go to step 3) below. Confirm whether customer filled the engine coolant or not. If customer filled the engine coolant, skip following steps and go to “Diagnostic Procedure”, EC-1452. Start engine and make sure that cooling fan (crankshaft driven) operates. If NG, go to “Diagnostic Procedure”, EC-1489. After repair, go to next step. Check for blocked coolant passage. Warm up engine to normal operating temperature, then grasp upper and lower radiator hoses and make sure that coolant flows. If NG, go to step 4 of “Diagnostic Procedure”, EC-1452. After repair, go to next step. Be extremely careful not to touch any moving or adjacent parts. Check radiator for blocked air passage Check for blocked condenser or radiator (condenser or radiator fins damaged, condenser or radiator clogged), after market fog lamps ...etc. Check for condenser or radiator fin damage, shroud damage, vehicle front end for clogging of debris or insects ...etc. Check for improper fitting of front end cover, damaged radiator grille or bumper, vehicle frontal area damaged by collision but not repaired. If NG, take appropriate action and then go to next step. Check ECT sensor for proper operation. Refer to step 5 of “Diagnostic Procedure”, EC-1452. If NG, replace ECT sensor and go to next step.

EC-1450

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33ER

Overall Function Check (Cont’d)

7.

Check ignition timing. Refer to “Basic Inspection”, EC-1273. Make sure that ignition timing is 10° ± 2° at 700 ± 50 rpm. If NG, adjust ignition timing and then recheck.

GI MA EM LC

SEF927Z

WITHOUT CONSULT-II 1.

쐌 쐌 SEF621W

a)

b)

2.

3.

4.

5.

6.

NGEC1241S02

Check the coolant level and mixture ratio (Using coolant tester) in the reservoir tank and radiator. Allow engine to cool before checking coolant level and mixture ratio. If the coolant level in the reservoir and/or radiator is below the proper range, skip the following steps and go to “Diagnostic Procedure”, EC-1452. If the coolant mixture ratio is out of range between 45 to 55%, replace the coolant. Refer to “Changing Engine Coolant”, MA-28. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pouring coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to “Anti-freeze Coolant Mixture Ratio”, MA-15. After refilling coolant, run engine to ensure that no water-flow noise is emitted. After checking or replacing coolant, go to step 3) below. Confirm whether customer filled the engine coolant or not. If customer filled engine coolant, skip following steps and go to “Diagnostic Procedure”, EC-1452. Start engine and make sure that cooling fan operates. Be careful not to overheat engine. If NG, go to step 1 of “Diagnostic Procedure”, EC-1452. After repair, go to next step. Check for blocked coolant passage. Warm up engine to normal operating temperature, then grasp upper and lower radiator hoses and make sure that coolant flows. If NG, go to step 4 of “Diagnostic Procedure”, EC-1452. After repair, go to next step. Be extremely careful not to touch any moving or adjacent parts. Check radiator for blocked air passage Check for blocked condenser or radiator (condenser or radiator fins damaged, condenser or radiator clogged), after market fog lamps,...etc. Check for condenser or radiator fin damage, shroud damage, vehicle front end for clogging of debris or insects ...etc. Check for improper fitting of front end cover, damaged radiator grille or bumper, vehicle frontal area damaged by collision but not repaired. If NG, take appropriate action and then go to next step. Check ECT sensor for proper operation. Refer to step 5 of “Diagnostic Procedure”, EC-1452. If NG, replace ECT sensor and go to next step.

EC-1451

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33ER

Overall Function Check (Cont’d)

7.

Check ignition timing. Refer to “Basic Inspection”, EC-1273. Make sure that ignition timing is 10° ± 2° at 700 ± 50 rpm. If NG, adjust ignition timing and then recheck.

SEF927Z

Diagnostic Procedure 1

NGEC1243

CHECK COOLING FAN (CRANKSHAFT DRIVEN) OPERATION

Start engine and make sure that cooling fan (crankshaft driven) operates. OK or NG OK

䊳

GO TO 2.

NG

䊳

Check cooling fan (crankshaft driven). Refer to LC-34, “Cooling Fan”.

2

CHECK COOLING SYSTEM FOR LEAK

Apply pressure to the cooling system with a tester, and check if the pressure drops. CAUTION: Higher than the specified pressure may cause radiator damage. Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi)

SLC754A

Pressure should not drop. OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following for leak: 쐌 Hose 쐌 Radiator 쐌 Water pump Refer to LC-29, “Water Pump”.

EC-1452

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK RADIATOR CAP

Apply pressure to cap with a tester and check radiator cap relief pressure.

GI MA EM LC SLC755A

Radiator cap relief pressure: 59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi)

FE

OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace radiator cap.

4

CL MT

CHECK THERMOSTAT

1. Check valve seating condition at normal room temperatures. It should seat tightly. 2. Check valve opening temperature and valve lift.

AT TF PD AX

SLC343

Valve opening temperature: 76.5°C (170°F) [standard] Valve lift: More than 10 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-31, “Thermostat”.

SU BR ST

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace thermostat.

RS BT HA SC EL

EC-1453

IDX

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33ER

Diagnostic Procedure (Cont’d)

5

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

SEF152P



MTBL0229

SEF012P

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace engine coolant temperature sensor.

6

CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-1455. 䊳

INSPECTION END

EC-1454

DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION

VG33ER

Main 12 Causes of Overheating

Main 12 Causes of Overheating Engine

Step

OFF

1

Inspection item 쐌 쐌 쐌 쐌

Blocked Blocked Blocked Blocked

radiator condenser radiator grille bumper

Equipment 쐌 Visual

Standard No blocking

NGEC1244

Reference page —

MA

2

쐌 Coolant mixture

쐌 Coolant tester

50 - 50% coolant mixture See “RECOMMENDED FLUIDS AND LUBRICANTS” in MA-13.

3

쐌 Coolant level

쐌 Visual

Coolant up to MAX level in reservoir tank and radiator filler neck

See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA-28.

4

쐌 Radiator cap

쐌 Pressure tester

59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi) (Limit)

See “System Check” in LC-28.

ON*1

5

쐌 Coolant leaks

쐌 Visual

No leaks

See “System Check” in LC-29.

ON*1

6

쐌 Thermostat

쐌 Touch the upper and lower radiator hoses

Both hoses should be hot

See “Thermostat” and “Radiator” in LC-31, LC-32.

ON*1

7

쐌 Cooling fan (Crankshaft driven)

쐌 Visual

Operating

See LC-34, “Cooling Fan”.

OFF

8

쐌 Combustion gas leak

쐌 Color checker chemical tester 4 Gas analyzer

Negative

—

ON*2

9

쐌 Coolant temperature gauge

쐌 Visual

Gauge less than 3/4 when driving

—

쐌 Coolant overflow to reservoir tank

쐌 Visual

No overflow during driving and idling

OFF*3

OFF

GI

EM LC

FE CL MT AT TF

See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA-28.

PD AX

쐌 Coolant return from 쐌 Visual reservoir tank to radiator

Should be initial level in reservoir tank

See “ENGINE MAINTENANCE” in MA-26.

SU

11

쐌 Cylinder head

0.1 mm (0.004 in) Maximum distortion (warping)

See “Inspection”, “CYLINDER HEAD” in EM-96.

BR

12

쐌 Cylinder block and pis- 쐌 Visual tons

No scuffing on cylinder walls or piston

See “Inspection”, “CYLINDER BLOCK” in EM-117.

ST

10

쐌 Straight gauge feeler gauge

*1: Engine running at 3,000 rpm for 10 minutes. *2: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *3: After 60 minutes of cool down time. For more information, refer to “OVERHEATING CAUSE ANALYSIS”, LC-35.

RS BT HA SC EL

EC-1455

IDX

DTC P0245 SCB VALVE CONTROL SOLENOID VALVE

VG33ER

Description

Description

NGEC1359

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

NGEC1359S01

ECM function

Actuator

SuperSCB valve control solenoid charged air valve control

This system controls supercharged air according to the engine operating conditions. This control operation is accomplished through the ECM and the SCB valve control solenoid valve. When the solenoid valve is ON, the SCB valve shuts. Then intake air is lead to supercharger, and supercharged air is sent to the cylinder. When the solenoid valve is OFF, the SCB valve opens. Then intake air is sent to the cylinder directly. When the ECM detects any of the following conditions, current does not flow through the solenoid valve. 쐌 Engine stopped 쐌 Engine starting 쐌 High-load, high-speed engine operation 쐌 Excessively low engine coolant temperature 쐌 Mass air flow sensor malfunction 쐌 Engine coolant temperature sensor malfunction 쐌 Throttle position sensor malfunction

SEC313C

COMPONENT DESCRIPTION SCB Valve Control Solenoid Valve

NGEC1359S02 NGEC1359S0201

The SCB valve control solenoid valve responds to signals from the ECM. When the ECM sends an ON (ground) signal, the solenoid valve is bypassed to apply intake manifold vacuum to the SCB valve actuator. This operation closes the SCB valve. When the ECM sends an OFF signal, the vacuum signal is cut and the SCB valve opens.

LEC806

EC-1456

DTC P0245 SCB VALVE CONTROL SOLENOID VALVE

VG33ER

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NGEC1360

Specification data are reference values. MONITOR ITEM

SCB/V CON S/V

CONDITION

SPECIFICATION

More than 5 seconds after turning ignition switch ON (Engine stopped)

OFF

Engine speed: Idle

ON

MA EM

ECM Terminals and Reference Value

NGEC1361

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 the ECM terminals, such as the ground. TERMINAL NO.

6

WIRE COLOR

G/W

ITEM

CONDITION

[Ignition switch ON] SCB valve control solenoid 쐌 Engine stopped valve [Engine is running] 쐌 Idle speed

GI

DATA (DC Voltage)

LC

FE CL

BATTERY VOLTAGE (11 - 14V)

MT

Approximately 0V

AT TF PD AX

On Board Diagnosis Logic

NGEC1362

Malfunction is detected when the improper voltage signal is sent to ECM through SCB valve control solenoid valve. Freeze frame data will not be stored in the ECM for the SCB valve control solenoid. The MIL will not light for SCB valve control solenoid malfunction.

POSSIBLE CAUSE 쐌 쐌

SU BR ST

NGEC1362S01

Harness or connectors (The SCB valve control solenoid valve circuit is open or shorted.) SCB valve control solenoid valve

RS BT HA SC EL

EC-1457

IDX

DTC P0245 SCB VALVE CONTROL SOLENOID VALVE

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC1363

With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 10 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1460. With GST Follow the procedure “WITH CONSULT-II” above. SEF058Y

EC-1458

DTC P0245 SCB VALVE CONTROL SOLENOID VALVE

VG33ER Wiring Diagram

Wiring Diagram

NGEC1364

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC008A

EC-1459

EL IDX

DTC P0245 SCB VALVE CONTROL SOLENOID VALVE

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1365

CHECK SCB VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect SCB valve control solenoid valve harness connector.

LEC806

3. Turn ignition switch “ON”. 4. Check voltage between SCB valve control solenoid valve terminal 1 and ground with CONSULT-II or tester.

SEF657W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between SCB valve control solenoid valve and fuse 䊳

3

Repair harness or connectors.

CHECK SCB VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 6 and SCB valve control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1460

DTC P0245 SCB VALVE CONTROL SOLENOID VALVE

VG33ER

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E74, M82 쐌 Harness connectors M58, F28 쐌 Harness for open or short between SCB valve control solenoid valve and ECM 䊳

GI MA

Repair open circuit or short to ground or short to power in harness or connectors.

EM 5

CHECK SCB VALVE CONTROL SOLENOID VALVE

With CONSULT-II 1. Perform “SCB/V CONT SOL/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time under the following conditions.

LC

FE CL MT SEC314C

Without CONSULT-II Check air passage continuity and operation delay time under the following conditions.

AT TF PD AX

SEC315C

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace SCB valve control solenoid valve.

6

SU BR ST

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

RS

INSPECTION END

BT HA SC EL

EC-1461

IDX

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33ER On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1245

When a misfire occurs, engine speed will fluctuate. If the engine speed fluctuates enough to cause the CKP sensor signal to vary, ECM can determine that a misfire is occurring. Sensor Crankshaft position sensor (OBD)

Input Signal to ECM Engine speed

ECM function On board diagnosis of misfire

The misfire detection logic consists of the following two conditions. 1. One Trip Detection Logic (Three Way Catalyst Damage) On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to overheating, the MIL 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 MIL will turn off. If another misfire condition occurs that can damage the TWC on a second trip, the MIL will blink. When the misfire condition decreases to a level that will not damage the TWC, the MIL will remain on. If another misfire condition occurs that can damage the TWC, the MIL will begin to blink again. 2. Two Trip Detection Logic (Exhaust quality deterioration) For misfire conditions that will not damage the TWC (but will affect vehicle emissions), the MIL 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. Malfunction is detected when multiple cylinders misfire, No. 1 cylinder misfires, No. 2 cylinder misfires, No. 3 cylinder misfires, No. 4 cylinder misfires, No. 5 cylinder misfires and No. 6 cylinder misfires.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

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 Drive plate or flywheel Heated oxygen sensor 1 Incorrect distributor rotor

EC-1462

NGEC1245S01

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33ER DTC Confirmation Procedure

DTC Confirmation Procedure

SEF213Y

Diagnostic Procedure 1

=NGEC1246

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 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 warm it up to normal operating temperature. 3) Turn ignition switch OFF and wait at least 5 seconds. 4) Start engine again and drive at 1,500 to 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-1463. With GST Follow the procedure “With CONSULT-II”.

CHECK FOR INTAKE AIR LEAK

1. Start engine and run it at idle speed. 2. Listen for the sound of the intake air leak.

NGEC1247

GI MA EM LC

FE CL MT AT TF

OK or NG

PD

OK

䊳

GO TO 2.

NG

䊳

Discover air leak location and repair.

AX 2

CHECK FOR EXHAUST SYSTEM CLOGGING

Stop engine and visually check exhaust tube, three way catalyst and muffler for dents.

SU

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace it.

BR ST RS BT HA SC EL

EC-1463

IDX

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33ER Diagnostic Procedure (Cont’d)

3

PERFORM POWER BALANCE TEST

With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode.

SEF070Y

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?

LEC809

Yes or No Yes

䊳

GO TO 4.

No

䊳

GO TO 7.

4

CHECK INJECTOR

Does each injector make an operating sound at idle?

MEC703B

Yes or No Yes

䊳

GO TO 5.

No

䊳

Check injector(s) and circuit(s). Refer to EC-1725.

EC-1464

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33ER Diagnostic Procedure (Cont’d)

5 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.

GI MA EM LC

SEF282G

FE

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

CL MT

6

CHECK IGNITION WIRES

1. Inspect wires for cracks, damage, burned terminals and for improper fit. 2. Measure the resistance of wires to their distributor cap terminal. Move each wire while testing to check for intermittent breaks.

AT TF PD AX SU

SEF174P

Resistance:

BR ST RS

MTBL0235

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.

BT HA

OK or NG OK

䊳

Check the following: 쐌 Distributor rotor head for incorrect parts 쐌 Ignition coil, power transistor and their circuits Refer to EC-1718.

NG

䊳

Replace.

EC-1465

SC EL IDX

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33ER Diagnostic Procedure (Cont’d)

7

CHECK SPARK PLUGS

Remove the spark plugs and check for fouling, etc.

SEF156I

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to “ENGINE MAINTENANCE”, MA-34.

8

CHECK COMPRESSION PRESSURE

Refer to EM-77. 쐌 Check compression pressure. Standard: 1,196 kPa (12.2 kg/cm2, 173 psi)/300 rpm Minimum: 883 kPa (9.0 kg/cm2, 128 psi)/300 rpm Difference between each cylinder: 98 kPa (1.0 kg/cm2, 14 psi)/300 rpm OK or NG OK

䊳

GO TO 9.

NG

䊳

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-1217. 3. Install fuel pressure gauge and check fuel pressure.

AEC064B

At idle: Approx. 235 kPa (2.4 kg/cm2, 34 psi) OK or NG OK

䊳

GO TO 11.

NG

䊳

GO TO 10.

EC-1466

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33ER Diagnostic Procedure (Cont’d)

10

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuel pump and circuit (Refer to EC-1733.) 쐌 Fuel pressure regulator (Refer to EC-1218.) 쐌 Fuel lines (Refer to “ENGINE MAINTENANCE”, MA-31.) 쐌 Fuel filter for clogging 䊳

11

GI MA

Repair or replace.

EM

CHECK IGNITION TIMING

LC

Check the following items. Refer to “Basic Inspection”, EC-1273.

FE CL MTBL0576

OK or NG OK (With CONSULT-II)

䊳

GO TO 12.

OK (Without CONSULTII)

䊳

GO TO 13.

NG

䊳

Adjust ignition timing.

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1467

IDX

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33ER Diagnostic Procedure (Cont’d)

12

CHECK HEATED OXYGEN SENSOR 1

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 with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown left:

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace heated oxygen sensor 1.

EC-1468

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33ER Diagnostic Procedure (Cont’d)

13

CHECK FRONT HEATED OXYGEN SENSOR LH/RH

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (right bank sensor signal) or 51 (left bank sensor signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

GI MA EM LC

SEF796Z

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.

FE CL

OK or NG OK

䊳

GO TO 15.

NG

䊳

GO TO 14.

MT AT

14

REPLACE HEATED OXYGEN SENSOR 2

TF

1. Stop vehicle and turn ignition switch OFF. 2. Check heated oxygen sensor 2 harness protector color.

PD AX SU

SEC301CA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 2.

BR ST RS BT HA SC EL

EC-1469

IDX

DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE VG33ER Diagnostic Procedure (Cont’d)

15

CHECK MASS AIR FLOW SENSOR

With CONSULT-II Check mass air flow sensor signal in “DATA MONITOR” mode with CONSULT-II. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm With GST Check mass air flow sensor signal in MODE 1 with GST. 3.3 - 4.8 g·m/sec: at idling 12.0 - 14.9 g·m/sec: at 2,500 rpm OK or NG OK

䊳

GO TO 16.

NG

䊳

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-1334.

16

CHECK SYMPTOM MATRIX CHART

Check items on the rough idle symptom in “Symptom Matrix Chart”, EC-1290. OK or NG OK

䊳

GO TO 17.

NG

䊳

Repair or replace.

17

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-1246. 䊳

18

GO TO 18.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1470

DTC P0327, P0328 KS

VG33ER Component Description

Component Description

NGEC1248

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 MIL will not light for knock sensor malfunction. The knock sensor has one trip detection logic.

ECM Terminals and Reference Value

W

ITEM

Knock sensor

EM

NGEC1249

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 the ECM terminals, such as the ground.

64

MA

LC

SEF332I

TERMIWIRE NAL COLOR NO.

GI

CONDITION [Engine is running] 쐌 Idle speed

DATA (DC Voltage)

CL

Approximately 2.5V

On Board Diagnosis Logic

FE

MT NGEC1250

Malfunction is detected when an excessively low (P0327) or high (P0328) voltage from the knock sensor is sent to ECM.

AT

POSSIBLE CAUSE

TF

쐌 쐌

NGEC1250S01

Harness or connectors (The knock sensor circuit is open or shorted.) Knock sensor

PD AX

DTC Confirmation Procedure

SEF059Y

NGEC1251

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. 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-1473. With GST Follow the procedure “With CONSULT-II”.

SU BR ST RS BT HA SC EL

EC-1471

IDX

DTC P0327, P0328 KS

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1252

WEC189A

EC-1472

DTC P0327, P0328 KS

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1253

CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT-I

GI

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check resistance between ECM terminal 64 and engine ground. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. Resistance: Approximately 500 - 620 kΩ [at 25°C (77°F)] 4. Also check harness for short to ground and short to power.

MA EM LC

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 2.

2

FE

CHECK INPUT SIGNAL CIRCUIT-II

1. Disconnect knock sensor harness connector. 2. Check harness continuity between ECM terminal 64 and knock sensor terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

CL MT

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

AT

DETECT MALFUNCTIONING PART

TF

Check the following. 쐌 Harness connector F37, F101 쐌 Harness for open or short between ECM and knock sensor 䊳

PD

Repair open circuit or short to ground or short to power in harness or connectors.

AX 4

CHECK KNOCK SENSOR

쐌 Use an ohmmeter which can measure more than 10 MΩ. 1. Disconnect knock sensor harness connector. 2. Check resistance between terminal 1 and ground.

SU BR ST RS BT SEF799Z

CAUTION: Do not use any knock sensors that have been dropped or physically damaged. Use only new ones.

HA

OK or NG

SC

OK

䊳

GO TO 8.

NG

䊳

Replace knock sensor.

EL

EC-1473

IDX

DTC P0327, P0328 KS

VG33ER

Diagnostic Procedure (Cont’d)

5

RETIGHTEN GROUND SCREWS

Loose and retighten engine ground screws.

LEC657

䊳

6

GO TO 6.

CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT

1. Disconnect harness connectors F37, F101. 2. Check harness continuity between harness connector F37 terminal 7 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F37, F101 쐌 Joint connectors-1 (if equipped) 쐌 Harness for open between harness connector F37 and engine ground 䊳

8

Repair open circuit or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1474

DTC P0335 CKP SENSOR (OBD)

VG33ER Component Description

Component Description

SEF804Z

NGEC1254

The crankshaft position sensor (OBD) is located on the transaxle 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.

GI MA EM LC

FE CL MT

WEC549

ECM Terminals and Reference Value

NGEC1255

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (AC Voltage) 1 - 2V (AC range)

AT TF PD AX SU

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

BR SEF690W

47

L

Crankshaft position sensor (OBD)

ST

3 - 4V (AC range)

RS [Engine is running] 쐌 Engine speed is 2,000 rpm

BT SEF691W

HA SC EL

EC-1475

IDX

DTC P0335 CKP SENSOR (OBD)

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1256

Malfunction is detected when the proper pulse signal from the crankshaft position sensor (OBD) is not sent to ECM while the engine is running at the specified engine speed.

POSSIBLE CAUSE 쐌 쐌

DTC Confirmation Procedure

SEF058Y

NGEC1256S01

Harness or connectors [The crankshaft position sensor (OBD) circuit is open.] Crankshaft position sensor (OBD)

NGEC1257

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 15 seconds at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1478. With GST Follow the procedure “With CONSULT-II”.

EC-1476

DTC P0335 CKP SENSOR (OBD)

VG33ER Wiring Diagram

Wiring Diagram

NGEC1258

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC190A

EC-1477

EL IDX

DTC P0335 CKP SENSOR (OBD)

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1259

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC657

䊳

2

GO TO 2.

CHECK CKPS (OBD) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.

WEC549

2. Check continuity between ECM terminal 47 and 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

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Harness for open or short between ECM and crankshaft position sensor (OBD) 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1478

DTC P0335 CKP SENSOR (OBD)

VG33ER Diagnostic Procedure (Cont’d)

4

CHECK CKPS (OBD) GROUND CIRCUIT FOR OPEN AND SHORT

1. Reconnect ECM harness connector. 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 power.

GI MA

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

EM LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Joint connector-4 (if equipped) 쐌 Harness for open or short between crankshaft position sensor (OBD) and ECM 䊳

FE

Repair open circuit or short to power in harness or connectors.

6

CHECK CRANKSHAFT POSITION SENSOR (OBD)

CL

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.

MT AT TF PD AX SEF960N

SU

5. Check resistance as shown in the figure.

BR ST RS SEF504V

Resistance: Approximately 512 - 632Ω [at 20°C (68°F)] OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace crankshaft position sensor (OBD).

BT HA SC EL

EC-1479

IDX

DTC P0335 CKP SENSOR (OBD)

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK CKPS (OBD) SHIELD CIRCUIT FOR OPEN AND SHORT

1. Disconnect harness connectors F38, F102. 2. Check harness continuity between harness connector F38 terminal 7 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Joint connector-1 (if equipped) 쐌 Harness for open between harness connector F38 and engine ground 䊳

9

Repair open circuit or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1480

DTC P0340 CMP SENSOR

VG33ER Component Description

Component Description

SEF928V

NGEC1260

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 ECM 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 6 slits for a 120° (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. NOTE: The rotor screw which secures the distributor rotor head to the distributor shaft must be torqued properly. : 3.6±0.3 N·m (37±3 kg-cm, 32±3 in-lb)

ECM Terminals and Reference Value

NGEC1261

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 the ECM terminals, such as the ground.

4

WIRE COLOR

OR/B

ITEM

ECM relay (Self shutoff)

MA EM LC

FE CL MT

SEF614B

TERMINAL NO.

GI

CONDITION

DATA (DC Voltage)

[Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

0 - 1.5V

[Ignition switch OFF] 쐌 A few seconds passed after turning ignition switch OFF

BATTERY VOLTAGE (11 - 14V)

AT TF PD AX SU BR

0.3 - 0.5V

ST 44

[Engine is running] 쐌 Idle speed

PU

RS SEF997U

Camshaft position sensor (Reference signal)

BT

0.3 - 0.5V

HA 48

PU

[Engine is running] 쐌 Engine speed is 2,000 rpm

SC SEF998U

EC-1481

EL IDX

DTC P0340 CMP SENSOR

VG33ER

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) Approximately 2.5V

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

49

LG

SEF999U

Camshaft position sensor (Position signal)

Approximately 2.5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

SEF001V

67

B/P

72

B/P

117

B/P

Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

On Board Diagnosis Logic

NGEC1262

Malfunction is detected when (Malfunction A) either 1° or 120° signal is not sent to ECM for the first few seconds during engine cranking, (Malfunction B) either 1° or 120° signal is not sent to ECM often enough while the engine speed is higher than the specified engine speed, (Malfunction C) the relation between 1° and 120° signal is not in the normal range during the specified engine speed.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌

NGEC1262S01

Harness or connectors (The camshaft position sensor circuit is open or shorted.) Camshaft position sensor Starter motor (Refer to SC-11.) Starting system circuit (Refer to SC-14.) Dead (Weak) battery

EC-1482

DTC P0340 CMP SENSOR

VG33ER DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC1263

NOTE: 쐌 Perform “PROCEDURE FOR MALFUNCTION A” first. If DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B AND C”. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle.

PROCEDURE FOR MALFUNCTION A

GI MA EM LC

NGEC1263S01

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”, EC-1485. With GST Follow the procedure “With CONSULT-II”.

FE CL MT

SEF013Y

PROCEDURE FOR MALFUNCTION B AND C

NGEC1263S02

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”, EC-1485. With GST Follow the procedure “With CONSULT-II”.

AT TF PD AX

SEF058Y

SU BR ST RS BT HA SC EL

EC-1483

IDX

DTC P0340 CMP SENSOR

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1264

WEC180A

EC-1484

DTC P0340 CMP SENSOR

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1265

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

LEC657

䊳

FE

GO TO 2.

CL 2

CHECK CMPS POWER SUPPLY CIRCUIT

MT

1. Disconnect camshaft position sensor harness connector.

AT TF PD AX LEC810

2. Turn ignition switch ON. 3. Check voltage between CMPS terminal 5 and ground with CONSULT-II or tester.

SU BR ST RS SEF708U

Voltage: Battery voltage OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

BT HA SC EL

EC-1485

IDX

DTC P0340 CMP SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between camshaft position sensor and ECM relay 쐌 Harness for open or short between camshaft position sensor and ECM 䊳

4

Repair harness or connectors.

CHECK CMPS INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between CMPS terminal 4 and ECM terminal 49, CMPS terminal 3 and ECM terminals 44, 48. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

5

CHECK CMPS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between CMPS terminal 6 and engine ground. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-2 (if equipped) 쐌 Harness for open between camshaft position sensor and engine ground 䊳

Repair open circuit or short to power in harness or connector.

EC-1486

DTC P0340 CMP SENSOR

VG33ER Diagnostic Procedure (Cont’d)

7

CHECK CAMSHAFT POSITION SENSOR

1. Install any parts removed. 2. Start engine. 3. Check voltage between ECM terminals 44, 48 and ground, ECM terminal 49 and ground with DC range.

GI MA EM LC

FE CL MT AT TF PD AEC072B

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace distributor assembly with camshaft position sensor.

8

CHECK CMPS SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector-1. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector-1 (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-1.

AX SU BR ST RS BT

OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair open circuit or short to power in harness or connectors.

9

HA SC

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1487

EL IDX

DTC P0420, P0430 THREE WAY CATALYST FUNCTION

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

SEF484YC

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌

SEF345Z

NGEC1266S01

Warm-up three way catalyst Exhaust tube Intake air leaks Injectors Injector leaks Spark plug Improper ignition timing

DTC Confirmation Procedure

SEF344Z

NGEC1266

The ECM monitors the switching frequency ratio of heated oxygen sensors 1 and 2. A warm-up three way catalyst with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2. As oxygen storage capacity decreases, the heated oxygen sensor 2 switching frequency will increase. When the frequency ratio of heated oxygen sensors 1 and 2 approaches a specified limit value, the warm-up three way catalyst malfunction is diagnosed. Malfunction is detected when warm-up three way catalyst does not operate properly, warm-up three way catalyst does not have enough oxygen storage capacity.

NGEC1267

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 TESTING CONDITION 쐌 Open engine hood before conducting the following procedure. 쐌 Do not hold engine speed for more than the specified minutes below. 1) Turn ignition switch ON. 2) Select “DTC & SRT CONFIRMATION” the SRT WORK SUPPORT” mode with CONSULT-II. 3) Start engine. 4) Rev engine up to 2,500 to 3,500 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 2,000 to 3,000 rpm and maintain it until “INCMP” of “CATALYST” changes to “CMPLT” (It will take maximum of approximately 5 minute.). 7) Select “SELF-DIAG RESULTS” mode with CONSULT-II. If the 1st trip DTC is detected, go to “DIAGNOSTIC PROCEDURE”, EC-1490. If not “CMPLT”, stop engine and cool down “COOLANT TEMP/SE” to less than 70°C (158°F) and retest from step 1).

SEF560X

EC-1488

DTC P0420, P0430 THREE WAY CATALYST FUNCTION

VG33ER

Overall Function Check

Overall Function Check

SEF441V

SEF442V

NGEC1268

Use this procedure to check the overall function of the warm-up three way catalyst. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 50 [heated oxygen sensor 1 (bank 1) signal], 51 [heated oxygen sensor 1 (bank 2) signal] and engine ground, and ECM terminals 56 [heated oxygen sensor 2 (bank 1) signal], 57 [heated oxygen sensor 2 (bank 2) 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 terminals 56 and engine ground, or 57 and engine ground is very less than that of ECM terminals 50 and engine ground, or 51 and engine ground. Switching frequency ratio = A/B A: Heated oxygen sensor 2 voltage switching frequency B: Heated oxygen sensor 1 voltage switching frequency This ratio should be less than 0.75. If the ratio is greater than above, it means warm-up three way catalyst does not operate properly. Go to “Diagnostic Procedure”, EC-1490. NOTE: If the voltage at terminal 50 or 51 does not switch periodically more than 5 times within 10 seconds at step 5, perform trouble diagnosis for “DTC P0133, P0153” first. (See EC-1382.)

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1489

IDX

DTC P0420, P0430 THREE WAY CATALYST FUNCTION

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

=NGEC1269

CHECK EXHAUST SYSTEM

Visually check exhaust tubes and muffler for dent. OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair or replace it.

2

CHECK EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before the warm-up three way catalyst.

SEF099P

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace.

3

CHECK INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace.

4

CHECK IGNITION TIMING

Check the following items. Refer to “Basic Inspection”, EC-1273.

MTBL0576

OK or NG OK

䊳

GO TO 5.

NG

䊳

Adjust ignition timing.

EC-1490

DTC P0420, P0430 THREE WAY CATALYST FUNCTION

VG33ER

Diagnostic Procedure (Cont’d)

5

CHECK INJECTOR CIRCUITS

1. Refer to WIRING DIAGRAM for Injectors, EC-1725. 2. Stop engine and then turn ignition switch ON. 3. Check voltage between ECM terminals 102, 104, 106, 109, 111 and 113 and ground with CONSULT-II or tester.

GI MA EM LC SEF711U

Battery voltage should exist. OK or NG OK

䊳

GO TO 6.

NG

䊳

Perform “Diagnostic Procedure”, “INJECTOR”, EC-1726.

6 1. 2. 3. 4. 5.

FE CL

CHECK IGNITION SPARK

MT

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.

AT TF PD AX SU SEF282G

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

BR ST RS BT HA SC EL

EC-1491

IDX

DTC P0420, P0430 THREE WAY CATALYST FUNCTION

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK IGNITION WIRES

1. Inspect wires for cracks, damage, burned terminals and for improper fit. 2. Measure the resistance of wires to their distributor cap terminal. Move each wire while testing to check for intermittent breaks.

SEF174P

Resistance:

MTBL0235

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. OK or NG OK

䊳

Check ignition coil, power transistor and their circuits. Refer to EC-1718.

NG

䊳

Replace.

8

CHECK INJECTOR

1. Turn ignition switch OFF. 2. Remove injector assembly. Refer to EC-1218. Keep fuel hose and all injectors connected to injector gallery. 3. Disconnect all ignition coil harness connectors. 4. Turn ignition switch ON. Make sure fuel does not drip from injector. OK or NG OK (Does not drip)

䊳

GO TO 9.

NG (Drips)

䊳

Replace the injector(s) from which fuel is dripping.

9

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. Trouble is fixed

䊳

INSPECTION END

Trouble is not fixed

䊳

Replace warm-up three way catalyst.

EC-1492

DTC P0441 EVAP CONTROL SYSTEM

VG33ER System Description

System Description

NGEC1393

NOTE: If DTC P0441 is displayed with P0510, perform trouble diagnosis for DTC P0510 first. (See EC-1592.)

GI MA EM LC

FE CL SEC666C

In this evaporative emission (EVAP) control system, purge flow occurs during non-closed throttle conditions. Purge volume is related to air intake volume. Under normal purge conditions (non-closed throttle), the EVAP canister purge volume control solenoid valve is open. Purge flow exposes the EVAP control system pressure sensor to intake manifold vacuum.

MT AT TF PD AX

On Board Diagnosis Logic

NGEC1394

Under normal conditions (non-closed throttle), sensor output voltage indicates if pressure drop and purge flow are adequate. If not, a fault is determined. Malfunction is detected when EVAP control system does not operate properly, EVAP control system has a leak between intake manifold and EVAP control system pressure sensor.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

BR ST

NGEC1394S01

EVAP canister purge volume control solenoid valve stuck closed EVAP control system pressure sensor and the circuit Loose, disconnected or improper connection of rubber tube Blocked rubber tube Blocked or bent rubber tube to MAP/BARO switch solenoid valve Cracked EVAP canister EVAP canister purge volume control solenoid valve circuit Closed throttle position switch Blocked purge port EVAP canister vent control valve

EC-1493

SU

RS BT HA SC EL IDX

DTC P0441 EVAP CONTROL SYSTEM

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

SEC723C

SEC724C

Selector lever

Suitable position

Vehicle speed

32 - 120 km/h (20 - 75 MPH)

ENG SPEED

500 - 3,400 rpm

B/FUEL SCHDL

1.0 - 11.0 msec

Engine coolant temperature

70 - 100°C (158 - 212°F)

7) SEC725C

NGEC1395

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 5 seconds before conducting the next test. TESTING CONDITION: Always perform test at a temperature of 5°C (41°F) or more. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Start engine and let it idle for at least 70 seconds. 4) Select “PURG FLOW P0441” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. 5) Touch “START”. If “COMPLETED” is displayed, go to step 7. 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 at least 35 seconds.)

If “TESTING” is not changed for a long time, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-1496.

EC-1494

DTC P0441 EVAP CONTROL SYSTEM

VG33ER Overall Function Check

Overall Function Check

SEF906U

=NGEC1396

Use this procedure to check the overall monitoring function of the EVAP control system purge flow monitoring. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Lift up drive wheels. 2) Start engine and warm it up to normal operating temperature. 3) Turn ignition switch OFF, wait at least 5 seconds. 4) Start engine and wait at least 70 seconds. 5) Set voltmeter probes to ECM terminals 62 (EVAP control system pressure sensor signal) and ground. 6) Check EVAP control system pressure sensor value at idle speed and note it. 7) Establish and maintain the following conditions for at least 1 minute. Air conditioner switch

ON

Steering wheel

Fully turned

Headlamp switch

ON

Rear window defogger switch

ON

Engine speed

Approx. 3,000 rpm

Gear position

Any position other than “P”, “N” or “R”

8)

9)

Verify that EVAP control system pressure sensor value stays 0.1V less than the value at idle speed (measured at step 6) for at least 1 second. If NG, go to “Diagnostic Procedure”, EC-1496.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1495

IDX

DTC P0441 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

=NGEC1397

CHECK EVAP CANISTER

1. Turn ignition switch OFF. 2. Check EVAP canister for cracks. OK or NG OK (With CONSULT-II)

䊳

GO TO 2.

OK (Without CONSULTII)

䊳

GO TO 3.

NG

䊳

Replace EVAP canister.

2

CHECK PURGE FLOW

With CONSULT-II 1. Disconnect vacuum hose connected to EVAP canister purge volume control solenoid valve at EVAP service port and install vacuum gauge.

AEC649A

2. 3. 4. 5.

Start engine and let it idle. Select “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Rev engine up to 2,000 rpm. Touch “Qd” and “Qu” on CONSULT-II screen to adjust “PURG VOL CONT/V” opening.

SEF012Z

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 4.

EC-1496

DTC P0441 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

3

CHECK PURGE FLOW

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Stop engine. 3. Disconnect vacuum hose connected to EVAP canister purge volume control solenoid valve at EVAP service port and install vacuum gauge.

GI MA EM LC

AEC649A

4. Start engine and let it idle for at least 80 seconds. 5. Check vacuum gauge indication when revving engine up to 2,000 rpm. Vacuum should exist. 6. Release the accelerator pedal fully and let idle. Vacuum should not exist.

FE CL MT

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 4.

4

AT TF

CHECK EVAP PURGE LINE

1. Turn ignition switch OFF. 2. Check EVAP purge line for improper connection or disconnection. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-1203. OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair it.

PD AX SU BR ST RS BT HA SC EL

EC-1497

IDX

DTC P0441 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

5

CHECK EVAP PURGE HOSE AND PURGE PORT

1. Disconnect purge hoses connected to EVAP service port A and EVAP canister purge volume control solenoid valve B.

SEF367U

2. Blow air into each hose and EVAP purge port C. 3. Check that air flows freely.

SEF368U

OK or NG OK (with CONSULT-II)

䊳

GO TO 6.

OK (without CONSULTII)

䊳

GO TO 7.

NG

䊳

Repair or clean hoses and/or purge port.

EC-1498

DTC P0441 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

6

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

GI MA EM LC

SEF985Y

If OK, inspection end. If NG, go to following step. 3. Check air passage continuity.

FE CL MT AT TF

SEF660U

PD AX MTBL0241

If NG, replace the EVAP canister purge volume control solenoid valve.

SU

OK or NG

BR

OK

䊳

GO TO 8.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

ST RS BT HA SC EL

EC-1499

IDX

DTC P0441 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

Without CONSULT-II Check air passage continuity.

SEF661U

MTBL0242

If NG, replace the EVAP canister purge volume control solenoid valve. OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

8

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

1. Turn ignition switch OFF. 2. Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair it.

9

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

AEC651A

2. Check connectors for water. Water should not exist. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

EC-1500

DTC P0441 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

10

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR FUNCTION

Refer to “DTC Confirmation Procedure” for DTC P0452, P0453, EC-1533.

GI

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP control system pressure sensor.

11

MA EM

CHECK EVAP CANISTER VENT CONTROL VALVE

Check air passage continuity. With CONSULT-II Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

LC

FE CL MT SEF991Y

Without CONSULT-II

AT TF MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

PD AX SU BR ST

AEC783A

Make sure new O-ring is installed properly.

RS

OK or NG

BT

OK (With CONSULT-II)

䊳

GO TO 12.

OK (Without CONSULTII)

䊳

GO TO 13.

NG

䊳

Replace EVAP canister vent control valve.

HA SC EL

EC-1501

IDX

DTC P0441 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

12 1. 2. 3. 4. 5.

CHECK CLOSED THROTTLE POSITION SWITCH With CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check indication of “CLSD THL/P SW”. Measurement must be made with closed throttle position switch installed in vehicle.

MTBL0355

If NG, adjust closed throttle position switch. Check the following items. Refer to “Basic Inspection”, EC-1273.

MTBL0576

6. If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch. OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace throttle position switch with throttle position sensor.

EC-1502

DTC P0441 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

13 1. 2. 3. 4.

CHECK CLOSED THROTTLE POSITION SWITCH Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect closed throttle position switch harness connector. Check continuity between closed throttle position switch terminals 4 and 5. Resistance measurement must be made with closed throttle position switch installed in vehicle.

GI MA EM LC

FE AEC654A

CL MT MTBL0247

If NG, adjust closed throttle position switch. Check the following items. Refer to “Basic Inspection”, EC-1273.

AT TF PD AX MTBL0576

5. If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch. OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace throttle position switch with throttle position sensor.

14

SU BR ST

CHECK EVAP PURGE LINE

Inspect EVAP purge line (pipe and rubber tube). Check for evidence of leaks. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-1203.

RS

OK or NG OK

䊳

GO TO 15.

NG

䊳

Replace it.

15

BT HA

CLEAN EVAP PURGE LINE

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

SC

GO TO 16.

EL

EC-1503

IDX

DTC P0441 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d)

16

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1504

VG33ER

DTC P0442 EVAP CONTROL SYSTEM

VG33ER On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1270

NOTE: If DTC P0442 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-1679.) This diagnosis detects leaks in the EVAP purge line using engine intake manifold vacuum. If pressure does not increase, the ECM will check for leaks in the line between the fuel tank and EVAP canister purge volume control solenoid valve, under the following “Vacuum test” conditions. The vacuum cut valve bypass valve is opened to clear the line between the fuel tank and the EVAP canister purge volume control solenoid valve. The EVAP canister vent control valve will then be closed to shut the EVAP purge line off. The EVAP canister purge volume control solenoid valve is opened to depressurize the EVAP purge line using intake manifold vacuum. After this occurs, the EVAP canister purge volume control solenoid valve will be closed.

GI MA EM LC

FE CL MT AT TF PD AX SEC666C

SU Malfunction is detected when EVAP control system has a leak, EVAP control system does not operate properly. CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC1270S01

Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Fuel filler cap remains open or fails to close. Foreign matter caught in fuel filler cap. Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. Foreign matter caught in EVAP canister vent control valve. EVAP canister or fuel tank leaks EVAP purge line (pipe and rubber tube) leaks EVAP purge line rubber tube bent.

EC-1505

BR ST RS BT HA SC EL IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33ER

On Board Diagnosis Logic (Cont’d)

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit EVAP canister purge volume control solenoid valve and the circuit Fuel tank temperature sensor O-ring of EVAP canister vent control valve is missing or damaged. Water separator EVAP canister is saturated with water. EVAP control system pressure sensor Fuel level sensor and the circuit. Refueling EVAP vapor cut ORVR system leaks

EC-1506

DTC P0442 EVAP CONTROL SYSTEM

VG33ER DTC Confirmation Procedure

DTC Confirmation Procedure

SEC716C

SEC717C

SEC718C

SEC719C

NGEC1271

NOTE: 쐌 If DTC P0442 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-1679.) 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is between 1/4 to 3/4 full and vehicle is placed on flat level surface. 쐌 Open engine hood before conducting the following procedure. With CONSULT-II 1) Turn ignition switch ON. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 4) Make sure that the following conditions are met. COOLAN TEMP/S: 0 - 32°C (32 - 90°F) INT/A TEMP SE: More than 0°C (32°F) 5) Select “EVAP SML LEAK P0442” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-1273. 6) Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-1508. NOTE: Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. With GST NOTE: Be sure to read the explanation of “Driving Pattern” on EC-1239 before driving vehicle. 1) Start engine. 2) Drive vehicle according to “Driving Pattern”, EC-1239. 3) Stop vehicle. 4) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is not set yet, go to the following step. 쐌 If SRT of EVAP system is set, the result will be OK. 5) Turn ignition switch OFF and wait at least 5 seconds. 6) Start engine. It is not necessary to cool engine down before driving. 7) Drive vehicle again according to the “Driving Pattern”, EC-1239. 8) Stop vehicle. 9) Select “MODE 3” with GST. 쐌 If P0442 is displayed on the screen, go to “Diagnostic Procedure”, EC-1508. 쐌 If P0441 is displayed on the screen, go to “Diagnostic Procedure” for “DTC P0441”, EC-1496.

EC-1507

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33ER

DTC Confirmation Procedure (Cont’d)

쐌

If P0442 and P0441 are not displayed on the screen, go to the following step. 10) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is set, the result will be OK. 쐌 If SRT of EVAP system is not set, go to step 6.

Diagnostic Procedure 1

NGEC1272

CHECK FUEL FILLER CAP DESIGN

1. Turn ignition switch “OFF”. 2. Check for genuine NISSAN fuel filler cap design.

SEF915U

OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace with genuine NISSAN fuel filler cap.

2

CHECK FUEL FILLER CAP INSTALLATION

Check that the cap is tightened properly by rotating the cap clockwise. OK or NG OK

䊳

GO TO 3.

NG

䊳

쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard.

3

CHECK FUEL FILLER CAP FUNCTION

Check for air releasing sound while opening the fuel filler cap. OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 4.

4

CHECK FUEL TANK VACUUM RELIEF VALVE

Refer to “Evaporative Emission System”, EC-1199. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace fuel filler cap with a genuine one.

EC-1508

DTC P0442 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

5

INSTALL THE PRESSURE PUMP

To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely.

GI MA EM LC AEC649A

FE CL MT SEF916U

NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. Models with CONSULT-II

䊳

GO TO 6.

Models without CONSULT-II

䊳

GO TO 7.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1509

IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

6

CHECK FOR EVAP LEAK

With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system.

PEF917U

4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-1203.

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

EC-1510

DTC P0442 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

7

CHECK FOR EVAP LEAK

Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.)

GI MA EM LC

AEC632A

4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-1203.

FE CL MT AT TF PD AX

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

SU BR ST RS BT HA SC EL

EC-1511

IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace water separator.

9

CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT

Refer to “DTC Confirmation Procedure”, EC-1527. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair or replace EVAP canister vent control valve and O-ring or harness/connector.

10

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

SEF596U

Yes or No Yes

䊳

GO TO 11.

No (With CONSULT-II)

䊳

GO TO 13.

No (Without CONSULTII)

䊳

GO TO 14.

EC-1512

DTC P0442 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

11

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb).

GI

OK or NG OK (With CONSULT-II)

䊳

GO TO 13.

OK (Without CONSULTII)

䊳

GO TO 14.

NG

䊳

GO TO 12.

MA EM LC

12

DETECT MALFUNCTIONING PART

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

13 1. 2. 3. 4. 5.

FE

Repair hose or replace EVAP canister.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

CL

With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100.0%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm.

MT AT TF PD AX SEF984Y

SU

OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 15.

BR ST

14 1. 2. 3. 4. 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist.

RS BT HA

OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 15.

SC EL

EC-1513

IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

15

CHECK VACUUM HOSE

Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-1193. OK or NG OK

䊳

GO TO 16.

NG

䊳

Repair or reconnect the hose.

16

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

SEF985Y

OK or NG OK

䊳

GO TO 18.

NG

䊳

GO TO 17.

EC-1514

DTC P0442 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

17

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

GI MA EM LC

AEC652A

FE CL MT SEF334X

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

AT TF PD AX SU

AEC652A

BR ST RS BT

SEF335X

HA

OK or NG OK

䊳

GO TO 18.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

SC EL

EC-1515

IDX

DTC P0442 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

18

CHECK FUEL TANK TEMPERATURE SENSOR

1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit and fuel pump terminals 1 and 2 by heating with hot water or heat gun as shown in the figure.

SEC311C

OK or NG OK

䊳

GO TO 19.

NG

䊳

Replace fuel tank temperature sensor.

19

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

1. 2. 3. 4.

Remove EVAP control system pressure sensor with its harness connector connected. Remove hose from EVAP control system pressure sensor. Turn ignition switch “ON”. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or over 101.3 kPa (760 mmHg, 29.92 inHg) of pressure. 5. Check input voltage between ECM terminal 62 and ground.

SEC649C

CAUTION: 쐌 Discard and EVAP control system pressure 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. OK or NG OK

䊳

GO TO 20.

NG

䊳

Replace EVAP control system pressure sensor.

20

CHECK EVAP PURGE LINE

Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to “Evaporative Emission System”, EC-1199. OK or NG OK

䊳

GO TO 21.

NG

䊳

Repair or reconnect the hose.

EC-1516

DTC P0442 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

21

CLEAN EVAP PURGE LINE

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

GI

GO TO 22.

MA 22

CHECK REFUELING EVAP VAPOR LINE

Check refueling EVAP vapor line between EVAP canister and fuel tank for clogging, kink, looseness and improper connection. For location, refer to “ON BOARD REFUELING VAPOR RECOVERY (ORVR)”, EC-1205.

EM

OK or NG

LC

OK

䊳

GO TO 23.

NG

䊳

Repair or replace hoses and tubes.

23

CHECK SIGNAL LINE AND RECIRCULATION LINE

Check signal line and recirculation line between filler neck tube and fuel tank for clogging, kink, cracks, looseness and improper connection. OK or NG OK

䊳

GO TO 24.

NG

䊳

Repair or replace hoses, tubes or filler neck tube.

24

CHECK REFUELING CONTROL VALVE

FE CL MT

1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage.

AT TF PD AX SU BR ST RS BT

SEF706Z

HA

OK or NG OK

䊳

GO TO 25.

NG

䊳

Replace refueling control valve with fuel tank.

SC EL

EC-1517

IDX

DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d)

25

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “FUEL LEVEL SENSOR UNIT CHECK”. OK or NG OK

䊳

GO TO 26.

NG

䊳

Replace fuel level sensor unit.

26

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1518

VG33ER

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33ER Description

Description

NGEC1273

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

Throttle position switch

Closed throttle position

Heated oxygen sensors 1 (front)

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Fuel tank temperature sensor

Fuel temperature in fuel tank

Vehicle speed sensor

Vehicle speed

NGEC1273S01

ECM function

GI

Actuator

MA EM

EVAP canEVAP canister purge volume ister purge control solenoid valve flow control

LC

FE CL

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.

MT AT TF PD AX

COMPONENT DESCRIPTION

NGEC1273S02

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.

SU BR ST RS

SEF337U

CONSULT-II Reference Value in Data Monitor Mode

BT

NGEC1274

Specification data are reference values. MONITOR ITEM

PURG VOL C/V

HA CONDITION

쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch OFF Shift lever: “N” No-load

SPECIFICATION

Idle (Vehicle stopped)

0%

2,000 rpm

—

EC-1519

SC EL IDX

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33ER ECM Terminals and Reference Value

ECM Terminals and Reference Value

NGEC1275

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 the ECM terminals, such as the ground. TERMINAL NO.

4

WIRE COLOR

OR/B

ITEM

ECM relay (Self shutoff)

CONDITION

DATA (DC Voltage)

[Engine is running] [Ignition switch OFF] 쐌 For a few seconds after turning ignition switch OFF

0 - 1.5V

[Ignition switch OFF] 쐌 A few seconds passed after turning ignition switch OFF

BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed

5

R/Y

EVAP canister purge volume control solenoid valve

SEF994U

BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Engine speed is 2,000 rpm (More than 100 seconds after starting engine)

SEF995U

67

B/P Power supply for ECM [Ignition switch ON]

72

B/P

117

B/P

Current return

[Engine is running] 쐌 Idle speed

EC-1520

BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V)

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33ER On Board Diagnosis Logic

On Board Diagnosis Logic

=NGEC1276

Malfunction is detected when an excessively low (P0444) or high (P0445) voltage signal is sent to ECM through the valve.

POSSIBLE CAUSE 쐌 쐌

NGEC1276S01

Harness or connectors (The valve circuit is open or shorted.) EVAP canister purge volume control solenoid valve

GI MA EM LC

DTC Confirmation Procedure

SEF058Y

NGEC1277

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. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle. 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 13 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1523. With GST Follow the procedure “With CONSULT-II”.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1521

IDX

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33ER Wiring Diagram

Wiring Diagram

NGEC1278

LEC813

EC-1522

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1279

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector.

GI MA EM LC

AEC652A

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

FE CL MT AT

SEF646W

Voltage: Battery voltage

TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

PD AX

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F36, M81 쐌 Harness connectors M82, E74 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM relay 䊳

SU BR

Repair harness or connectors.

ST 3

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 5 and solenoid terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG

RS BT HA

OK (With CONSULT-II)

䊳

GO TO 5.

OK (Without CONSULTII)

䊳

GO TO 6.

SC

NG

䊳

GO TO 4.

EL

EC-1523

IDX

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33ER Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E74, M82 쐌 Harness connectors M81, F36 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM 䊳

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

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.

SEF985Y

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

EC-1524

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE VG33ER Diagnostic Procedure (Cont’d)

6

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II 1. Check air passage continuity under the following conditions.

GI MA EM LC

SEF660U

FE CL MTBL0241

MT

Without CONSULT-II 1. Check air passage continuity under the following conditions.

AT TF PD AX SEF661U

SU BR MTBL0242

ST

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

7

RS BT

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

HA SC EL

EC-1525

IDX

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Component Description

Component Description

SEF032W

NGEC1280

The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid valve responds to signals from the ECM. When the ECM sends an ON signal, the coil in the solenoid valve is energized. A plunger will then move to seal the canister vent. The ability to seal the vent is necessary for the on board diagnosis of other evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis.

SEF143S

CONSULT-II Reference Value in Data Monitor Mode

NGEC1281

Specification data are reference values. MONITOR ITEM VENT CONT/V

CONDITION

SPECIFICATION

쐌 Ignition switch: ON

OFF

ECM Terminals and Reference Value

NGEC1282

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO. 108

R/G

ITEM

CONDITION

EVAP canister vent control [Ignition switch ON] valve

EC-1526

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

=NGEC1283

Malfunction is detected when an improper voltage signal is sent to ECM through EVAP canister vent control valve.

POSSIBLE CAUSE 쐌 쐌

NGEC1283S01

Harness or connectors (The valve circuit is open or shorted.) EVAP canister vent control valve

GI MA EM LC

DTC Confirmation Procedure

NGEC1284

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. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle.

FE CL MT

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 8 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1529. With GST Follow the procedure “With CONSULT-II”. 1) 2) 3) 4)

AT TF PD AX

SEF058Y

SU BR ST RS BT HA SC EL

EC-1527

IDX

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1285

WEC006A

EC-1528

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1286

INSPECTION START

GI

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

MA EM

CHECK EVAP CANISTER VENT CONTROL VALVE CIRCUIT

LC

1. Turn ignition switch “OFF” and then turn “ON”. 2. Select “VENT CONTROL/V” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON/OFF” on CONSULT-II screen.

FE CL MT SEF989Y

4. Check for operating sound of the valve. Clicking noise should be heard. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 3.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1529

IDX

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK EVAP CANISTER VENT CONTROL VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect EVAP canister vent control valve harness connector.

SEF143S

3. Turn ignition switch “ON”. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

SEF648W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M67, B101 and B113, C3 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between EVAP canister vent control valve and fuse 䊳

5

Repair harness or connectors.

CHECK EVAP CANISTER VENT CONTROL VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 108 and EVAP canister vent control valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

EC-1530

DTC P0447 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure (Cont’d)

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C3, B113 and B101, M67 쐌 Harness connectors M81, F36 쐌 Harness for open or short between EVAP canister vent control valve and ECM 䊳

GI MA

Repair open circuit or short to ground or short to power in harness or connectors.

EM 7

CHECK EVAP CANISTER VENT CONTROL VALVE

With CONSULT-II 1. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time.

LC

FE CL MT SEF991Y

AT

Without CONSULT-II 1. Check air passage continuity and operation delay time under the following conditions.

TF PD MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

AX SU BR ST RS

AEC783A

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace EVAP canister vent control valve.

8

BT HA SC

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

EL

INSPECTION END

EC-1531

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

Component Description

Component Description

NGEC1287

The EVAP control system pressure sensor detects pressure in the purge line. The sensor output voltage to the ECM increases as pressure increases. The EVAP control system pressure sensor is not used to control the engine system. It is used only for on board diagnosis.

SEF052VC

SEF946SB

CONSULT-II Reference Value in Data Monitor Mode

NGEC1288

Specification data are reference values. MONITOR ITEM EVAP SYS PRES

CONDITION

SPECIFICATION

쐌 Ignition switch: ON

Approx. 1.8 - 4.8V

ECM Terminals and Reference Value

NGEC1289

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

42

B/W

Sensors’ power supply

[Ignition switch ON]

Approximately 5V

43

BR

Sensors’ ground

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

Approximately 0V

62

Y

EVAP control system pressure sensor

[Ignition switch ON]

Approximately 1.8 - 4.8V

EC-1532

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

=NGEC1290

Malfunction is detected when an excessively low (P0452) or high (P0453) voltage signal from EVAP control system pressure sensor is sent to ECM.

GI

POSSIBLE CAUSE

MA

쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC1290S01

Harness or connectors (The EVAP control system pressure sensor circuit is open or shorted.) Rubber hose to EVAP control system pressure sensor is clogged, vent, kinked, disconnected or improper connection. EVAP control system pressure sensor EVAP canister vent control valve EVAP canister purge volume control solenoid valve EVAP canister Rubber hose from EVAP canister vent control valve to water separator

EM LC

FE CL MT

DTC Confirmation Procedure

NGEC1291

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. TESTING CONDITION: Always perform test at a temperature of 5°C (41°F) or more.

AT TF PD AX

With CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 5 seconds. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Make sure that “FUEL T/TMP SE” is more than 0°C (32°F). Start engine and wait at least 20 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1535. With GST Follow the procedure “With CONSULT-II”. 1) 2) 3) 4) 5) 6) 7)

SEF194Y

SU BR ST RS BT HA SC EL

EC-1533

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1292

WEC181A

EC-1534

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1293

CHECK RUBBER TUBE

GI

1. Turn ignition switch “OFF”. 2. Check rubber tube connected to the sensor for clogging, vent, kink, disconnection or improper connection.

MA EM LC

AEC651A

OK or NG OK

䊳

GO TO 2.

NG

䊳

Reconnect, repair or replace.

2

FE CL MT

RETIGHTEN GROUND SCREWS

1. Loosen and retighten engine ground screws.

AT TF PD AX LEC657

SU 䊳

GO TO 3.

BR 3

CHECK CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector. 2. Check sensor harness connector for water. Water should not exist. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace harness connector.

ST RS BT HA SC EL

EC-1535

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

4

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR POWER SUPPLY CIRCUIT

1. Turn ignition switch “ON”. 2. Check voltage between terminal 3 and ground with CONSULT-II or tester.

SEF889U

Voltage: Approximately 5V OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C3, B113 and B101, M67 쐌 Harness connectors M58, F28 쐌 Harness for open or short between EVAP control system pressure sensor and ECM 䊳

6

Repair harness or connectors.

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check harness continuity between EVAP control system pressure sensor terminal 1 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C3, B113 and B101, M67 쐌 Harness connectors M59, F27 쐌 Joint connector-4 (if equipped) 쐌 Harness for open or short between EVAP control system pressure sensor and ECM 䊳

Repair open circuit or short to power in harness or connectors.

EC-1536

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

8

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 62 and EVAP control system pressure sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

MA EM

OK or NG OK (With CONSULT-II)

䊳

GO TO 10.

OK (Without CONSULTII)

䊳

GO TO 11.

NG

䊳

GO TO 9.

9

GI

LC

DETECT MALFUNCTIONING PART

FE

Check the following. 쐌 Harness connectors C3, B113 and B101, M67 쐌 Harness connectors M59, F27 쐌 Harness for open or short between ECM and EVAP control system pressure sensor 䊳

CL

Repair open circuit or short to ground or short to power in harness or connectors.

MT 10

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

AT TF PD AX SU

SEF068Y

BR

OK or NG OK

䊳

GO TO 12.

NG

䊳

GO TO 11.

ST RS BT HA SC EL

EC-1537

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

11

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II 1. Check air passage continuity under the following conditions.

SEF660U

MTBL0241

Without CONSULT-II 1. Check air passage continuity under the following conditions.

SEF661U

MTBL0242

AEC652A

OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EC-1538

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

12

CHECK EVAP CANISTER VENT CONTROL VALVE

With CONSULT-II 1. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time under the following conditions.

GI MA EM LC

SEF991Y

FE Without CONSULT-II 1. Check air passage continuity and operation delay time under the following conditions.

CL MT MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

AT TF PD AX SU

AEC783A

Make sure new O-ring is installed properly.

BR OK or NG

OK

䊳

GO TO 13.

NG

䊳

Replace EVAP canister vent control valve.

13

ST

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

Refer to “Component Inspection, EC-1541. OK or NG OK

䊳

GO TO 14.

NG

䊳

Replace EVAP control system pressure sensor.

RS BT HA SC EL

EC-1539

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

14

CHECK RUBBER TUBE

Check obstructed rubber tube connected to EVAP canister vent control valve. OK or NG OK

䊳

GO TO 15.

NG

䊳

Clean, repair or replace rubber tube.

15 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 16.

NG

䊳

Replace water separator.

16

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

SEF596U

Yes or No Yes

䊳

GO TO 17.

No

䊳

GO TO 19.

EC-1540

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

17

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb).

GI

OK or NG OK

䊳

GO TO 19.

NG

䊳

GO TO 18.

18

MA EM

DETECT MALFUNCTIONING PART

LC

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

19

Repair hose or replace EVAP canister.

FE

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT

1. Reconnect harness connectors disconnected. 2. Disconnect harness connectors C3, B113. 3. Check harness continuity between harness connector B113 terminal 6 and engine ground. Continuity should exist. 4. Also check harness for short to power.

CL MT

OK or NG OK

䊳

GO TO 21.

NG

䊳

GO TO 20.

20

AT TF

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connector B113 and B101, M67 쐌 Harness connectors M59, F27 쐌 Joint connector-1 (if equipped) 쐌 Harness for open between harness connector M67 and engine ground 䊳

PD AX

Repair open circuit or short to power in harness or connectors.

SU 21

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

BR

INSPECTION END

ST RS

Component Inspection EVAP CONTROL SYSTEM PRESSURE SENSOR 1. 2. 3.

NGEC1501

BT

NGEC1501S01

Remove EVAP control system pressure sensor with its harness connector connected. Remove hose from EVAP control system pressure sensor. Install a vacuum pump to EVAP control system pressure sensor.

HA SC EL

EC-1541

IDX

DTC P0452, P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR

VG33ER

Component Inspection (Cont’d)

4.

LEC199A

Turn ignition switch ON and check output voltage between ECM terminal 62 and ground under the following conditions. Applied vacuum kPa (mmHg, inHg)

Voltage V

Not applied

1.8 – 4.8

-26.7 (-200, -7.87)

2.1 to 2.5V lower than above value

CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply vacuum below -93.3 kPa (-700 mmHg, -27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 5. If NG, replace EVAP control system pressure sensor.

EC-1542

DTC P0455 EVAP CONTROL SYSTEM

VG33ER On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1294

NOTE: If DTC P0455 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-1683.) This diagnosis detects a very large leak (fuel filler cap fell off etc.) in the EVAP system between the fuel tank and the EVAP canister purge volume control solenoid valve.

GI MA EM LC

FE CL MT AT SEC666C

TF Malfunction is detected when EVAP control system has a very large leak, such as fuel filler cap fell off, EVAP control system does not operate properly. CAUTION: 쐌 Fuel filler cap remains open or fails to close. 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC1294S01

Fuel filler cap remains open or fails to close. Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Foreign matter caught in fuel filler cap. Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. Foreign matter caught in EVAP canister vent control valve. EVAP canister or fuel tank leaks EVAP purge line (pipe and rubber tube) leaks EVAP purge line rubber tube bent. Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit EVAP canister purge volume control solenoid valve and the circuit Fuel tank temperature sensor

EC-1543

PD AX SU BR ST RS BT HA SC EL IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33ER

On Board Diagnosis Logic (Cont’d)

쐌 쐌 쐌 쐌

O-ring of EVAP canister vent control valve is missing or damaged. EVAP control system pressure sensor Refueling control valve ORVR system leaks

DTC Confirmation Procedure

SEC716C

SEC717C

SEC718C

SEC719C

NGEC1295

CAUTION: Never remove fuel filter cap during the DTC confirmation procedure. NOTE: 쐌 If DTC P0455 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-1683.) 쐌 Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is between 1/4 to 3/4 full and vehicle is placed on flat level surface. 쐌 Open engine hood before conducting the following procedure. With CONSULT-II 1) Tighten fuel filter cap securely until ratcheting sound is heard. 2) Turn ignition switch ON. 3) Turn ignition switch OFF and wait at least 5 seconds. 4) Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that the following conditions are met. COOLAN TEMP/S: 0 - 32°C (32 - 90°F) INT/A TEMP SE: More than 0°C (32°F) 6) Select “EVAP SML LEAK P0442” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-1273. 7) Make sure that “OK” is displayed. If “NG” is displayed, select “SELF-DIAG RESULTS” mode with CONSULT-II and make sure that “EVAP GROSS LEAK [P0455] is displayed, refer to “Diagnostic Procedure”, EC-1546. If P0442 is displayed, perform “Diagnostic Procedure” for DTC P0442. With GST NOTE: Be sure to read the explanation of “Driving Pattern” on EC-1239 before driving vehicle.

EC-1544

DTC P0455 EVAP CONTROL SYSTEM

VG33ER

DTC Confirmation Procedure (Cont’d)

1) 2) 3) 4) 쐌 쐌 5) 6)

Start engine. Drive vehicle according to “Driving Pattern”, EC-1239. Stop vehicle. Select “MODE 1” with GST. If SRT of EVAP system is not set yet, go to the following step. If SRT of EVAP system is set, the result will be OK. Turn ignition switch “OFF” and wait at least 5 seconds. Start engine. It is not necessary to cool engine down before driving. 7) Drive vehicle again according to the “Driving Pattern”, EC-1239. 8) Stop vehicle. 9) Select “MODE 3” with GST. 쐌 If P0455 is displayed on the screen, go to “Diagnostic Procedure”, EC-1546. 쐌 If P0442 is displayed on the screen, go to “Diagnostic Procedure”, EC-1508. 쐌 If P0441 is displayed on the screen, go to “Diagnostic Procedure” for “DTC P0441”, EC-1496. 쐌 If P0442, P0455 and P0441 are not displayed on the screen, go to the following step. 10) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is set, the result will be OK. 쐌 If SRT of EVAP system is not set, go to step 6.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1545

IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

=NGEC1296

CHECK FUEL FILLER CAP DESIGN

1. Turn ignition switch OFF. 2. Check for genuine NISSAN fuel filler cap design.

SEF915U

OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace with genuine NISSAN fuel filler cap.

2

CHECK FUEL FILLER CAP INSTALLATION

Check that the cap is tightened properly by rotating the cap clockwise. OK or NG OK

䊳

GO TO 3.

NG

䊳

쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard.

3

CHECK FUEL FILLER CAP FUNCTION

Check for air releasing sound while opening the fuel filler cap. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-1546

DTC P0455 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

4

CHECK FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)

1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum.

GI MA EM LC

SEF445Y

FE CL MT AT SEF943S

Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace fuel filler cap with a genuine one.

5

PD AX SU

CHECK EVAP PURGE LINE

Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks, improper connection or disconnection. Refer to “Evaporative Emission System”, EC-1200. OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair or reconnect the hose.

6

TF

CLEAN EVAP PURGE LINE

BR ST RS BT

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

7

GO TO 7.

HA

CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT

Refer to “DTC Confirmation Procedure”, EC-1527.

SC

OK or NG

EL

OK

䊳

GO TO 8.

NG

䊳

Repair or replace EVAP canister vent control valve and O-ring or harness/connector.

EC-1547

IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

8

INSTALL THE PRESSURE PUMP

To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely.

AEC649A

SEF916U

NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. Models with CONSULT-II

䊳

GO TO 9.

Models without CONSULT-II

䊳

GO TO 10.

EC-1548

DTC P0455 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

9

CHECK FOR EVAP LEAK

With CONSULT-II 1. Turn ignition switch ON. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system.

GI MA EM LC

FE PEF917U

4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-1203.

CL MT AT TF PD

SEF200U

OK or NG OK

䊳

GO TO 11.

NG

䊳

Repair or replace.

AX SU BR ST RS BT HA SC EL

EC-1549

IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

10

CHECK FOR EVAP LEAK

Without CONSULT-II 1. Turn ignition switch OFF. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.)

AEC632A

4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-1203.

SEF200U

OK or NG OK

䊳

GO TO 12.

NG

䊳

Repair or replace.

EC-1550

DTC P0455 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

11 1. 2. 3. 4. 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100.0%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm.

GI MA EM LC

FE SEF984Y

Vacuum should exist.

CL OK or NG

OK

䊳

GO TO 14.

NG

䊳

GO TO 13.

12 1. 2. 3. 4. 5.

MT

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist. OK or NG

OK

䊳

GO TO 15.

NG

䊳

GO TO 13.

13

AT TF PD AX SU BR

CHECK VACUUM HOSE

Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-1193. OK or NG OK (With CONSULT-II)

䊳

GO TO 14.

OK (Without CONSULTII)

䊳

GO TO 15.

NG

䊳

Repair or reconnect the hose.

ST RS BT HA SC EL

EC-1551

IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

14

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

SEF985Y

If OK, inspection end. If NG, go to following step. 3. Check air passage continuity.

SEF660U

MTBL0241

OK or NG OK

䊳

GO TO 16.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EC-1552

DTC P0455 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

15

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

Without CONSULT-II Check air passage continuity.

GI MA EM LC

SEF661U

FE CL MTBL0242

MT AT TF PD AEC652A

OK or NG OK

䊳

GO TO 16.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

AX SU BR ST RS BT HA SC EL

EC-1553

IDX

DTC P0455 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

16

CHECK FUEL TANK TEMPERATURE SENSOR

1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit terminals T and E by heating with hot water or heat gun as shown in the figure.

SEC311C

LEC764

OK or NG OK

䊳

GO TO 17.

NG

䊳

Replace fuel tank temperature sensor.

EC-1554

DTC P0455 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

17 1. 2. 3. 4. 5.

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR Remove EVAP control system pressure sensor with its harness connector connected. Remove hose from EVAP control system pressure sensor. Turn ignition switch ON. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. Check input voltage between ECM terminal 62 and ground.

GI MA EM LC

SEC649C

CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or over 101.3 kPa (760 mmHg, 29.92 inHg) of pressure. 쐌 Discard and EVAP control system pressure 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.

FE CL MT AT TF PD

AEC651A

OK or NG OK

䊳

GO TO 18.

NG

䊳

Replace EVAP control system pressure sensor.

18

AX SU BR

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

ST

INSPECTION END

RS BT HA SC EL

EC-1555

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1375

This diagnosis detects very small leaks in the EVAP line between the fuel tank and the EVAP canister purge volume control solenoid valve using intake manifold vacuum (negative pressure when P0456) or fuel tank vapor pressure (positive pressure when P1456) in the same way as conventional EVAP small leak diagnosis. If the ECM judges a leak equivalent to a very small leak, the very small leak DTC P0456 or P1456 will be detected. If the ECM judges a leak equivalent to a small leak, the EVAP small leak DTC P0442 or P1442 will be detected. Correspondingly, if the ECM judges there is no leak, the diagnosis result is OK.

SEC666C

Malfunction is detected when EVAP control system has a very small leak, EVAP control system does not operate properly. CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC1375S01

Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Fuel filler cap remains open or fails to close. Foreign matter caught in fuel filler cap. Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. Foreign matter caught in EVAP canister vent control valve. EVAP canister or fuel tank leaks EVAP purge line (pipe and rubber tube) leaks EVAP purge line rubber tube bent. Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit

EC-1556

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

On Board Diagnosis Logic (Cont’d)

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

EVAP canister purge volume control solenoid valve Fuel tank temperature sensor O-ring of EVAP canister vent control valve is missing or damaged. Water separator EVAP canister is saturated with water. Fuel level sensor and the circuit EVAP control system pressure sensor Refueling control valve ORVR system leaks

DTC Confirmation Procedure

SEC720C

SEC721C

SEC722C

MA EM LC

NGEC1376

CAUTION: Never remove fuel filler cap during the DTC confirmation procedure. NOTE: 쐌 If DTC P0456 or P1456 is displayed with P0442, perform TROUBLE DIAGNOSIS FOR DTC P0456 or P1456 first. 쐌 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. 쐌 After repair, make sure that the hoses and clips are installed properly. TESTING CONDITION: 쐌 Open engine hood before conducting following procedure. 쐌 If any of following condition is met just before the DTC confirmation procedure, leave the vehicle for more than 1 hour. a) Fuel filler cap is removed. b) Refilled or drained the fuel. c) EVAP component parts is/are removed. 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Make sure the following conditions are met. FUEL LEVEL SE: 1.08 - 0.2V COOLAN TEMP/S: 0 - 32°C (32 - 90°F) FUEL T/TMP SE: 0 - 35°C (32 - 95°F) INT A/TEMP SE: More than 0°C (32°F) If NG, turn ignition switch “OFF” and leave the vehicle in a cool place (soak the vehicle) or refilling/draining fuel until the output voltage condition of the “FUEL LEVEL SE” meets within the range above and leave the vehicle for more than 1 hour. Then start from step 1). 3) Turn ignition switch “OFF” and wait at least 5 seconds. 4) Turn ignition switch “ON”. 5) Select “EVAP VERY/SML LEAK P0456 or P1456” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. 6) Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-1559.

EC-1557

GI

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

DTC Confirmation Procedure (Cont’d)

NOTE: 쐌 If the engine speed cannot be maintained within the range displayed on CONSULT-II screen, go to “Basic inspection”, EC-1273. 쐌 Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly.

Overall Function Check

NGEC1377

With GST Use this procedure to check the overall function of the EVAP very small leak function. During this check, a 1st trip DTC might not be confirmed.

SEF462UA

CAUTION: 쐌 Never use compressed air, doing so may damage the EVAP system. 쐌 Do not start engine. 쐌 Do not exceeded 4.12 kPa (0.042 kg/cm2, 0.6 psi). 1) Attach the EVAP service port adapter securely to the EVAP service port. 2) Set the pressure pump and a hose. 3) Also set a vacuum gauge via 3-way connector and a hose. 4) Turn ignition switch “ON”. 5) Connect GST and select mode 8. 6) Using mode 8 control the EVAP canister vent control valve (close) and vacuum cut valve bypass valve (open). 7) Apply pressure and make sure the following conditions are satisfied. Pressure to be applied: 2.7 kPa (20 mmHg, 0.79 inHg) Time to be waited after the pressure drawn in to the EVAP system and the pressure to be dropped: 60 seconds and the pressure should not be dropped more than 0.4 kPa (3 mmHg, 0.12 inHg) If NG, go to diagnostic procedure, EC-1559. NOTE: For more information, refer to GST instruction manual.

EC-1558

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1378

CHECK FUEL FILLER CAP DESIGN

GI

1. Turn ignition switch “OFF”. 2. Check for genuine NISSAN fuel filler cap design.

MA EM LC SEF915U

OK or NG

FE

OK

䊳

GO TO 2.

NG

䊳

Replace with genuine NISSAN fuel filler cap.

CL 2

CHECK FUEL FILLER CAP INSTALLATION

Check that the cap is tightened properly by rotating the cap clockwise.

MT

OK or NG OK

䊳

GO TO 3.

NG

䊳

쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard.

3

AT TF

CHECK FUEL FILLER CAP FUNCTION

Check for air releasing sound while opening the fuel filler cap.

PD

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

AX SU BR ST RS BT HA SC EL

EC-1559

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

4

CHECK FUEL TANK VACUUM RELIEF VALVE

1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum.

SEF445Y

SEF943S

Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace fuel filler cap with a genuine one.

EC-1560

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

5

INSTALL THE PRESSURE PUMP

To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely.

GI MA EM LC AEC649A

FE CL MT SEF916U

NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. Models with CONSULT-II

䊳

GO TO 6.

Models without CONSULT-II

䊳

GO TO 7.

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1561

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

6

CHECK FOR EVAP LEAK

With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system.

PEF917U

4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-1203.

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

EC-1562

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK FOR EVAP LEAK

Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.)

GI MA EM LC

AEC632A

4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-1203.

FE CL MT AT TF PD AX

SEF200U

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair or replace.

SU BR ST RS BT HA SC EL

EC-1563

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace water separator.

9

CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT

Refer to “DTC Confirmation Procedure”, EC-1527. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair or replace EVAP canister vent control valve and O-ring or harness/connector.

10

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Does water drain from the EVAP canister?

SEF596U

Yes or No Yes

䊳

GO TO 11.

No (With CONSULT-II)

䊳

GO TO 13.

No (Without CONSULTII)

䊳

GO TO 14.

EC-1564

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

11

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb).

GI

OK or NG OK (With CONSULT-II)

䊳

GO TO 13.

OK (Without CONSULTII)

䊳

GO TO 14.

NG

䊳

GO TO 12.

MA EM LC

12

DETECT MALFUNCTIONING PART

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

13 1. 2. 3. 4. 5.

FE

Repair hose or replace EVAP canister.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

CL

With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100.0%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm.

MT AT TF PD AX SEF984Y

SU

OK or NG OK

䊳

GO TO 16.

NG

䊳

GO TO 15.

BR ST

14 1. 2. 3. 4. 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist.

RS BT HA

OK or NG OK

䊳

GO TO 17.

NG

䊳

GO TO 15.

SC EL

EC-1565

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

15

CHECK VACUUM HOSE

Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-1193. OK or NG OK (With CONSULT-II)

䊳

GO TO 16.

OK (Without CONSULTII)

䊳

GO TO 17.

NG

䊳

Repair or reconnect the hose.

16

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

SEF985Y

OK or NG OK

䊳

GO TO 18.

NG

䊳

GO TO 17.

EC-1566

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

17

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

GI MA EM LC

WEC547

FE CL MT AT SEF334X

Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions.

TF PD AX SU

WEC547

BR ST RS BT

SEF335X

HA

OK or NG

SC

OK

䊳

GO TO 18.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EL

EC-1567

IDX

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

18

CHECK FUEL TANK TEMPERATURE SENSOR

1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit terminals T and E by heating with hot water or heat gun as shown in the figure.

SEC668C

OK or NG OK

䊳

GO TO 19.

NG

䊳

Replace fuel level sensor unit.

19

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR

1. 2. 3. 4.

Remove EVAP control system pressure sensor with its harness connector connected. Remove hose from EVAP control system pressure sensor. Turn ignition switch “ON”. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or over 101.3 kPa (760 mmHg, 29.92 inHg) of pressure. 5. Check input voltage between ECM terminal 62 and ground.

SEC649C

CAUTION: 쐌 Discard and EVAP control system pressure 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. OK or NG OK

䊳

GO TO 20.

NG

䊳

Replace EVAP control system pressure sensor.

20

CHECK EVAP PURGE LINE

Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to “Evaporative Emission System”, EC-1199. OK or NG OK

䊳

GO TO 21.

NG

䊳

Repair or reconnect the hose.

EC-1568

DTC P0456, P1456 EVAP CONTROL SYSTEM

VG33ER

Diagnostic Procedure (Cont’d)

21

CLEAN EVAP PURGE LINE

Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳

GI

GO TO 22.

MA 22

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “FUEL LEVEL SENSOR UNIT CHECK”.

EM OK or NG

OK

䊳

GO TO 23.

NG

䊳

Replace fuel level sensor unit.

23

LC

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

FE

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1569

IDX

DTC P0460 FUEL LEVEL SENSOR

VG33ER

Component Description

Component Description

NGEC1297

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

SEF800Z

ECM Terminals and Reference Value

NGEC1298

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)

46

OR/B

Fuel level sensor

[Ignition switch “ON”]

Approximately 0 - 4.8V Output voltage varies with fuel level.

66

B

Fuel level sensor ground

[Engine is running] 쐌 Idle speed

Approximately 0V

On Board Diagnosis Logic

NGEC1299

When the vehicle is parked, naturally the fuel level in the fuel tank is stable. It means that output signal of the fuel level sensor does not change. If ECM senses sloshing signal from the sensor, fuel level sensor malfunction is detected. Malfunction is detected when even though the vehicle is parked, a signal being varied is sent from the fuel level sensor to ECM.

POSSIBLE CAUSE 쐌 쐌

Fuel level sensor circuit (The fuel level sensor circuit is open or shorted.) Fuel level sensor

EC-1570

NGEC1299S01

DTC P0460 FUEL LEVEL SENSOR

VG33ER DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC1300

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

SEF195Y

1) 2) 3) 4)

MA

NGEC1300S01

Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait maximum of 2 consecutive minutes. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1573.

WITH GST

GI

EM LC

NGEC1300S02

Follow the procedure “WITH CONSULT-II” above.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1571

IDX

DTC P0460 FUEL LEVEL SENSOR

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1301

WEC993

EC-1572

DTC P0460 FUEL LEVEL SENSOR

VG33ER Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4.

=NGEC1302

CHECK FUEL LEVEL SENSOR POWER SUPPLY CIRCUIT

GI

Turn ignition switch “OFF”. Disconnect fuel level sensor unit harness connector. Turn ignition switch “ON”. Check voltage between fuel level sensor unit terminal 2 and ground with CONSULT-II or a tester.

MA EM LC

FE SEC650C

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

MT

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M67, C101 쐌 Harness for open or short between combination meter and fuel level sensor unit 䊳

3

Repair or replace harness or connectors.

CHECK FUEL LEVEL SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check harness continuity between fuel level sensor unit terminal 4 and body ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

CL

AT TF PD AX SU BR ST

DETECT MALFUNCTIONING PART

Check the harness connectors C101, M67. 䊳

5

Repair or replace harness or connectors.

CHECK FUEL LEVEL SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 46 and fuel level sensor unit terminal 2, ECM terminal 66 and fuel level sensor unit terminal 4. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

RS BT HA SC EL

EC-1573

IDX

DTC P0460 FUEL LEVEL SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M67, C101 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuel level sensor 䊳

7

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “FUEL LEVEL SENSOR UNIT CHECK”. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace fuel level sensor unit.

8

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1574

DTC P0461 FUEL LEVEL SENSOR

VG33ER Component Description

Component Description

=NGEC1303

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

GI MA EM LC

SEF800Z

On Board Diagnosis Logic

NGEC1304

Driving long distances naturally affect fuel gauge level. This diagnosis detects the fuel gauge malfunction of the gauge not moving even after a long distance has been driven. Malfunction is detected when the output signal of the fuel level sensor does not change within the specified range even though the vehicle has been driven a long distance.

POSSIBLE CAUSE 쐌 쐌

FE CL

NGEC1304S01

Harness or connectors (The level sensor circuit is open or shorted.) Fuel level sensor

MT AT TF PD AX

Overall Function Check

NGEC1305

Use this procedure to check the overall function of the fuel level sensor function. During this check, a 1st trip DTC might not be confirmed. WARNING: When performing following procedure, be sure to observe the handling of the fuel. Refer to FE-5, “FUEL TANK”. TESTING CONDITION: Before starting overall function check, preparation of draining fuel and refilling fuel is required.

WITH CONSULT-II

SEF195Y

NGEC1305S01

NOTE: Start from step 11, if it is possible to confirm that the fuel cannot be drained by 30 (7-7/8 US gal, 6-5/8 Imp gal) in advance. 1) Prepare a fuel container and a spare hose. 2) Release fuel pressure from fuel line, refer to “Fuel Pressure Release”, EC-1217. 3) Remove the fuel feed hose on the fuel level sensor unit. 4) Connect a spare fuel hose where the fuel feed hose was removed.

EC-1575

SU BR ST RS BT HA SC EL IDX

DTC P0461 FUEL LEVEL SENSOR

VG33ER

Overall Function Check (Cont’d)

5)

Turn ignition switch “OFF” and wait at least 5 seconds then turn “ON”. 6) Select “FUEL LEVEL SE” in “DATA MONITOR” mode with CONSULT-II. 7) Check “FUEL LEVEL SE” output voltage and note it. 8) Select “FUEL PUMP” in “ACTIVE TEST” mode with CONSULT-II. 9) Touch “ON” and drain fuel approximately 30 (7-7/8 US gal, 6-5/8 Imp gal) and stop it. 10) Fill fuel into the fuel tank for 30 (7-7/8 US gal, 6-5/8 Imp gal). 11) Check “FUEL LEVEL SE” output voltage and note it. 12) Check “FUEL LEVEL SE” output voltage and confirm whether the voltage changes more than 0.03V during step 7 to 11. If NG, check the fuel level sensor, refer to EL-89, “FUEL LEVEL SENSOR UNIT CHECK”.

WITH GST

SEF802Z

NGEC1305S02

NOTE: Start from step 11, if it is possible to confirm that the fuel cannot be drained by 30 (7-7/8 US gal, 6-5/8 Imp gal) in advance. 1) Prepare a fuel container and a spare hose. 2) Release fuel pressure from fuel line, refer to “Fuel Pressure Release”, EC-1217. 3) Remove the fuel feed hose on the fuel level sensor unit. 4) Connect a spare fuel hose where the fuel feed hose was removed. 5) Turn ignition switch “OFF”. 6) Set voltmeters probe between ECM terminal 46 (fuel level sensor signal) and ground. 7) Turn ignition switch “ON”. 8) Check voltage between ECM terminal 46 and ground and note it. 9) Drain fuel by 30 (7-7/8 US gal, 6-5/8 Imp gal) from the fuel tank using proper equipment. 10) Fill fuel into the fuel tank for 30 (7-7/8 US gal, 6-5/8 Imp gal). 11) Confirm that the voltage between ECM terminal 46 and ground changes more than 0.03V during step 8 - 10. If NG, check component of fuel level sensor, refer to EL-89, “FUEL LEVEL SENSOR UNIT CHECK”.

EC-1576

DTC P0462, P0463 FUEL LEVEL SENSOR

VG33ER Component Description

Component Description

NGEC1306

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

GI MA EM LC

SEF800Z

ECM Terminals and Reference Value

NGEC1307

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

FE

DATA (DC Voltage)

CL

46

OR/B

Fuel level sensor

[Ignition switch “ON”]

Approximately 0 - 4.8V Output voltage varies with fuel level.

MT

66

B

Fuel level sensor ground

[Engine is running] 쐌 Idle speed

Approximately 0V

AT TF PD AX

On Board Diagnosis Logic

NGEC1308

ECM receives two signals from the fuel level sensor circuit. One is fuel level sensor power supply circuit, and the other is fuel level sensor ground circuit. This diagnosis indicates the former, to detect open or short circuit malfunction. Malfunction is detected when an excessively low (P0462) or high (P0463) voltage is sent from the sensor is sent to ECM.

POSSIBLE CAUSE 쐌 쐌

Fuel level sensor circuit (The fuel level sensor circuit is open or shorted.) Fuel level sensor

NGEC1308S01

SU BR ST RS BT HA SC EL

EC-1577

IDX

DTC P0462, P0463 FUEL LEVEL SENSOR

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC1309

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at ignition switch “ON”.

WITH CONSULT-II 1) 2) 3) 4)

NGEC1309S01

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”, EC-1580.

WITH GST Follow the procedure “WITH CONSULT-II” above. SEF195Y

EC-1578

NGEC1309S02

DTC P0462, P0463 FUEL LEVEL SENSOR

VG33ER Wiring Diagram

Wiring Diagram

NGEC1310

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC994

EC-1579

EL IDX

DTC P0462, P0463 FUEL LEVEL SENSOR

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4.

=NGEC1311

CHECK FUEL LEVEL SENSOR POWER SUPPLY CIRCUIT Turn ignition switch “OFF”. Disconnect fuel level sensor unit harness connector. Turn ignition switch “ON”. Check voltage between fuel level sensor unit terminal G and ground with CONSULT-II or tester.

SEC650C

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M67, C101 쐌 Harness for open or short between combination meter and fuel level sensor unit 䊳

3

Repair or replace harness or connectors.

CHECK FUEL LEVEL SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check harness continuity between fuel level sensor unit terminal 4 and body ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace harness or connectors.

4

CHECK FUEL LEVEL SENSOR INPUT CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 46 and fuel level sensor unit 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

䊳

GO TO 6.

NG

䊳

GO TO 5.

EC-1580

DTC P0462, P0463 FUEL LEVEL SENSOR

VG33ER

Diagnostic Procedure (Cont’d)

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M67, C101 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuel level sensor 䊳

GI MA

Repair open circuit or short to ground or short to power in harness on connectors.

EM 6

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “Fuel Level Sensor Unit Check”. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace fuel level sensor unit.

7

LC

FE

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

CL

INSPECTION END

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1581

IDX

DTC P0500 VSS

VG33ER

Component Description

Component Description

NGEC1312

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.

AEC110

ECM Terminals and Reference Value

NGEC1313

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 2 - 3V

29

G/B

Vehicle speed sensor

[Engine is running] 쐌 Lift up the vehicle 쐌 In 1st gear position 쐌 Vehicle speed is 40 km/h (25 MPH) SEF996U

On Board Diagnosis Logic

NGEC1314

Malfunction is detected when the almost 0 km/h (0 MPH) signal from vehicle speed sensor is sent to ECM even when vehicle is being driven.

POSSIBLE CAUSE 쐌 쐌

NGEC1314S01

Harness or connector (The vehicle speed sensor circuit is open or shorted.) Vehicle speed sensor

DTC Confirmation Procedure

NGEC1315

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 5 seconds before conducting the next test. TESTING CONDITION: Steps 1 and 2 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle.

EC-1582

DTC P0500 VSS

VG33ER DTC Confirmation Procedure (Cont’d)

1) 2)

SEF196Y

3) 4) 5)

With CONSULT-II Start engine Read “VHCL SPEED SE” 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-1585. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Warm engine up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds.

END SPEED

More than 1,800 rpm (A/T models) More than 1,900 rpm (M/T models)

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

5.5 - 16.0 msec

Selector lever

Suitable position

PW/ST SIGNAL

OFF

6)

MA EM LC

FE CL

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1585.

Overall Function Check

GI

NGEC1316

Use this procedure to check the overall function of the vehicle speed sensor circuit. During this check, a 1st trip DTC might not be confirmed. With GST 1) Lift up drive wheels. 2) Start engine. 3) Read vehicle speed sensor signal in “MODE 1” with GST. The vehicle speed sensor on GST should be able to exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. 4) If NG, go to “Diagnostic Procedure”, EC-1585.

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1583

IDX

DTC P0500 VSS

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1317

WEC995

EC-1584

DTC P0500 VSS

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1318

CHECK VEHICLE SPEED SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 29 and combination meter terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power.

GI MA EM

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and combination meter 䊳

3

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK SPEEDOMETER FUNCTION

FE CL MT

Make sure that speedometer functions properly. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

TF

CHECK SPEEDOMETER CIRCUIT FOR OPEN AND SHORT

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness connectors F43, F201 쐌 Harness for open or short between combination meter and vehicle speed sensor OK or NG OK

䊳

Check combination meter and vehicle speed sensor. Refer to EL-75, “METERS AND GAUGES”.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

5

AT

CHECK INTERMITTENT INCIDENT

PD AX SU BR ST

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

RS BT HA SC EL

EC-1585

IDX

DTC P0505 ISC SYSTEM

VG33ER

Description

Description

NGEC1319

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

Park/neutral 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

Vehicle speed

Ambient air temperature switch

Ambient air temperature

Intake air temperature sensor

Intake air temperature

NGEC1319S01

ECM function

Idle air control

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 bypasses the throttle valve via IACV-AAC valve. The IACV-AAC valve repeats ON/OFF operation according to the signal sent from the ECM. The camshaft position sensor detects the actual engine speed and sends a signal to the ECM. The ECM then controls the ON/OFF time 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 and power steering).

COMPONENT DESCRIPTION IACV-AAC Valve

NGEC1319S02 NGEC1319S0201

The IACV-AAC valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of air that will flow through the valve. The more air that flows through the valve, the higher the idle speed.

SEF040E

EC-1586

DTC P0505 ISC SYSTEM

VG33ER

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NGEC1320

Specification data are reference values. MONITOR ITEM

IACV-AAC/V

CONDITION 쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

SPECIFICATION

Idle

10 - 20%

2,000 rpm

—

GI MA EM

ECM Terminals and Reference Value

NGEC1321

LC

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

FE ITEM

CONDITION

DATA (DC Voltage)

CL

8 - 11V

MT

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

AT SEF005V

101

OR/L

IACV-AAC valve

TF

7 - 10V

PD [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 3,000 rpm

AX SEF692W

SU BR ST RS

On Board Diagnosis Logic

NGEC1322

Malfunction is detected when (Malfunction A) the IACV-AAC valve does not operate properly, (Malfunction B) the IACV-AAC valve does not operate properly.

POSSIBLE CAUSE 쐌 쐌 쐌

Harness or connectors (The IACV-AAC valve circuit is open.) Harness or connectors (The IACV-AAC valve circuit is shorted.) IACV-AAC valve

EC-1587

NGEC1322S01

BT HA SC EL IDX

DTC P0505 ISC SYSTEM

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC1323

NOTE: 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test. 쐌 Perform “PROCEDURE FOR MALFUNCTION A” first. If 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”.

PROCEDURE FOR MALFUNCTION A

SEF058Y

PROCEDURE FOR MALFUNCTION B

SEF174Y

NGEC1323S01

TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch “ON”. With CONSULT-II 1) Turn ignition switch ON. 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”, EC-1590. With GST Follow the procedure “With CONSULT-II”.

NGEC1323S02

TESTING CONDITION: 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) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON again and select “DATA MONITOR” mode with CONSULT-II. 4) Start engine and run it for at least 1 minute at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1590. With GST Follow the procedure “With CONSULT-II”.

EC-1588

DTC P0505 ISC SYSTEM

VG33ER Wiring Diagram

Wiring Diagram

NGEC1324

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC672

EC-1589

EL IDX

DTC P0505 ISC SYSTEM

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1325

CHECK IACV-AAC VALVE POWER SUPPLY CIRCUIT

1. Stop engine. 2. Disconnect IACV-AAC valve harness connector.

LEC766

3. Turn ignition switch ON. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF651W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness connectors F37, F101 쐌 Fuse block (J/B) connector M27 쐌 10A fuse 쐌 Harness for open or short between IACV-AAC valve and fuse 䊳

3

Repair harness or connectors.

CHECK IACV-AAC VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 101 and IACV-AAC valve terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-1590

DTC P0505 ISC SYSTEM

VG33ER Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F101, F37 쐌 Harness for open or short between IACV-AAC valve and ECM 䊳

5

GI MA

Repair open circuit or short to ground or short to power in harness or connectors.

EM

CHECK IACV-AAC VALVE

1. Disconnect IACV-AAC valve harness connector. 2. Remove IACV-AAC valve. 쐌 Check IACV-AAC valve resistance.

LC

FE CL SEF202V

Resistance: Approximately 10Ω [at 20°C (68°F)] 쐌 Check plunger for seizing or sticking. 쐌 Check for broken spring. 3. Supply battery voltage between IACV-AAC valve connector terminals. Plunger should move.

MT AT TF

OK or NG

PD

OK

䊳

GO TO 6.

NG

䊳

Replace IACV-AAC valve.

AX 6

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

SU

INSPECTION END

BR ST RS BT HA SC EL

EC-1591

IDX

DTC P0510 CTP SWITCH

VG33ER

Component Description

Component Description

NGEC1326

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 A/T 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 volume control solenoid valve when the throttle position sensor is malfunctioning. SEF505V

CONSULT-II Reference Value in Data Monitor Mode

NGEC1327

Specification data are reference values. MONITOR ITEM CLSD THL/P SW

CONDITION 쐌 Engine: After warming up, idle the engine

SPECIFICATION

Throttle valve: Idle position

ON

Throttle valve: Slightly open

OFF

ECM Terminals and Reference Value

NGEC1328

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 the ECM terminals, such as the ground. TERWIRE MINAL COLOR NO.

28

BR/W

ITEM

Throttle position switch (Closed position)

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Warm-up condition 쐌 Accelerator pedal fully released

BATTERY VOLTAGE (11 - 14V)

[Ignition switch “ON”] 쐌 Accelerator pedal depressed

Approximately 0V

On Board Diagnosis Logic

NGEC1329

Malfunction is detected when battery voltage from the closed throttle position switch is sent to ECM with the throttle valve opened.

POSSIBLE CAUSE 쐌 쐌 쐌

Harness or connectors (The closed throttle position switch circuit is shorted.) Closed throttle position switch Throttle position sensor

EC-1592

NGEC1329S01

DTC P0510 CTP SWITCH

VG33ER DTC Confirmation Procedure

DTC Confirmation Procedure

SEF197Y

Condition

SEF198Y

ON

Throttle valve: Slightly open

OFF

5) 6)

GI MA EM LC

Signal indication

Throttle valve: Idle position

FE

If the result is NG, go to “Diagnostic Procedure”, EC-1595. 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. More than 2.5V

VHCL SPEED SE

More than 5 km/h (3 MPH)

Selector lever

Suitable position

Driving location

Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test.

MT

TF

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1595.

Overall Function Check

CL

AT

THRTL POS SEN

7)

SEF872U

NGEC1330

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 5 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, wait at least 5 seconds and then start engine. 3) Select “CLSD THL/P SW” in “DATA MONITOR” mode. 4) Check the signal under the following conditions.

NGEC1331

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 28 (Closed throttle position switch signal) and ground under the following conditions. At idle: Battery voltage At 2,000 rpm: Approximately 0V 3) If NG, go to “Diagnostic Procedure”, EC-1595.

PD AX SU BR ST RS BT HA SC EL

EC-1593

IDX

DTC P0510 CTP SWITCH

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1332

AEC964A

EC-1594

DTC P0510 CTP SWITCH

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1333

CHECK CLOSED THROTTLE POSITION SWITCH POWER SUPPLY CIRCUIT

GI

1. Turn ignition switch OFF. 2. Disconnect throttle position switch harness connector.

MA EM LC

AEC653A

3. Turn ignition switch ON. 4. Check voltage between terminal 5 and engine ground with CONSULT-II or tester.

FE CL MT AT

SEF715U

Voltage: Battery voltage

TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

PD AX

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness for open or short between throttle position switch and ECM relay 쐌 Harness for open or short between throttle position switch and ECM 䊳

3

Repair harness or connectors.

CHECK CLOSED THROTTLE POSITION SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 28 and throttle position switch terminal 4. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power.

SU BR ST RS BT

OK or NG

HA

OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

SC EL

EC-1595

IDX

DTC P0510 CTP SWITCH

VG33ER

Diagnostic Procedure (Cont’d)

4

CHECK IGNITION TIMING AND ENGINE IDLE SPEED

Check the following items. Refer to “Basic Inspection”, EC-1273.

MTBL0632

with CONSULT-II

䊳

GO TO 5.

without CONSULT-II

䊳

GO TO 6.

5 1. 2. 3. 4. 5.

CHECK CLOSED THROTTLE POSITION SWITCH With CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check indication of “CLSD THL/P SW”. Measurement must be made with closed throttle position switch installed in vehicle.

MTBL0355

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

EC-1596

DTC P0510 CTP SWITCH

VG33ER Diagnostic Procedure (Cont’d)

6 1. 2. 3. 4.

CHECK CLOSED THROTTLE POSITION SWITCH Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect closed throttle position switch harness connector. Check continuity between closed throttle position switch terminals 4 and 5. Resistance measurement must be made with closed throttle position switch installed in vehicle.

GI MA EM LC

FE AEC654A

CL MT MTBL0247

OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 7.

7

AT TF

ADJUST THROTTLE POSITION SWITCH

PD

Check the following items. Refer to “Basic Inspection”, EC-1273.

AX SU BR MTBL0576

If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch.

ST

OK or NG OK (with CONSULT-II)

䊳

GO TO 8.

OK (without CONSULTII)

䊳

GO TO 9.

NG

䊳

Replace throttle position switch.

RS BT HA SC EL

EC-1597

IDX

DTC P0510 CTP SWITCH

VG33ER

Diagnostic Procedure (Cont’d)

8 1. 2. 3. 4. 5.

CHECK THROTTLE POSITION SENSOR With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine (ignition switch OFF). Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Check voltage of “THRTL POS SEN”.

MTBL0230

Voltage measurement must be made with throttle position sensor installed in vehicle. If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-1273. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace throttle position sensor.

9 1. 2. 3. 4.

CHECK 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 23 (Throttle position sensor signal) and ground. Voltage measurement must be made with throttle position sensor installed in vehicle.

MTBL0231

If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-1273. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace throttle position sensor.

10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1598

DTC P0600 A/T CONTROL

VG33ER System Description

System Description

NGEC1334

These circuit lines are used to control the smooth shifting up and down of A/T during the hard acceleration/ deceleration. Voltage signals are exchanged between ECM and TCM (Transmission Control Module).

ECM Terminals and Reference Value

MA NGEC1335

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 the ECM terminals, such as the ground. TERMINAL NO.

GI

EM LC

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

26

PU/W

A/T signal No. 1

[Engine is running] 쐌 Idle speed

Approximately 0 - 1.0V

27

P/B

A/T signal No. 2

[Engine is running] 쐌 Idle speed

Approximately 0 - 1.0V

33

W/G

A/T signal No. 4

[Engine is running] 쐌 Idle speed

Approximately 0 - 1.0V

CL

34

R/Y

A/T signal No. 5

[Engine is running] 쐌 Idle speed

Approximately 8V

MT

35

G/R

A/T signal No. 3

[Engine is running] 쐌 Idle speed

Approximately 0 - 1.0V

FE

AT TF PD AX

On Board Diagnosis Logic

NGEC1336

Malfunction is detected when ECM receives incorrect voltage from TCM (Transmission Control Module) continuously.

POSSIBLE CAUSE 쐌

SU BR

NGEC1336S01

Harness or connectors [The circuit between ECM and TCM (Transmission Control Module) is open or shorted.]

ST RS BT HA SC EL

EC-1599

IDX

DTC P0600 A/T CONTROL

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF058Y

=NGEC1337

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. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine, and rev engine more than 1,000 rpm once, then let it idle for more than 40 seconds. 4) If DTC is detected, go to “Diagnostic Procedure”, EC-1602.

EC-1600

DTC P0600 A/T CONTROL

VG33ER Wiring Diagram

Wiring Diagram

NGEC1338

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC191A

EC-1601

EL IDX

DTC P0600 A/T CONTROL

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1339

CHECK A/T CONTROL INPUT SIGNAL CIRCUIT FOR OPEN

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector and TCM (Transmission Control Module) harness connector.

SEF324V

AEC655A

3. Check harness continuity between ECM terminal 26 and TCM terminal 5, ECM terminal 27 and TCM terminal 6, ECM terminal 33 and TCM terminal 9, ECM terminal 34 and TCM terminal 8, ECM terminal 35 and TCM terminal 7. Refer to Wiring Diagram. Continuity should exist. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and TCM (Transmission Control Module) 䊳

3

Repair harness or connectors.

CHECK A/T CONTROL INPUT SIGNAL CIRCUIT FOR SHORT

1. Check harness continuity between ECM terminal 26 and ground, ECM terminal 27 and ground, ECM terminal 33 and ground, ECM terminal 34 and ground, ECM terminal 35 and ground. Refer to Wiring Diagram. Continuity should not exist. 2. Also check harness for short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-1602

DTC P0600 A/T CONTROL

VG33ER Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and TCM (Transmission Control Module). 䊳

GI

Repair open circuit or short to ground or short to power in harness.

MA 5

CHECK A/T CONTROL SHIELD CIRCUIT FOR OPEN AND SHORT

1. Disconnect harness connectors M58, F28. 2. Check harness continuity between harness connector F28 terminal 19 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

6

Check the following. 쐌 Harness connectors M58, F28 쐌 Joint connectors-1 (if equipped) 쐌 Harness for open between harness connector F28 and engine ground

7

LC

FE

DETECT MALFUNCTIONING PART

䊳

EM

Repair open circuit or short to power in harness or connectors.

CL MT AT

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

TF PD AX SU BR ST RS BT HA SC EL

EC-1603

IDX

DTC P0605 ECM

VG33ER

Component Description

Component Description

NGEC1340

The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the engine.

SEC220B

On Board Diagnosis Logic

NGEC1341

Malfunction is detected when ECM calculation function is malfunctioning.

POSSIBLE CAUSE 쐌

NGEC1341S01

ECM

DTC Confirmation Procedure

NGEC1342

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 Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine. Run engine for at least 2 seconds at idle speed. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1605. With GST Follow the procedure “With CONSULT-II”. 1) 2) 3) 4) 5)

SEF058Y

EC-1604

DTC P0605 ECM

VG33ER Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4. 5.

INSPECTION START

NGEC1343

GI

With CONSULT-II Turn ignition switch ON. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See EC-1604. Is the 1st trip DTC P0605 displayed again?

With GST Turn ignition switch ON. Select MODE 4 with GST. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See EC-1604. 5. Is the 1st trip DTC P0605 displayed again?

MA EM LC

1. 2. 3. 4.

FE Yes or No

Yes

䊳

Replace ECM.

No

䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1605

IDX

DTC P1143, P1163 HO2S1

VG33ER

Component Description

Component Description

NGEC1148

The heated oxygen sensor 1 is placed into the front tube. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NGEC1149

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 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

NGEC1150

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

50

B

Heated oxygen sensor (bank 1) [Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

51

G

Heated oxygen sensor (bank 2) SEF002V

EC-1606

DTC P1143, P1163 HO2S1

VG33ER On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1151

To judge the malfunction, the output from the heated oxygen sensor 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. Malfunction is detected when the maximum and minimum voltage from the sensor are not reached to the specified voltages.

POSSIBLE CAUSE SEF300U

쐌 쐌 쐌 쐌 쐌

Heated oxygen sensor 1 Heated oxygen sensor 1 heater Fuel pressure Injectors Intake air leaks

GI MA EM

NGEC1151S01

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1607

IDX

DTC P1143, P1163 HO2S1

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC1152

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 Before performing following procedure, confirm that battery voltage is more than 11V at idle.

With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine and wait at least 5 seconds. Turn ignition switch “ON” and select “HO2S1 (B1)/(B2) P1143/ P1163” 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 2,800 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.) 1) 2) 3)

SEC704C

EGN SPEED

1,200 - 2,700 rpm

Vehicle speed

Less than 100 km/h (62 MPH)

B/FUEL SCHDL

2.0 - 14.0 msec

Selector lever

Suitable position

SEC705C

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-1609.

SEC706C

EC-1608

DTC P1143, P1163 HO2S1

VG33ER Overall Function Check

Overall Function Check

SEF919UA

NGEC1153

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3) Check one of the following with engine speed held at 2,000 rpm constant under no load. 쐌 The maximum voltage is over 0.6V at least one time. 쐌 The minimum voltage is over 0.1V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-1609.

GI MA EM LC

FE CL MT

Diagnostic Procedure 1

NGEC1154

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

AT TF PD AX SU

LEC657

䊳

2

ST

GO TO 2.

RETIGHTEN HEATED OXYGEN SENSOR 1

RS

Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

BR

GO TO 3.

BT HA SC EL

EC-1609

IDX

DTC P1143, P1163 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

3

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 “CLEAR”.

SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine? Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-1246. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6.

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171, P0174. Refer to EC-1427.

No

䊳

GO TO 4.

EC-1610

DTC P1143, P1163 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

4

CHECK HEATED OXYGEN SENSOR 1 HEATER

1. Stop engine. 2. Check heated oxygen sensor 1 harness protector color.

GI MA EM LC SEF505YB

3. Check resistance between HO2S1 terminals 3 and 1.

FE CL MT AT AEC158A

Resistance: 2.3 - 4.3Ω at 25°C (77°F) 4. Check continuity between HO2S1 (front) terminals 2 and 1, 3 and 2. Continuity should not exist. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

TF PD AX

OK or NG OK (With CONSULT-II)

䊳

GO TO 5.

OK (Without CONSULTII)

䊳

GO TO 6.

NG

䊳

SU BR

Replace malfunctioning heated oxygen sensor 1.

ST RS BT HA SC EL

EC-1611

IDX

DTC P1143, P1163 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 1

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “MANU TRIG” in “DATA MONITOR” mode with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below.

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace malfunctioning heated oxygen sensor 1.

EC-1612

DTC P1143, P1163 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

6

CHECK FRONT HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

GI MA EM LC

SEF796Z

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.

FE CL

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

MT

REPLACE HEATED OXYGEN SENSOR 1

AT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

TF

7

PD AX SU SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

BR ST

Replace malfunctioning heated oxygen sensor 1.

RS BT HA SC EL

EC-1613

IDX

DTC P1143, P1163 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

8

CHECK HO2S1 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. 3. For circuit, refer to “DTC P0134, P0154 HEATED OXYGEN SENSOR 1 (BANK 1)/(BANK 2) (CIRCUIT)”, EC-1396. 4. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 5. Also check harness for short to power. 6. Then reconnect joint connector. OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair open circuit or short to power in harness or connectors.

9

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. For circuit, refer to “DTC P0134, P0154 HEATED OXYGEN SENSOR (BANK 1)/(BANK 2) (CIRCUIT)”, EC-1396. 䊳

INSPECTION END

EC-1614

DTC P1144, P1164 HO2S1

VG33ER Component Description

Component Description

NGEC1155

The heated oxygen sensor 1 is placed into the front tube. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V.

GI MA EM LC

SEF463R

FE CL MT

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

AT

CONDITION

TF

NGEC1156

Specification data are reference values. MONITOR ITEM

SPECIFICATION

HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

AX SU

ECM Terminals and Reference Value

NGEC1157

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 the ECM terminals, such as the ground. TERMINAL NO.

PD

BR ST

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

RS 0 - Approximately 1.0V

50

B

Heated oxygen sensor 1 (Bank 1)

BT [Engine is running] 쐌 After warming up to normal operating temperature and engine speed is 2,000 rpm

51

G

HA

Heated oxygen sensor 1 (Bank 2) SEF002V

SC EL

EC-1615

IDX

DTC P1144, P1164 HO2S1

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1158

To judge the malfunction, the output from the heated oxygen sensor 1 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. Malfunction is detected when the maximum and minimum voltages from the sensor are beyond the specified voltages.

POSSIBLE CAUSE SEF299U

쐌 쐌 쐌 쐌

Heated oxygen sensor 1 Fuel pressure Injectors Heated oxygen sensor 1 heater

EC-1616

NGEC1158S01

DTC P1144, P1164 HO2S1

VG33ER DTC Confirmation Procedure

DTC Confirmation Procedure

=NGEC1159

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

GI MA EM LC

FE CL MT With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine and wait at least 5 seconds. Turn ignition switch ON and select “HO2S1 (B1)/(B2) P1144/ P1164” 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 2,800 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.) 1) 2) 3)

SEC707C

ENG SPEED

1,200 - 2,700 rpm

Vehicle speed

Less than 100 km/h (62 MPH)

B/FUEL SCHDL

2.0 - 14.0 msec

Selector lever

Suitable position

SEC708C

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-1618.

AT TF PD AX SU BR ST RS BT HA SC EL

SEC709C

EC-1617

IDX

DTC P1144, P1164 HO2S1

VG33ER

Overall Function Check

Overall Function Check

SEF919UA

Diagnostic Procedure 1

NGEC1160

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3) Check one of the following with engine speed held at 2,000 rpm constant under no load. 쐌 The maximum voltage is below 0.8V at least one time. 쐌 The minimum voltage is below 0.35V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-1618.

NGEC1161

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC657

䊳

2

GO TO 2.

RETIGHTEN HEATED OXYGEN SENSOR 1

Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳

GO TO 3.

EC-1618

DTC P1144, P1164 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

3

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 “CLEAR”.

GI MA EM LC

SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6. 7. 8.

FE CL

Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-1246. Make sure DTC P0000 is displayed. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine?

MT AT TF PD

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0172, P0175. Refer to EC-1436.

No

䊳

GO TO 4.

AX SU

4

CHECK HO2S 1 CONNECTOR FOR WATER

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

BR ST RS BT SEF505YB

3. Disconnect heated oxygen sensor 1 harness connector. 4. Check connectors for water. Water should not exist.

HA SC

OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair or replace harness or connectors.

EL

EC-1619

IDX

DTC P1144, P1164 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 1 HEATER

Check resistance between HO2S1 terminals 3 and 1.

AEC158A

Resistance: 2.3 - 4.3Ω at 25°C (77°F) Check continuity between HO2S1 terminals 2 and 1, 3 and 2. Continuity should not exist. 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. OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

GO TO 8.

EC-1620

DTC P1144, P1164 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

6

CHECK HEATED OXYGEN SENSOR 1

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “MANU TRIG” in “DATA MONITOR” mode with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen.

GI MA EM LC

FE SEF967Y

5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below.

CL MT AT TF PD

SEF647Y

쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

AX SU BR ST RS SEF648Y

CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BT HA

OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

SC EL

EC-1621

IDX

DTC P1144, P1164 HO2S1

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK HEATED OXYGEN SENSOR 1

Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 50 (bank 1 signal) or 51 (bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load.

SEF796Z

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. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 8.

8

REPLACE HEATED OXYGEN SENSOR 1

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 1 harness protector color.

SEF505YB

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 1.

EC-1622

DTC P1144, P1164 HO2S1

VG33ER Diagnostic Procedure (Cont’d)

9

CHECK HO2S1 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. For circuit, refer to “DTC P0134, P0154 HEATED OXYGEN SENSOR (BANK 1)/(BANK 2) (CIRCUIT)”, EC-1396. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector.

GI MA EM LC

OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

FE

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. For circuit, refer to “DTC P0134, P0154 FRONT HEATED OXYGEN SENSOR (BANK 1)/(BANK 2) (CIRCUIT)”, EC-1396. 䊳

CL

INSPECTION END

MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1623

IDX

DTC P1146, P1166 HO2S2

VG33ER

Component Description

Component Description

SEF327R

NGEC1184

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NGEC1185

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up

Revving engine from idle up to 2,000 rpm LEAN +, RICH

ECM Terminals and Reference Value

NGEC1186

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 the ECM terminals, such as the ground. TERMINAL NO. 56 57

WIRE COLOR

ITEM

CONDITION

OR

Heated oxygen sensor 2 (bank 1)

Y

Heated oxygen sensor 2 (bank 2)

[Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 2,000 rpm

On Board Diagnosis Logic

DATA (DC Voltage)

0 - Approximately 1.0V

NGEC1187

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the minimum voltage of sensor is sufficiently low during the various driving condition such as fuelcut. Malfunction is detected when the minimum voltage from the sensor is not reached to the specified voltage. SEF972Z

EC-1624

DTC P1146, P1166 HO2S2

VG33ER On Board Diagnosis Logic (Cont’d)

POSSIBLE CAUSE 쐌 쐌 쐌 쐌

NGEC1187S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 2 Fuel pressure Injectors

GI MA EM LC

DTC Confirmation Procedure

SEC710C

SEC711C

NGEC1188

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. TESTING CONDITION: Open engine hood before conducting following procedure With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that “COOLANT TEMP/S” is more than 70°C (158°F). 6) Select “HO2S2 (B1)/(B2) P1146/P1166” of “HO2S2” in DTC WORK SUPPORT” mode with CONSULT. 7) Start engine and follow the instructions of CONSULT-II. 8) Make sure that “OK” is displayed after touching “SELF_DIAG RESULTS”. If NG is displayed, refer to “DIAGNOSTIC PROCEDURE”, EC-1629. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. a) Stop engine and cool down “COOLANT TEMP/SE” to less than 70°C (158°F). b) Turn ignition switch ON. c) Select “DATA MONITOR” mode with CONSULT-II. d) Start engine. e) Perform from step 6) again when the “COOLANT TEMP/S” reaches to 70°C (158°F)

FE CL MT AT TF PD AX SU BR ST RS

SEC712C

BT HA SC EL

EC-1625

IDX

DTC P1146, P1166 HO2S2

VG33ER

Overall Function Check

Overall Function Check

SEF922UA

=NGEC1189

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. 4) Check the voltage when racing 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 0.48V 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 “O/D” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-1629.

EC-1626

DTC P1146, P1166 HO2S2

VG33ER Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1190 NGEC1190S01

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC174A

EC-1627

IDX

DTC P1146, P1166 HO2S2

VG33ER

Wiring Diagram (Cont’d)

LEFT BANK

NGEC1190S02

WEC175A

EC-1628

DTC P1146, P1166 HO2S2

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1191

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

LEC657

䊳

FE

GO TO 2.

CL 2

CLEAR THE SELF-LEARNING DATA

MT

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 “CLEAR”.

AT TF PD AX SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine?

SU BR

Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-1246. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6.

ST RS BT HA

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0172, P0175. Refer to EC-1437.

No

䊳

GO TO 3.

SC EL

EC-1629

IDX

DTC P1146, P1166 HO2S2

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 2 harness protector color.

SEC301CA

3. Disconnect corresponding heated oxygen sensor 2 harness connector.

LEC659

4. Disconnect ECM harness connector. 5. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram.

MTBL0951

Continuity should exist. 6. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram.

MTBL0952

Continuity should not exist. 7. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1630

DTC P1146, P1166 HO2S2

VG33ER Diagnostic Procedure (Cont’d)

4

CHECK HO2S GROUND CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power.

GI MA

OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

GO TO 5.

5

EM LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-3 (if equipped) 쐌 Harness for open between heated oxygen sensor 2 and engine ground. 䊳

6

FE

Repair open circuit or short to power in harness or connectors.

CL

CHECK HEATED OXYGEN SENSOR 2

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)/(B2)” as the monitor item with CONSULTII. 4. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

MT AT TF PD AX SU

SEF989RD

“HO2S2 (B1)/(B2)” should be above 0.62V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

BR ST RS BT HA SC EL

EC-1631

IDX

DTC P1146, P1166 HO2S2

VG33ER

Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without 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. Set voltmeter probes between ECM terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (depress and release accelerator pedal as soon as possible)

SEF797ZB

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 “O/D” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

REPLACE HEATED OXYGEN SENSOR 2

1. Stop vehicle and turn ignition switch OFF. 2. Check heated oxygen sensor 2 harness protector color.

SEC301CA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 2.

EC-1632

DTC P1146, P1166 HO2S2

VG33ER Diagnostic Procedure (Cont’d)

9

CHECK HO2S2 SHIELD CIRCUIT FOR OPEN AND SHORT (IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector-3. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector-3. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

CHECK INTERMITTENT INCIDENT

GI MA EM LC

FE

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1633

IDX

DTC P1147, P1167 HO2S2

VG33ER

Component Description

Component Description

SEF327R

NGEC1192

The heated oxygen sensor 2, after three way catalyst, monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NGEC1193

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2)

0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up

Revving engine from idle up to 2,000 rpm LEAN +, RICH

ECM Terminals and Reference Value

NGEC1194

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 the ECM terminals, such as the ground. TERMINAL NO. 56 57

WIRE COLOR

ITEM

CONDITION

OR

Heated oxygen sensor 2 (bank 1)

Y

Heated oxygen sensor 2 (bank 2)

[Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 2,000 rpm

On Board Diagnosis Logic

DATA (DC Voltage)

0 - Approximately 1.0V

NGEC1195

The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the maximum voltage of the sensor is sufficiently high during the various driving condition such as fuel-cut. Malfunction is detected when the maximum voltage from the sensor is not reached to the specified voltage. SEF303UC

EC-1634

DTC P1147, P1167 HO2S2

VG33ER On Board Diagnosis Logic (Cont’d)

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌

NGEC1195S01

Harness or connectors (The sensor circuit is open or shorted.) Heated oxygen sensor 2 Fuel pressure Injectors Intake air leaks

GI MA EM LC

DTC Confirmation Procedure

SEC713C

SEC714C

NGEC1196

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. TESTING CONDITION: Open engine hood before conducting following procedure With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that “COOLANT TEMP/S” is more than 70°C (158°F). 6) Select “HO2S2 (B1)/(B2), P1147/P1167” of “HO2S2” in DTC WORK SUPPORT” mode with CONSULT-II. 7) Start engine and follow the instructions of CONSULT-II. 8) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If NG is displayed, refer to “DIAGNOSTIC PROCEDURE”, EC-1639. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. a) Stop engine and cool down “COOLANT TEMP/SE” to less than 70°C (158°F). b) Turn ignition switch ON. c) Select “DATA MONITOR” mode with CONSULT-II. d) Start engine. e) Perform from step 6) again when the “COOLANT TEMP/S” reaches to 70°C (158°F)

FE CL MT AT TF PD AX SU BR ST RS

SEC715C

BT HA SC EL

EC-1635

IDX

DTC P1147, P1167 HO2S2

VG33ER

Overall Function Check

Overall Function Check

SEF922UA

=NGEC1197

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. 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 terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. 4) Check the voltage when racing 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 0.62V 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 “O/D” OFF (A/T). The voltage should be above 0.62V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-1639.

EC-1636

DTC P1147, P1167 HO2S2

VG33ER Wiring Diagram

Wiring Diagram RIGHT BANK

NGEC1198 NGEC1198S01

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL WEC174A

EC-1637

IDX

DTC P1147, P1167 HO2S2

VG33ER

Wiring Diagram (Cont’d)

LEFT BANK

NGEC1198S02

WEC175A

EC-1638

DTC P1147, P1167 HO2S2

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1199

RETIGHTEN GROUND SCREWS

GI

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

MA EM LC

LEC657

䊳

FE

GO TO 2.

CL 2

CLEAR THE SELF-LEARNING DATA

MT

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 “CLEAR”.

AT TF PD AX SEF968Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine?

SU BR

Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure 1st trip DTC P0102 is displayed. Erase the 1st trip DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-1246. 7. Make sure DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6.

ST RS BT HA

Yes or No Yes

䊳

Perform trouble diagnosis for DTC P0171, P0174. Refer to EC-1428.

No

䊳

GO TO 3.

SC EL

EC-1639

IDX

DTC P1147, P1167 HO2S2

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Check heated oxygen sensor 2 harness protector color.

SEC301CA

3. Disconnect corresponding heated oxygen sensor 2 harness connector. 4. Disconnect ECM harness connector. 5. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram.

SEC661C

Continuity should exist. 6. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram.

SEC662C

Continuity should not exist. 7. Also check harness for short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1640

DTC P1147, P1167 HO2S2

VG33ER Diagnostic Procedure (Cont’d)

4

CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power.

GI MA

OK or NG OK (With CONSULT-II)

䊳

GO TO 6.

OK (Without CONSULTII)

䊳

GO TO 7.

NG

䊳

GO TO 5.

5

EM LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Joint connector-3 (if equipped) 쐌 Harness for open between heated oxygen sensor 2 and engine ground. 䊳

6

FE

Repair open circuit or short to power in harness or connectors.

CL

CHECK HEATED OXYGEN SENSOR 2

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)/(B2)” as the monitor item with CONSULTII. 4. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

MT AT TF PD AX SU

SEF989RD

“HO2S2 (B1)/(B2)” should be above 0.62V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V at least once when the “FUEL INJECTION” is −25%. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

BR ST RS

OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

BT HA SC EL

EC-1641

IDX

DTC P1147, P1167 HO2S2

VG33ER

Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 2 Without 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. Set voltmeter probes between ECM terminal 56 (bank 1 signal) or 57 (bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (depress and release accelerator pedal as soon as possible)

SEF797ZB

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 “O/D” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. 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. OK or NG OK

䊳

GO TO 9.

NG

䊳

GO TO 8.

8

REPLACE HEATED OXYGEN SENSOR 2

1. Stop vehicle and turn ignition switch OFF. 2. Check heated oxygen sensor 2 harness protector color.

SEC301CA

CAUTION: Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 䊳

Replace malfunctioning heated oxygen sensor 2.

EC-1642

DTC P1147, P1167 HO2S2

VG33ER Diagnostic Procedure (Cont’d)

9

CHECK HO2S2 SHIELD CIRCUIT FOR OPEN AND SHORT(IF EQUIPPED)

1. Turn ignition switch OFF. 2. Disconnect joint connector. 3. Check the following. 쐌 Continuity between joint connector terminal 1 and ground 쐌 Joint connector (Refer to EL-250, “HARNESS LAYOUT”.) Continuity should exist. 4. Also check harness for short to power. 5. Then reconnect joint connector. OK or NG OK

䊳

GO TO 10.

NG

䊳

Repair open circuit or short to power in harness or connectors.

10

CHECK INTERMITTENT INCIDENT

GI MA EM LC

FE

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1643

IDX

DTC P1148, P1168 CLOSED LOOP CONTROL

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1347

★ The closed loop control has the one trip detection logic. Malfunction is detected when the closed loop control function for right bank does not operate even when vehicle is driving in the specified condition, the closed loop control function for left bank does not operate even when vehicle is driving in the specified condition.

POSSIBLE CAUSE 쐌 쐌 쐌

NGEC1347S01

The heated oxygen sensor 1 circuit is open or shorted. Heated oxygen sensor 1 Heated oxygen sensor 1 heater

DTC Confirmation Procedure

NGEC1348

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 5 seconds before conducting the next test. TESTING CONDITION: 쐌 Never raise engine speed above 2,800 rpm during the “DTC Confirmation Procedure”. If the engine speed limit is exceeded, retry the procedure from step 2. 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

With CONSULT-II Start engine and warm it up to normal operating temperature. Select “DATA MONITOR” mode with CONSULT-II. Hold engine speed at 2,000 rpm and check one of the following. 쐌 “HO2S1 (B1)/(B2)” voltage should go above 0.70V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage should go below 0.21V at least once. If the check result is NG, perform “Diagnosis Procedure”, EC-1645.

1) 2) 3)

SEF967Y

EC-1644

DTC P1148, P1168 CLOSED LOOP CONTROL

VG33ER

DTC Confirmation Procedure (Cont’d)

4) 5)

If the check result is OK, perform the following step. Let engine idle at least 5 minutes. Maintain the following condition at least 50 consecutive seconds.

B/FUEL SCHDL

2.0 msec or more

ENG SPEED

1,500 rpm or more

Selector lever

Suitable position

VHCL SPEED SE

More than 71 km/h (44 MPH)

6)

GI MA EM

During this test, P0134 and/or P0154 may be displayed on CONSULT-II screen. If DTC is detected, go to “Diagnostic Procedure”, EC-1645.

LC

FE CL MT

Overall Function Check

SEF919UA

NGEC1349

Use this procedure to check the overall function of the closed loop control. During this check, a 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 50 [heated oxygen sensor 1 (bank 1) signal] or 51 [heated oxygen sensor 1 (bank 2) signal] and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no-load. 쐌 The voltage should go above 0.70V at least once. 쐌 The voltage should go below 0.21V at least once. 4) If NG, go to “Diagnostic Procedure”, EC-1645.

AT TF PD AX SU BR ST RS

Diagnostic Procedure

NGEC1350

BT

Perform trouble diagnosis for “DTC P0133, P0153”, EC-1382.

HA SC EL

EC-1645

IDX

DTC P1217 ENGINE OVER TEMPERATURE

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1354

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. Malfunction is detected when engine coolant temperature reaches an abnormally high temperature. CAUTION: When a malfunction is indicated be sure to replace the coolant, follow the procedure in “Changing Engine Coolant”, “ENGINE MAINTENANCE”, MA-28. Also, replace the engine oil. 1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pouring coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to “Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-15. 2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.

POSSIBLE CAUSE 쐌 Cooling fan (Crankshaft driven) 쐌 Radiator hose 쐌 Radiator 쐌 Radiator cap 쐌 Water pump 쐌 Thermostat For more information, refer to OVERHEATING”, EC-1650.

Overall Function Check

SEF621W

NGEC1354S01

“MAIN

12

CAUSES

OF

NGEC1355

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-1647. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-1647. 3) Start engine. 4) Make sure that cooling fan (crankshaft driven) operates. 5) If NG, go to “Diagnostic Procedure”, EC-1647.

EC-1646

DTC P1217 ENGINE OVER TEMPERATURE

VG33ER

Overall Function Check (Cont’d)

1)

2)

3)

4)

Without CONSULT-II 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-1647. Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-1647. Start engine and make sure that cooling fan (crankshaft driven) operates. Be careful not to overheat engine. If NG, go to “Diagnostic Procedure”, EC-1647.

GI MA EM LC

FE CL MT

Diagnostic Procedure 1

NGEC1357

CHECK COOLING FAN (CRANKSHAFT DRIVEN) OPERATION

Start engine and make sure that cooling fan (crankshaft driven) operates.

TF

OK or NG OK

䊳

GO TO 2.

NG

䊳

Check cooling fan (crankshaft driven). Refer to LC-16, “Cooling Fan”.

2

AT

PD AX

CHECK COOLING SYSTEM FOR LEAK

Apply pressure to the cooling system with a tester, and check if the pressure drops. CAUTION: Higher than the specified pressure may cause radiator damage. Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi)

SU BR ST RS BT SLC754A

Pressure should not drop. OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following for leak 쐌 Hose 쐌 Radiator 쐌 Water pump Refer to “Water Pump”, LC-29.

EC-1647

HA SC EL IDX

DTC P1217 ENGINE OVER TEMPERATURE

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK RADIATOR CAP

Apply pressure to cap with a tester and check radiator cap relief pressure.

SLC755A

Radiator cap relief pressure: 59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi) OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace radiator cap.

4

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 10 mm/90°C (0.39 in/194°F) 3. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to “Thermostat”, LC-13. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace thermostat

EC-1648

DTC P1217 ENGINE OVER TEMPERATURE

VG33ER

Diagnostic Procedure (Cont’d)

5

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Check resistance as shown in the figure.

GI MA EM LC SEF152P



FE CL MTBL0229

MT AT TF PD SEF012P

OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace engine coolant temperature sensor.

6

AX SU BR

CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-1650. 䊳

ST

INSPECTION END

RS BT HA SC EL

EC-1649

IDX

DTC P1217 ENGINE OVER TEMPERATURE

VG33ER

Main 12 Causes of Overheating

Main 12 Causes of Overheating Engine

Step

Inspection item

OFF

1

쐌 쐌 쐌 쐌

2

Equipment

Standard

NGEC1358

Reference page

쐌 Visual

No blocking

쐌 Coolant mixture

쐌 Coolant tester

50 - 50% coolant mixture See “RECOMMENDED FLUIDS AND LUBRICANTS”,MA-13.

3

쐌 Coolant level

쐌 Visual

Coolant up to MAX level in reservoir tank and radiator filler neck

See “Changing Engine Coolant”, “ENGINE MAINTENANCE”, MA-28.

4

쐌 Radiator cap

쐌 Pressure tester

59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi) (Limit)

See “System Check”, “ENGINE COOLING SYSTEM”, LC-28.

ON*1

5

쐌 Coolant leaks

쐌 Visual

No leaks

See “System Check”, “ENGINE COOLING SYSTEM”, LC-29.

ON*1

6

쐌 Thermostat

쐌 Touch the upper and lower radiator hoses

Both hoses should be hot

See “Thermostat” and “Radiator”, “ENGINE COOLING SYSTEM”, LC-31, LC-32.

ON*1

7

쐌 Cooling fan (Crankshaft driven)

쐌 Visual

Operating

See LC-34, “Cooling Fan”.

OFF

8

쐌 Combustion gas leak

쐌 Color checker chemical tester 4 Gas analyzer

Negative

—

ON*2

9

쐌 Coolant temperature gauge

쐌 Visual

Gauge less than 3/4 when driving

—

쐌 Coolant overflow to reservoir tank

쐌 Visual

No overflow during driving and idling

See “Changing Engine Coolant”, “ENGINE MAINTENANCE”, MA-28.

Blocked Blocked Blocked Blocked

radiator condenser radiator grille bumper

—

OFF*3

10

쐌 Coolant return from 쐌 Visual reservoir tank to radiator

Should be initial level in reservoir tank

See “ENGINE MAINTENANCE”, MA-26.

OFF

11

쐌 Cylinder head

0.1 mm (0.004 in) Maximum distortion (warping)

See “Inspection”, “CYLINDER HEAD DISTORTION”, EM-96.

12

쐌 Cylinder block and pis- 쐌 Visual tons

No scuffing on cylinder walls or piston

See “Inspection”, “CYLINDER BLOCK DISTORTION AND WEAR”, EM-117.

쐌 Straight gauge feeler gauge

*1: Engine running at 3,000 rpm for 10 minutes. *2: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *3: After 60 minutes of cool down time. For more information, refer to “Engine Cooling System”, “OVERHEATING CAUSE ANALYSIS”, LC-35.

EC-1650

DTC P1336 CKP SENSOR (OBD)

VG33ER Component Description

Component Description

SEF804Z

NGEC1366

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.

GI MA EM LC

FE CL MT

WEC549

ECM Terminals and Reference Value

NGEC1367

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (AC Voltage) 1 - 2V (AC range)

AT TF PD AX SU

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed

BR SEF690W

47

L

Crankshaft position sensor (OBD)

ST

3 - 4V (AC range)

RS [Engine is running] 쐌 Engine speed is 2,000 rpm

BT SEF691W

HA SC EL

EC-1651

IDX

DTC P1336 CKP SENSOR (OBD)

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1368

Malfunction is detected when a chipping of the flywheel or drive plate gear tooth (cog) is detected by the ECM.

POSSIBLE CAUSE 쐌 쐌 쐌

NGEC1368S01

Harness or connectors Crankshaft position sensor (OBD) Drive plate/Flywheel

DTC Confirmation Procedure

NGEC1369

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 Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 2 minutes at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1654. With GST Follow the procedure “With CONSULT-II”. 1)

SEF058Y

EC-1652

DTC P1336 CKP SENSOR (OBD)

VG33ER Wiring Diagram

Wiring Diagram

NGEC1370

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC190A

EC-1653

EL IDX

DTC P1336 CKP SENSOR (OBD)

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1371

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF. 2. Loosen and retighten engine ground screws.

LEC657

䊳

2

GO TO 2.

CHECK CKPS (OBD) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.

WEC549

2. Check continuity between ECM terminal 47 and CKPS (OBD) terminal 2. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Harness for open or short between ECM and crankshaft position sensor (OBD) 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1654

DTC P1336 CKP SENSOR (OBD)

VG33ER Diagnostic Procedure (Cont’d)

4

CHECK CKPS (OBD) GROUND CIRCUIT FOR OPEN AND SHORT

1. Reconnect ECM harness connectors. 2. Check harness continuity between CKPS (OBD) terminal 1 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power.

GI MA

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

EM LC

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Joint connector-4 (if equipped) 쐌 Harness for open between crankshaft position sensor (OBD) and ECM 䊳

6

Repair open circuit or short to ground or short to power in harness or connectors.

FE CL

CHECK IMPROPER INSTALLATION

1. Loosen and retighten the fixing bolt of the crankshaft position sensor (OBD). 2. Perform “DTC Confirmation Procedure”, EC-1652 again.

MT

Is a 1st trip DTC P1336 detected? Yes

䊳

GO TO 7.

No

䊳

INSPECTION END

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1655

IDX

DTC P1336 CKP SENSOR (OBD)

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK 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. Check resistance as shown in the figure.

SEF504V

Resistance: Approximately 512 - 632Ω [at 20°C (68°F)] OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace crankshaft position sensor (OBD).

8

CHECK CKPS (OBD) SHIELD CIRCUIT FOR OPEN AND SHORT

1. Disconnect harness connectors F38, F102. 2. Check harness continuity between harness connector F38 terminal 7 and engine ground. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 10.

NG

䊳

GO TO 9.

9

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Joint connector-1 (if equipped) 쐌 Harness for open between harness connector F38 and engine ground 䊳

Repair open circuit or short to power in harness or connectors.

EC-1656

DTC P1336 CKP SENSOR (OBD)

VG33ER Diagnostic Procedure (Cont’d)

10

CHECK GEAR TOOTH

Visually check for chipping flywheel or drive plate gear tooth (cog).

GI

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace the flywheel or drive plate.

11

MA EM

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1657

IDX

DTC P1442 EVAP CONTROL SYSTEM

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1372

NOTE: If DTC P1442 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-1679.) This diagnosis detects leaks in the EVAP purge line using of vapor pressure in the fuel tank. The EVAP canister vent control valve is closed to shut the EVAP purge line. The vacuum cut valve bypass valve will then be opened to clear the line between the fuel tank and the EVAP canister purge volume control solenoid valve. The EVAP control system pressure sensor can now monitor the pressure inside the fuel tank. If pressure increases, the PCM will check for leaks in the line between the vacuum cut valve and EVAP canister purge volume control solenoid valve.

SEC666C

Malfunction is detected when EVAP control system has a leak, EVAP control system does not operate properly. CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC1372S01

Incorrect fuel tank vacuum relief valve Incorrect fuel filler cap used Fuel filler cap remains open or fails to close Foreign matter caught in fuel filler cap Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve Foreign matter caught in EVAP canister vent control valve EVAP canister EVAP purge line (pipe and rubber tube) leaks EVAP purge line rubber tube bent

EC-1658

DTC P1442 EVAP CONTROL SYSTEM

VG33ER

On Board Diagnosis Logic (Cont’d)

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

Blocked or bent rubber tube to EVAP control system pressure sensor Loose or disconnected rubber tube EVAP canister vent control valve and the circuit EVAP canister purge volume control solenoid valve Absolute pressure sensor Fuel tank temperature sensor O-ring of EVAP canister vent control valve is missing or damaged Water separator EVAP canister is saturated with water Fuel level sensor and the circuit EVAP control system pressure sensor Refueling control valve ORVR system leaks Foreign matter caught in EVAP canister purge volume control solenoid valve

GI MA EM LC

FE CL MT

DTC Confirmation Procedure

NGEC1373

Refer to “P0456, P1456 EVAP CONTROL SYSTEM (VERY SMALL LEAK) (NEGATIVE PRESSURE)”, EC-1556.

AT TF PD AX

Diagnostic Procedure

NGEC1374

Refer to “P0456, P1456 EVAP CONTROL SYSTEM (VERY SMALL LEAK) (NEGATIVE PRESSURE)”, EC-1556.

SU BR ST RS BT HA SC EL

EC-1659

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

Description

Description

NGEC1379

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft 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

Throttle position switch

Closed throttle position

Heated oxygen sensors 1 (front)

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Fuel tank temperature sensor

Fuel temperature in fuel tank

Vehicle speed sensor

Vehicle speed

NGEC1379S01

ECM function

Actuator

EVAP canEVAP canister purge volume ister purge control solenoid valve flow control

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

NGEC1379S02

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

NGEC1380

Specification data are reference values. MONITOR ITEM

PURG VOL C/V

CONDITION 쐌 쐌 쐌 쐌

Engine: After warming up Air conditioner switch OFF Shift lever: “N” No-load

SPECIFICATION

Idle (Vehicle stopped)

0%

2,000 rpm

—

EC-1660

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

ECM Terminals and Reference Value

ECM Terminals and Reference Value

NGEC1381

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

4

OR/B

ITEM

ECM relay (Self shutoff)

CONDITION

DATA (DC Voltage)

MA EM

[Engine is running] [Ignition switch OFF] 0 - 1.5V 쐌 For a few seconds after turning ignition switch OFF [Ignition switch OFF] 쐌 A few seconds passed after turning ignition switch OFF

GI

LC

BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V)

FE CL

[Engine is running] 쐌 Idle speed

MT 5

R/Y

EVAP canister purge volume control solenoid valve

SEF994U

AT

BATTERY VOLTAGE (11 - 14V)

TF [Engine is running] 쐌 Engine speed is 2,000 rpm

PD SEF995U

67

B/P

72

B/P

117

B/P

Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE (11 - 14V)

Current return

[Engine is running] 쐌 Idle speed

BATTERY VOLTAGE (11 - 14V)

AX SU BR ST RS

On Board Diagnosis Logic

NGEC1382

Malfunction is detected when the canister purge flow is detected during the specified driving conditions, even when EVAP canister purge volume control solenoid valve is completely closed.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌

NGEC1382S01

EVAP control system pressure sensor EVAP canister purge volume control solenoid valve (The valve is stuck open.) EVAP canister vent control valve EVAP canister

EC-1661

BT HA SC EL IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

DTC Confirmation Procedure

쐌

Hoses (Hoses are connected incorrectly or clogged.)

DTC Confirmation Procedure

NGEC1383

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. TESTING CONDITION: Always perform test at a temperature of 5°C (41°F) or more.

1) 2) 3) 4) 5) 6) SEF205Y

7)

1) 2) 3) 4) 5) SEF206Y

With CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 5 seconds. Turn ignition switch ON. Select “PURG VOL CN/V P1444” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Start engine and let it idle until “TESTING” on CONSULT-II changes to “COMPLETED”. (It will take for approximately 10 seconds.) 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-1664. With GST Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 5 seconds. Start engine and let it idle for at least 20 seconds. Select “MODE 7” with GST. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1664.

SEF237Y

EC-1662

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER Wiring Diagram

Wiring Diagram

NGEC1384

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC813

EC-1663

EL IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1385

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector.

AEC652A

3. Turn ignition switch ON. 4. Check voltage between terminal 1 and engine ground with CONSULT-II or tester.

SEF646W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F36, M81 쐌 Harness connectors M65, E43 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM relay 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM 䊳

3

Repair harness or connectors.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 5 and EVAP canister purge volume ocntrol solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

EC-1664

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M81, F36 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM 䊳

GI MA

Repair open circuit or short to ground or short to power in harness or connectors.

EM 5

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

Check disconnection or improper connection of hose connected to EVAP control system pressure sensor.

LC

OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair it.

6

FE

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

CL MT AT TF AEC651A

2. Check connectors for water. Water should not exist.

PD OK or NG

OK

䊳

GO TO 7.

NG

䊳

Replace EVAP control system pressure sensor.

AX SU BR ST RS BT HA SC EL

EC-1665

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

Diagnostic Procedure (Cont’d)

7 1. 2. 3. 4. 5.

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR Remove EVAP control system pressure sensor with its harness connector connected. Remove hose from EVAP control system pressure sensor. Turn ignition switch ON. Use pump to apply vacuum and pressure to EVAP control system pressure sensor as shown in figure. Check input voltage between ECM terminal 62 and ground.

SEC649C

CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or over 101.3 kPa (760 mmHg, 29.92 inHg) of pressure. 쐌 Discard and EVAP control system pressure 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. OK or NG OK (with CONSULT-II)

䊳

GO TO 8.

OK (without CONSULTII)

䊳

GO TO 9.

NG

䊳

Replace EVAP control system pressure sensor.

EC-1666

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

Diagnostic Procedure (Cont’d)

8

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

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.

GI MA EM LC

SEF985Y

If OK, inspection end. If NG, go to following step. 3. Check air passage continuity.

FE CL MT AT TF

SEF660U

PD AX MTBL0241

If NG, replace the EVAP canister purge volume control solenoid valve.

SU

OK or NG

BR

OK

䊳

GO TO 10.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

ST RS BT HA SC EL

EC-1667

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

Diagnostic Procedure (Cont’d)

9

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

Without CONSULT-II Check air passage continuity.

SEF661U

MTBL0242

If NG, replace the EVAP canister purge volume control solenoid valve. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP canister purge volume control solenoid valve.

EC-1668

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

Diagnostic Procedure (Cont’d)

10

CHECK EVAP CANISTER VENT CONTROL VALVE

Check air passage continuity. With CONSULT-II Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

GI MA EM LC

SEF991Y

FE

Without CONSULT-II

CL MT MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

AT TF PD AX AEC783A

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP canister vent control valve.

11

SU BR ST

CHECK RUBBER TUBE

Check for obstructed rubber tube connected to EVAP canister vent control valve.

RS

OK or NG

BT

OK

䊳

GO TO 12.

NG

䊳

Clean, repair or replace rubber tube.

HA SC EL

EC-1669

IDX

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

Diagnostic Procedure (Cont’d)

12 1. 2. 3. 4.

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 13.

NG

䊳

Replace water separator.

13

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

SEF596U

Yes or No Yes

䊳

GO TO 14.

No

䊳

GO TO 16.

14

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 16.

NG

䊳

GO TO 15.

EC-1670

DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

VG33ER

Diagnostic Procedure (Cont’d)

15

DETECT MALFUNCTIONING PART

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

16

Repair hose or replace EVAP canister.

GI MA EM

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1671

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Component Description

Component Description

SEF032W

NGEC1386

The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid valve responds to signals from the ECM. When the ECM sends an ON signal, the coil in the solenoid valve is energized. A plunger will then move to seal the canister vent. The ability to seal the vent is necessary for the on board diagnosis of other evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis.

SEF143S

CONSULT-II Reference Value in Data Monitor Mode

NGEC1387

Specification data are reference values. MONITOR ITEM VENT CONT/V

CONDITION

SPECIFICATION

쐌 Ignition switch: ON

OFF

ECM Terminals and Reference Value

NGEC1388

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 the ECM terminals, such as the ground. TERMINAL NO. 108

WIRE COLOR R/G

ITEM EVAP canister vent control valve

CONDITION

[Ignition switch ON]

EC-1672

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

=NGEC1389

Malfunction is detected when EVAP canister vent control valve remains closed under specified driving conditions.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌

MA EM LC

DTC Confirmation Procedure

SEF201Y

NGEC1389S01

EVAP canister vent control valve EVAP control system pressure sensor and the circuit Blocked rubber tube to EVAP canister vent control valve Water separator EVAP canister is saturated with water.

GI

NGEC1390

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 5 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) Drive vehicle at a speed of approximately 80 km/h (50 MPH) for a maximum of 15 minutes. NOTE: If a malfunction exists, NG result may be displayed quicker. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1675. With GST Follow the procedure “With CONSULT-II”.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1673

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1391

WEC006A

EC-1674

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1392

CHECK RUBBER TUBE

GI

1. Turn ignition switch OFF. 2. Check obstructed rubber tube connected to EVAP canister vent control valve.

MA EM LC

SEF143S

FE

OK or NG OK

䊳

GO TO 2.

NG

䊳

Clean, repair or replace rubber tube.

2 1. 2. 3. 4.

CL MT

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

AT TF PD AX SU SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 3.

NG

䊳

Replace water separator.

BR ST RS BT HA SC EL

EC-1675

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK EVAP CANISTER VENT CONTROL VALVE AND O-RING

Check air passage continuity. With CONSULT-II Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

SEF991Y

Without CONSULT-II

MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

AEC783A

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace EVAP canister vent control valve and O-ring.

EC-1676

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure (Cont’d)

4

CHECK IF EVAP CANISTER SATURATED WITH WATER

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

GI MA EM LC

SEF596U

Yes or No Yes

䊳

GO TO 5.

No

䊳

GO TO 7.

5

CL

CHECK EVAP CANISTER

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

6

MT AT TF

DETECT MALFUNCTIONING PART

PD

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

FE

AX

Repair hose or replace EVAP canister.

SU 7

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

Check disconnection or improper connection of hose connected to EVAP control system pressure sensor.

BR

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair it.

ST RS BT HA SC EL

EC-1677

IDX

DTC P1446 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure (Cont’d)

8

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

AEC651A

2. Check connectors for water. Water should not exist. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace EVAP control system pressure sensor.

9

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR FUNCTION

Refer to “DTC Confirmation Procedure” for DTC P0452, or P0453, EC-1533. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1678

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Component Description

Component Description

SEF032W

NGEC1398

NOTE: If DTC P1448 is displayed with P0442, perform trouble diagnosis for DTC P1448 first. The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid valve responds to signals from the ECM. When the ECM sends an ON signal, the coil in the solenoid valve is energized. A plunger will then move to seal the canister vent. The ability to seal the vent is necessary for the on board diagnosis of other evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis.

GI MA EM LC

FE CL MT

SEF143S

CONSULT-II Reference Value in Data Monitor Mode

AT

CONDITION

TF

NGEC1399

Specification data are reference values. MONITOR ITEM VENT CONT/V

SPECIFICATION

쐌 Ignition switch: ON

OFF

PD

ECM Terminals and Reference Value

NGEC1400

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 the ECM terminals, such as the ground. TERMINAL NO. 108

WIRE COLOR R/G

ITEM EVAP canister vent control valve

CONDITION

[Ignition switch ON]

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

AX SU BR ST RS

On Board Diagnosis Logic

NGEC1401

Malfunction is detected when EVAP canister vent control valve remains opened under specified driving conditions.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌

HA

NGEC1401S01

EVAP canister vent control valve EVAP control system pressure sensor and circuit Blocked rubber tube to EVAP canister vent control valve Water separator EVAP canister is saturated with water. Vacuum cut valve

EC-1679

BT

SC EL IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC1402

NOTE: 쐌 If DTC P1448 is displayed with P0442, perform trouble diagnosis for DTC P1448 first. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 5 seconds before conducting the next test.

SEC716C

With CONSULT-II TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is less than 3/4 full and vehicle is placed on flat level surface. 쐌 Always perform test at a temperature of 0 to 30°C (32 to 86°F). 쐌 It is better that the fuel level is low. 1) Turn ignition switch ON. 2) Turn ignition switch OFF and wait at least 5 seconds. 3) Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. 4) Make sure that the following conditions are met. COOLAN TEMP/S

0 - 32°C (32 - 90°F)

INT/A TEMP SE

More than 0°C (32°F)

5)

SEC717C

Select “EVAP SML LEAK P0442” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-1273. 6) Make sure that “OK” is displayed. If “NG” is displayed, go to the following step. NOTE: Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. 7) Stop engine and wait at least 5 seconds, then turn ON. 8) Disconnect hose from water separator. 9) Select “VENT CONTROL/V” of “ACTIVE TEST” mode with CONSULT-II. 10) Touch ON and OFF alternately.

SEC719C

11) Make sure the following. Condition VENT CONTROL/V

Air passage continuity between A and B

ON

No

OFF

Yes

If the result is NG, go to “Diagnostic Procedure”, EC-1683. If the result is OK, go to “Diagnostic Procedure” for DTC P0442, EC-1505. SEF013Z

EC-1680

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Overall Function Check

Overall Function Check

NGEC1403

Use this procedure to check the overall function of the EVAP canister vent control valve circuit. During this check, a DTC might not be confirmed. Without CONSULT-II 1) Disconnect hose from water separator. 2) Disconnect EVAP canister vent control valve harness connector. 3) Verify the following. Condition

Air passage continuity

12V direct current supply between terminals 1 and 2

No

No supply

Yes

AEC783A

If the result is NG, go to “Diagnostic Procedure”, EC-1683. If the result is OK, go to “Diagnostic Procedure” for DTC P0442, EC-1505.

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1681

IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1404

WEC006A

EC-1682

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1405

CHECK RUBBER TUBE

GI

1. Turn ignition switch OFF. 2. Check obstructed rubber tube connected to EVAP canister vent control valve.

MA EM LC

SEF143S

FE

OK or NG OK

䊳

GO TO 2.

NG

䊳

Clean, repair or replace rubber tube.

2 1. 2. 3. 4.

CL MT

CHECK WATER SEPARATOR Check Check Check Check

visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged.

AT TF PD AX SU SEF829T

5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK

䊳

GO TO 3.

NG

䊳

Replace water separator.

BR ST RS BT HA SC EL

EC-1683

IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK EVAP CANISTER VENT CONTROL VALVE AND O-RING

Check air passage continuity. With CONSULT-II Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

SEF991Y

Without CONSULT-II

MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

AEC783A

Make sure new O-ring is installed properly. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace EVAP canister vent control valve and O-ring.

EC-1684

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure (Cont’d)

4

CHECK VACUUM CUT VALVE

Check vacuum cut valve as follows:

GI MA EM LC SEF379Q

1. 2. 3. 4. 5. 6. 7.

Plug port C and D with fingers. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Open port C and D. Blow air in port A check that air flows freely out of port C. Blow air in port B check that air flows freely out of port D.

FE CL

OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace vacuum cut valve.

5

MT AT

CHECK IF EVAP CANISTER SATURATED WITH WATER

TF

1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister.

PD AX SU BR SEF596U

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 8.

6

ST RS

CHECK EVAP CANISTER

BT

Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace the EVAP canister.

HA SC EL

EC-1685

IDX

DTC P1448 EVAP CANISTER VENT CONTROL VALVE

VG33ER

Diagnostic Procedure (Cont’d)

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳

8

Repair hose or replace EVAP canister.

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair it.

9

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

AEC651A

2. Check connectors for water. Water should not exist. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

10

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR FUNCTION

Refer to “DTC Confirmation Procedure” for DTC P0452, P0453, EC-1533. OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP control system pressure sensor.

11

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1686

DTC P1464 FUEL LEVEL SENSOR

VG33ER Component Description

Component Description

NGEC1406

The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the ECM. It consists of two parts, one is mechanical float and the other side is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float.

GI MA EM LC

SEF800Z

ECM Terminals and Reference Value

NGEC1407

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)

FE CL

46

OR/B

Fuel level sensor

[Ignition switch “ON”]

Approximately 0 - 4.8V Output voltage varies with fuel level.

MT

66

B

Fuel level sensor ground

[Engine is running] 쐌 Idle speed

Approximately 0V

AT TF PD AX

On Board Diagnosis Logic

NGEC1408

ECM receives two signals from the fuel level sensor. One is fuel level sensor power supply circuit, and the other is fuel level sensor ground circuit. This diagnosis indicates the latter to detect open circuit malfunction. Malfunction is detected when a high voltage from the sensor is sent to ECM.

POSSIBLE CAUSE 쐌

BR ST

NGEC1408S01

Fuel level sensor circuit (The fuel level sensor circuit is open or shorted.)

DTC Confirmation Procedure

SU

RS

NGEC1409

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.

BT HA SC EL

EC-1687

IDX

DTC P1464 FUEL LEVEL SENSOR

VG33ER

DTC Confirmation Procedure (Cont’d)

WITH CONSULT-II 1) 2) 3) 4)

NGEC1409S01

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”, EC-1690.

WITH GST Follow the procedure “WITH CONSULT-II” above. SEF195Y

EC-1688

NGEC1409S02

DTC P1464 FUEL LEVEL SENSOR

VG33ER Wiring Diagram

Wiring Diagram

NGEC1410

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC998

EC-1689

EL IDX

DTC P1464 FUEL LEVEL SENSOR

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

CHECK FUEL LEVEL SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 66 and body ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

1. Check the following. 쐌 Harness connectors F36, M81 쐌 Harness for open and short between ECM and body ground 䊳

3

Replace open circuit or short to power in harness or connectors.

CHECK FUEL LEVEL SENSOR

Refer to EL-89, “FUEL LEVEL SENSOR UNIT CHECK”. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace fuel level sensor unit.

4

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312 OK or NG 䊳

INSPECTION END

EC-1690

=NGEC1411

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33ER Description

Description

NGEC1412

COMPONENT DESCRIPTION

SEF186S

NGEC1412S01

The vacuum cut valve and vacuum cut valve bypass valve are installed in parallel on the EVAP purge line between the fuel tank and the EVAP canister. The vacuum cut valve prevents the intake manifold vacuum from being applied to the fuel tank. The vacuum cut valve bypass valve is a solenoid type valve and generally remains closed. It opens only for on board diagnosis. The vacuum cut valve bypass valve responds to signals from the ECM. When the ECM sends an ON (ground) signal, the valve is opened. The vacuum cut valve is then bypassed to apply intake manifold vacuum to the fuel tank.

EVAPORATIVE EMISSION SYSTEM DIAGRAM

GI MA EM LC

NGEC1412S02

FE CL MT AT TF PD SEC666C

CONSULT-II Reference Value in Data Monitor Mode

AX SU

NGEC1413

Specification data are reference values. MONITOR ITEM VC/V BYPASS/V

CONDITION

BR

SPECIFICATION

쐌 Ignition switch: ON

OFF

ST

ECM Terminals and Reference Value

NGEC1414

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 the ECM terminals, such as the ground. TERMINAL NO. 120

WIRE COLOR P/B

ITEM Vacuum cut valve bypass valve

CONDITION

[Ignition switch ON]

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

RS BT HA SC EL

EC-1691

IDX

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1415

Malfunction is detected when an improper voltage signal is sent to ECM through vacuum cut valve bypass valve.

POSSIBLE CAUSE 쐌 쐌

NGEC1415S01

Harness or connectors (The vacuum cut valve bypass valve circuit is open or shorted.) Vacuum cut valve bypass valve

DTC Confirmation Procedure

NGEC1416

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at idle speed.

With CONSULT-II Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1694. With GST Follow the procedure “With CONSULT-II”. 1) 2) 3) 4)

SEF058Y

EC-1692

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33ER Wiring Diagram

Wiring Diagram

NGEC1417

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC999

EC-1693

EL IDX

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1418

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

CHECK VACUUM CUT VALVE BYPASS VALVE CIRCUIT

With CONSULT-II 1. Turn ignition switch “OFF” and then “ON”. 2. Select “VC/V BYPASS/V” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON/OFF” on CONSULT-II screen.

SEF014Z

4. Make sure that clicking sound is heard from the vacuum cut valve bypass valve. OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 3.

EC-1694

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK VACUUM CUT VALVE BYPASS VALUE POWER SUPPLY CIRCUIT

Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Disconnect vacuum cut valve bypass valve harness connector.

GI MA EM LC

SEF186S

FE

3. Turn ignition switch “ON”. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

CL MT AT SEF659W

Voltage: Battery voltage

TF

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

PD AX

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M67, C101 and B113, C3 쐌 Fuse block (J/B) connector E49 쐌 10A fuse 쐌 Harness for open or short between vacuum cut valve bypass valve and fuse 䊳

5

Repair harness or connectors.

CHECK VACUUM CUT VALVE BYPASS VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 120 and vacuum cut valve bypass valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power.

SU BR ST RS BT HA

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

SC EL

EC-1695

IDX

DTC P1490 VACUUM CUT VALVE BYPASS VALVE

VG33ER

Diagnostic Procedure (Cont’d)

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors C3, B113 and B101, M67 쐌 Harness connectors M81, F36 쐌 Harness for open or short between vacuum cut valve bypass valve and ECM 䊳

7

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK VACUUM CUT VALVE BYPASS VALVE

With CONSULT-II 1. Perform “VC/V BYPASS/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time under the following conditions.

SEF016Z

Without CONSULT-II 1. Check air passage continuity and operation delay time under the following conditions.

SEF557Y

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace vacuum cut valve bypass valve.

8

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1696

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33ER Description

Description

NGEC1419

COMPONENT DESCRIPTION

SEF186S

NGEC1419S01

The vacuum cut valve and vacuum cut valve bypass valve are installed in parallel on the EVAP purge line between the fuel tank and the EVAP canister. The vacuum cut valve prevents the intake manifold vacuum from being applied to the fuel tank. The vacuum cut valve bypass valve is a solenoid type valve and generally remains closed. It opens only for on board diagnosis. The vacuum cut valve bypass valve responds to signals from the ECM. When the ECM sends an ON (ground) signal, the valve is opened. The vacuum cut valve is then bypassed to apply intake manifold vacuum to the fuel tank.

EVAPORATIVE EMISSION SYSTEM DIAGRAM

GI MA EM LC

NGEC1419S02

FE CL MT AT TF PD SEC666C

CONSULT-II Reference Value in Data Monitor Mode

AX SU

NGEC1420

Specification data are reference values. MONITOR ITEM VC/V BYPASS/V

CONDITION

BR

SPECIFICATION

쐌 Ignition switch: ON

OFF

ST

ECM Terminals and Reference Value

NGEC1421

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 the ECM terminals, such as the ground. TERMINAL NO. 120

WIRE COLOR P/B

ITEM Vacuum cut valve bypass valve

CONDITION

[Ignition switch ON]

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

RS BT HA SC EL

EC-1697

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33ER

On Board Diagnosis Logic

On Board Diagnosis Logic

NGEC1422

Malfunction is detected when vacuum cut valve bypass valve does not operate properly.

POSSIBLE CAUSE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGEC1422S01

Vacuum cut valve bypass valve Vacuum cut valve Bypass hoses for clogging EVAP control system pressure sensor and circuit EVAP canister vent control valve Hose between fuel tank and vacuum cut valve clogged Hose between vacuum cut valve and EVAP canister clogged EVAP canister EVAP purge port of fuel tank for clogging

DTC Confirmation Procedure

SEF210Y

NGEC1423

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 5 seconds before conducting the next test. TESTING CONDITION: Always perform test at a temperature of 5 to 30°C (41 to 86°F). With CONSULT-II 1) Turn ignition switch ON. 2) Start engine and warm it up to normal operating temperature. 3) Turn ignition switch OFF and wait at least 5 seconds. 4) Start engine and let it idle for at least 70 seconds. 5) Select “VC CUT/V BP/V P1491” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. 6) Touch “START”. 7) 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 at least 30 seconds.)

SEF211Y

CMPS·RPM (POS)

More than 500 rpm

Selector lever

Suitable position

Vehicle speed

More than 37 km/h (23 MPH)

B/FUEL SCHDL

1.0 - 11.0 msec

8)

If “TESTING” is not displayed after 5 minutes, retry from step 3. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-1701.

SEF239Y

EC-1698

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33ER

Overall Function Check

Overall Function Check

NGEC1424

Use this procedure to check the overall function of vacuum cut valve bypass valve. During this check, the 1st trip DTC might not be confirmed. Without CONSULT-II 1) Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. 2) Apply vacuum to port A and check that there is no suction from port B. 3) Apply vacuum to port B and check that there is suction from port A. 4) Blow air in port B and check that there is a resistance to flow out of port A. 5) Supply battery voltage to the terminal. 6) Blow air in port A and check that air flows freely out of port B. 7) Blow air in port B and check that air flows freely out of port A. 8) If NG, go to “Diagnostic Procedure”, EC-1701.

GI MA EM LC

FE CL MT

SEF530Q

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1699

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1425

LEC999

EC-1700

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1426

INSPECTION START

GI

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2 1. 2. 3. 4. 5. 6. 7. 8. 9.

MA EM

CHECK VACUUM CUT VALVE BYPASS VALVE OPERATION

LC

With CONSULT-II Turn ignition switch OFF. Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Turn ignition switch ON. Select “VC/V BYPASS/V” in “ACTIVE TEST” mode with CONSULT-II and touch “ON”. Blow air in port A and check that air flows freely out of port B. Blow air in port B and check that air flows freely out of port A.

FE CL MT AT TF SEF017Z

PD

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 5.

AX SU BR ST RS BT HA SC EL

EC-1701

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33ER

Diagnostic Procedure (Cont’d)

3 1. 2. 3. 4. 5. 6. 7. 8. 9.

CHECK VACUUM CUT VALVE BYPASS VALVE OPERATION Without CONSULT-II Turn ignition switch OFF. Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Disconnect vacuum cut valve bypass valve harness connector. Supply battery voltage to the terminal. Blow air in port A and check that air flows freely out of port B. Blow air in port B and check that air flows freely out of port A.

SEF914U

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 5.

4

CHECK EVAP PURGE LINE

1. Check EVAP purge line between EVAP canister and fuel tank for clogging or disconnection. 2. Check EVAP purge port of fuel tank for clogging. 3. Check EVAP canister. Refer to EC-1200. OK or NG OK

䊳

GO TO 8.

NG (Step 1)

䊳

Repair it.

NG (Step 2)

䊳

Clean EVAP purge port.

NG (Step 3)

䊳

Replace EVAP canister.

5

CHECK BYPASS HOSE

Check bypass hoses for clogging. OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair or replace hoses.

EC-1702

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33ER

Diagnostic Procedure (Cont’d)

6

CHECK VACUUM CUT VALVE BYPASS VALVE

With CONSULT-II 1. Perform “VC/V BYPASS/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time under the following conditions.

GI MA EM LC

SEF016Z

FE

1. Check air passage continuity and operation delay time under the following conditions. Without CONSULT-II

CL MT AT TF SEF557Y

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace vacuum cut valve bypass valve.

PD AX SU BR ST RS BT HA SC EL

EC-1703

IDX

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK VACUUM CUT VALVE

Check vacuum cut valve as follows:

SEF379Q

1. 2. 3. 4. 5. 6. 7.

Plug port C and D with fingers. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Open port C and D. Blow air in port A check that air flows freely out of port C. Blow air in port B check that air flows freely out of port D. OK or NG

OK

䊳

GO TO 8.

NG

䊳

Replace vacuum cut valve.

8

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE

1. Turn ignition switch OFF. 2. Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK

䊳

GO TO 9.

NG

䊳

Repair it

9

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR

1. Disconnect EVAP control system pressure sensor harness connector.

AEC651A

2. Check connectors for water. Water should not exist. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace EVAP control system pressure sensor.

EC-1704

DTC P1491 VACUUM CUT VALVE BYPASS VALVE

VG33ER

Diagnostic Procedure (Cont’d)

10

CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR FUNCTION

Refer to “DTC Confirmation Procedure” for DTC P0452, P0453, EC-1533.

GI

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace EVAP control system pressure sensor.

11

MA EM

CHECK EVAP CANISTER VENT CONTROL VALVE

Check air passage continuity. With CONSULT-II Perform “VENT CONTROL/V” in “ACTIVE TEST” mode.

LC

FE CL MT SEF991Y

Without CONSULT-II

AT TF MTBL0240

If NG or operation takes more than 1 second, clean valve using air blower or replace as necessary. If portion B is rusted, replace control valve.

PD AX SU BR ST

AEC783A

Make sure new O-ring is installed properly.

RS

OK or NG

BT

OK

䊳

GO TO 12.

NG

䊳

Replace EVAP canister vent control valve.

HA 12

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

SC

INSPECTION END

EL

EC-1705

IDX

DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE

VG33ER

Component Description

Component Description

NGEC1427

The malfunction information related to A/T (Automatic Transmission) 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 A/T related repair.

ECM Terminals and Reference Value

NGEC1428

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 the ECM terminals, such as the ground. TERMINAL NO. 7

WIRE COLOR G/B

ITEM

CONDITION [Ignition switch ON] [Engine is running]

A/T check signal

On Board Diagnosis Logic

DATA (DC Voltage)

0 - 3.0V

NGEC1429

Malfunction is detected when an incorrect signal from TCM (Transmission control module) is sent to ECM.

POSSIBLE CAUSE 쐌 쐌 쐌

DTC Confirmation Procedure

SEF985Y

NGEC1429S01

Harness or connectors [The communication line circuit between ECM and TCM (Transmission control module) is open or shorted.] Dead (Weak) battery TCM (Transmission control module)

NGEC1430

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. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle. With CONSULT-II 1) Turn ignition switch ON. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and wait at least 40 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1708. With GST Follow the procedure “With CONSULT-II”.

EC-1706

DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE

VG33ER Wiring Diagram

Wiring Diagram

NGEC1431

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC674

EC-1707

EL IDX

DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1432

CHECK A/T DIAGNOSIS COMMUNICATION LINE INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect ECM harness connector and TCM (Transmission Control Module) harness connector.

SEF324V

AEC655A

3. Check harness continuity between ECM terminal 7 and TCM terminal 15. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M58, F28 쐌 Harness for open or short between ECM and TCM (Transmission Control Module) 䊳

3

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1708

DTC P1706 PNP SWITCH

VG33ER Component Description

Component Description

NGEC1433

When the gear position is “P” (A/T models only) or “N”, park/neutral position (PNP) switch is “ON”. ECM detects the position because the continuity of the line (the “ON” signal) exists. For A/T models, the park/neutral position (PNP) switch assembly also includes a transmission range switch to detect selector lever position.

GI MA EM LC

AEC877A

CONSULT-II Reference Value in Data Monitor Mode

NGEC1434

Specification data are reference values. MONITOR ITEM P/N POSI SW

CONDITION 쐌 Ignition switch: ON

SPECIFICATION

Shift lever: “P” or “N”

ON

Except above

OFF

FE CL

ECM Terminals and Reference Value

NGEC1435

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 the ECM terminals, such as the ground. TERMINAL NO.

22

WIRE COLOR

L/B

ITEM

CONDITION

[Ignition switch ON] 쐌 Gear position is “N” or “P” (A/T models) Park/neutral position (PNP) 쐌 Gear position is neutral (M/T models) switch [Ignition switch ON] 쐌 Except the above gear position

DATA (DC Voltage)

MT AT TF PD

Approximately 0V

AX

Approximately 5V

SU BR ST RS

On Board Diagnosis Logic

NGEC1436

Malfunction is detected when the signal of the park/neutral position (PNP) switch is not changed in the process of engine starting and driving.

POSSIBLE CAUSE 쐌 쐌

NGEC1436S01

Harness or connectors [The park/neutral position (PNP) switch circuit is open or shorted.] Park/neutral position (PNP) switch

EC-1709

BT HA SC EL IDX

DTC P1706 PNP SWITCH

VG33ER

DTC Confirmation Procedure

DTC Confirmation Procedure

NGEC1437

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 5 seconds before conducting the next test.

With CONSULT-II 1) Turn ignition switch ON. 2) Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions. Position (Selector lever) “N” and “P” position

ON

Except the above position

OFF

SEF212Y

3) 4) 5)

SEF213Y

Known good signal

If NG, go to “Diagnostic Procedure”, EC-1713. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds.

ENG SPEED

1,400 - 2,700 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

2.0 - 14.0 msec

VHCL SPEED SE

More than 64 km/h (40 MPH)

Selector lever

Suitable position

6)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-1713.

EC-1710

DTC P1706 PNP SWITCH

VG33ER Overall Function Check

Overall Function Check

=NGEC1438

Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Turn ignition switch ON. 2) Check voltage between ECM terminal 22 and body ground under the following conditions. Condition (Gear position) SEF877U

MA EM

Voltage (V) (Known good data)

“P” and “N” position

Approx. 0

Except the above position

Approx. 5

3)

GI

LC

If NG, go to “Diagnostic Procedure”, EC-1713.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1711

IDX

DTC P1706 PNP SWITCH

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1439

WEC001A

EC-1712

DTC P1706 PNP SWITCH

VG33ER Diagnostic Procedure

Diagnostic Procedure FOR M/T MODELS 1

NGEC1440 NGEC1440S01

GI

CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect park/neutral position (PNP) switch harness connector.

MA EM LC

AEC877A

3. Check harness continuity between PNP switch terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power.

FE CL

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

MT AT

2

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F201, F43 쐌 Harness for open between park/neutral position (PNP) switch and engine ground 䊳

3

Repair open circuit or short to power in harness or connectors.

CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 22 and PNP switch 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

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

PD AX SU BR ST

DETECT MALFUNCTIONING PART

RS

Check the following. 쐌 Harness connectors F43, F201 쐌 Harness for open or short between ECM and park/neutral position (PNP) switch 䊳

TF

BT

Repair open circuit or short to ground or short to power in harness or connectors.

HA 5

CHECK PARK/NEUTRAL POSITION (PNP) SWITCH

Refer to MT-8, “Position Switch Check”.

SC OK or NG

OK

䊳

GO TO 6.

NG

䊳

Replace park/neutral position (PNP) switch.

EC-1713

EL IDX

DTC P1706 PNP SWITCH Diagnostic Procedure (Cont’d)

6

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1714

VG33ER

DTC P1706 PNP SWITCH

VG33ER Diagnostic Procedure (Cont’d)

FOR A/T MODELS 1 1. 2. 3. 4. 5.

=NGEC1440S02

CHECK PNP SWITCH POWER SUPPLY CIRCUIT-I

GI

Turn ignition switch OFF. Disconnect park/neutral position (PNP) relay. Turn ignition switch ON. Shift selector lever to “P” or “N” position. Check voltage between PNP relay terminal 2 and ground with CONSULT-II or tester.

MA EM LC

SEF661W

FE

Voltage: Battery voltage OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 2.

2

CL MT

CHECK PNP SWITCH POWER SUPPLY CIRCUIT-II

AT

1. Turn ignition switch OFF. 2. Disconnect park/neutral position (PNP) switch harness connector.

TF PD AX SU AEC662A

3. Check harness continuity between PNP switch terminal 2 and PNP relay terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

3

CHECK PNP SWITCH POWER SUPPLY CIRCUIT-III

1. Turn ignition switch ON. 2. Check voltage between PNP switch terminal 1 and ground with CONSULT-II or tester. Refer to Wiring Diagram. Voltage: Battery voltage

BR ST RS BT HA

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

SC EL

EC-1715

IDX

DTC P1706 PNP SWITCH

VG33ER

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuse block (J/B) connector E49 쐌 7.5A fuse 쐌 Harness for open or short between PNP switch and fuse 䊳

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK PARK/NEUTRAL POSITION (PNP) SWITCH

Refer to AT-312, “Component Inspection”. OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace park/neutral position (PNP) switch.

6

CHECK PNP RELAY GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between PNP relay terminals 1, 6 and body ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

䊳

GO TO 8.

NG (With power door locks system)

䊳

GO TO 7.

NG (Without power door locks system)

䊳

Repair open circuit or short to power in harness or connectors.

7

DETECT MALFUNCTIONING PART

Check the circuit between PNP relay and body ground. Refer to “STARTING SYSTEM”, SC-10. OK or NG OK

䊳

GO TO 11.

NG

䊳

Repair or replace.

8

CHECK PNP RELAY INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 22 and PNP relay terminal 7. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 10.

NG

䊳

GO TO 9.

9

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F36, M81 쐌 Harness connectors M65, E43 쐌 Harness for open or short between ECM and park/neutral position (PNP) relay 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1716

DTC P1706 PNP SWITCH

VG33ER Diagnostic Procedure (Cont’d)

10

CHECK PARK/NEUTRAL POSITION (PNP) RELAY

1. Apply 12V direct current between park/neutral position (PNP) relay terminals 1 and 2. 2. Check continuity between park/neutral position (PNP) relay terminals 3 and 5, 6 and 7.

GI MA EM LC

SEC202B

12V (1 and 2) applied: Continuity should exist. No voltage applied: Continuity should not exist.

FE

OK or NG OK

䊳

GO TO 11.

NG

䊳

Replace park/neutral position (PNP) relay.

CL MT

11

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

AT

INSPECTION END

TF PD AX SU BR ST RS BT HA SC EL

EC-1717

IDX

IGNITION SIGNAL

VG33ER

Component Description

Component Description

NGEC1441

IGNITION COIL & POWER TRANSISTOR

SEF928V

NGEC1441S01

The power transistor switches on and off the ignition coil primary circuit according to the ECM signal. As the primary circuit is turned on and off, the proper high voltage is induced in the secondary circuit. The distributor is not repairable except for the distributor cap and rotor head. NOTE: The rotor screw which secures the distributor rotor head to the distributor shaft must be torqued properly. : 3.6±0.3 N·m (37±3 kg-cm, 32±3 in-lb)

ECM Terminals and Reference Value

NGEC1442

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) Approximately 0.7V

[Engine is running] 쐌 Idle speed

SEF988U

1

PU/W

Ignition signal

1.1 - 1.5V

[Engine is running] 쐌 Engine speed is 2,000 rpm

SEF989U

EC-1718

IGNITION SIGNAL

VG33ER Wiring Diagram

Wiring Diagram

NGEC1443

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC182A

EC-1719

EL IDX

IGNITION SIGNAL

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1444

INSPECTION START

Turn ignition switch “OFF”, and restart engine. Is engine running? Yes or No Yes (With CONSULT-II)

䊳

GO TO 2.

Yes (Without CONSULTII)

䊳

GO TO 3.

No

䊳

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.

SEF070Y

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Let engine idle. 2. Read the voltage signal between ECM terminal 1 and ground with an oscilloscope. 3. Verify that the oscilloscope screen shows the signal wave as shown below.

SEC073C

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

EC-1720

IGNITION SIGNAL

VG33ER Diagnostic Procedure (Cont’d)

4

CHECK IGNITION COIL POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect ignition coil harness connector.

GI MA EM LC

LEC811

3. Turn ignition switch ON. 4. Check voltage between terminal 7 and ground with CONSULT-II or tester.

FE CL MT AT SEF721U

Voltage: Battery voltage

TF OK or NG

OK

䊳

GO TO 6.

NG

䊳

GO TO 5.

PD AX

5

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors E43, M65 쐌 Harness connectors M59, F27 쐌 Harness for open or short between ignition coil and ignition switch 䊳

6

Repair harness or connectors.

CHECK POWER TRANSISTOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect power transistor harness connector. 3. Check harness continuity between power transistor terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power.

SU BR ST RS BT

OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair open circuit or short to power in harness or connectors.

HA SC EL

EC-1721

IDX

IGNITION SIGNAL

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK POWER TRANSISTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 1 and power transistor 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

䊳

GO TO 8.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

8

CHECK IGNITION COIL

1. Disconnect ignition coil harness connector. 2. Check resistance as shown in the figure.

SEF013S

AEC657A

MTBL0638

For checking secondary coil, remove distributor cap and measure resistance between coil tower metal tip 9 and terminal 7. OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace distributor assembly.

EC-1722

IGNITION SIGNAL

VG33ER Diagnostic Procedure (Cont’d)

9

CHECK POWER TRANSISTOR

1. Disconnect camshaft position sensor & power transistor harness connector and ignition coil harness connector. 2. Check power transistor resistance between terminals 2 and 8.

GI MA EM LC

SEF015S

FE MTBL0249

CL

OK or NG

MT

OK

䊳

GO TO 10.

NG

䊳

Replace distributor assembly.

AT 10

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

TF

INSPECTION END

PD AX SU BR ST RS BT HA SC EL

EC-1723

IDX

INJECTOR

VG33ER

Component Description

Component Description

NGEC1445

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 ball 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. SEF812J

CONSULT-II Reference Value in Data Monitor Mode

NGEC1446

Specification data are reference values. MONITOR ITEM

CONDITION

INJ PULSE-B1 INJ PULSE-B2

쐌 쐌 쐌 쐌

B/FUEL SCHDL

ditto

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

SPECIFICATION

Idle

2.4 - 3.7 msec

2,000 rpm

1.9 - 3.3 msec

Idle

1.0 - 1.6 msec

2,000 rpm

0.7 - 1.4 msec

ECM Terminals and Reference Value

NGEC1447

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 the ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Warm-up condition 쐌 Idle speed 102 104 106 109 111 113

W/B W/R W/G W/L W/PU W

Injector Injector Injector Injector Injector Injector

No. No. No. No. No. No.

1 3 5 2 4 6

SEF007V

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm

SEF008V

EC-1724

INJECTOR

VG33ER Wiring Diagram

Wiring Diagram

NGEC1448

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC009A

EC-1725

EL IDX

INJECTOR

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1449

INSPECTION START

Turn ignition switch to START. Is any cylinder ignited? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

CHECK OVERALL FUNCTION

With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

SEF070Y

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

䊳

INSPECTION END

NG

䊳

GO TO 3.

EC-1726

INJECTOR

VG33ER Diagnostic Procedure (Cont’d)

3

CHECK INJECTOR POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect injector harness connector. 3. Check voltage between terminal 1 and ground with CONSULT-II or tester.

GI MA EM LC SEF671W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

CL

DETECT MALFUNCTIONING PART

MT

Check the following. 쐌 Harness connectors M59, F27 쐌 Harness connectors F37, F101 쐌 Fuse block (J/B) connector M26 쐌 10A fuse 쐌 Harness for open or short between injector and fuse 䊳

5

FE

AT

Repair harness or connectors.

CHECK INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between injector terminal 2 and ECM terminals 102, 104, 106, 109, 111, 113. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

TF PD AX SU

OK or NG OK

䊳

GO TO 7.

NG

䊳

GO TO 6.

BR ST

6

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F37, F101 쐌 Harness connectors F38, F102 쐌 Harness for open or short between ECM and injector 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

RS BT HA SC EL

EC-1727

IDX

INJECTOR

VG33ER

Diagnostic Procedure (Cont’d)

7

CHECK INJECTOR

1. Disconnect injector harness connector. 2. Check resistance between terminals as shown in the figure.

SEF625V

Resistance: 10 - 14Ω [at 25°C (77°F)] OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace injector.

8

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1728

START SIGNAL

VG33ER

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NGEC1450

Specification data are reference values. MONITOR ITEM START SIGNAL

CONDITION

SPECIFICATION

쐌 Ignition switch: ON , START , ON

MA

OFF , ON , OFF

ECM Terminals and Reference Value

NGEC1451

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

20

L/OR

ITEM

GI

CONDITION

LC

DATA (DC Voltage)

[Ignition switch ON]

Approximately 0V

[Ignition switch START]

BATTERY VOLTAGE (11 - 14V)

Start signal

EM

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EC-1729

IDX

START SIGNAL

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1452

AEC975A

EC-1730

START SIGNAL

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1453

INSPECTION START

GI

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

MA EM

CHECK OVERALL FUNCTION

LC

With CONSULT-II 1. Turn ignition switch ON. 2. Check “START SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.

FE CL MT SEF072Y

AT

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

3

TF PD

CHECK OVERALL FUNCTION

Without CONSULT-II Check voltage between ECM terminal 20 and ground under the following conditions.

AX SU BR ST SEF733U

RS MTBL0148

BT

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

HA SC EL

EC-1731

IDX

START SIGNAL

VG33ER

Diagnostic Procedure (Cont’d)

4

CHECK STARTING SYSTEM

Turn ignition switch OFF, then turn it to START. Does starter motor operate? Yes or No Yes

䊳

GO TO 5.

No

䊳

Refer to “STARTING SYSTEM”, SC-10.

5

CHECK FUSE

1. Turn ignition switch OFF. 2. Disconnect 7.5A fuse. 3. Check if 7.5A fuse is OK. OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace 7.5A fuse.

6

CHECK START SIGNAL INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 20 and fuse block. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuse 䊳

8

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1732

FUEL PUMP

VG33ER System Description

System Description Sensor

Input Signal to ECM

Camshaft position sensor

Engine speed

Ignition switch

Start signal

NGEC1454

ECM function Fuel pump control

GI

Actuator

MA

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 120° signal from the camshaft position sensor, it knows that the engine is rotating, and causes the pump to operate. If the 120° 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

EM LC

Fuel pump operation

Ignition switch is turned to ON.

Operates for 5 seconds

Engine running and cranking

FE

Operates

When engine is stopped

Stops in 1.5 seconds

Except as shown above

Stops

CL MT

Component Description

NGEC1455

The fuel pump with a fuel damper is an in-tank type (the pump and damper are located in the fuel tank).

AT TF PD AX

SEF018S

CONSULT-II Reference Value in Data Monitor Mode

SU

NGEC1456

Specification data are reference values. MONITOR ITEM

FUEL PUMP RLY

CONDITION

SPECIFICATION

쐌 Ignition switch is turned to ON. (Operates for 5 seconds.) 쐌 Engine running and cranking

ON

Except as shown above

OFF

BR ST RS BT HA SC EL

EC-1733

IDX

FUEL PUMP

VG33ER

ECM Terminals and Reference Value

ECM Terminals and Reference Value

=NGEC1457

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

11

W/R

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch ON] 쐌 For 5 seconds after turning ignition switch “ON” [Engine is running]

0 - 1V

[Ignition switch ON] 쐌 More than 5 seconds after turning ignition switch ON

BATTERY VOLTAGE (11 - 14V)

Fuel pump relay

EC-1734

FUEL PUMP

VG33ER Wiring Diagram

Wiring Diagram

NGEC1458

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC509

EC-1735

EL IDX

FUEL PUMP

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1459

CHECK OVERALL FUNCTION

1. Turn ignition switch “ON”. 2. Pinch fuel feed hose with fingers.

AEC663A

Fuel pressure pulsation should be felt on the fuel feed hose for 5 seconds after ignition switch is turned “ON”. OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 2.

2

CHECK FUEL PUMP RELAY POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect fuel pump relay.

SEF349V

3. Turn ignition switch “ON”. 4. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.

SEF674W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

EC-1736

FUEL PUMP

VG33ER Diagnostic Procedure (Cont’d)

3

DETECT MALFUNCTIONING PART

Check the following. 쐌 Fuse block (J/B) connector M31 쐌 15A fuse 쐌 Harness for open or short between fuse and fuel pump relay 䊳

GI MA

Repair harness or connectors.

EM 4

CHECK FUEL PUMP POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”. 2. Disconnect fuel pump harness connector.

LC

FE CL LEC764

3. Check harness continuity between fuel pump terminal 2 and body ground, fuel pump terminal 1 and fuel pump relay 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

䊳

GO TO 6.

NG

䊳

GO TO 5.

5

TF

AX

Check the following. 쐌 Harness connectors M67, B101 쐌 Harness for open between fuel pump and body ground 쐌 Harness for open or short between fuel pump and fuel pump relay

6

AT

PD

DETECT MALFUNCTIONING PART

䊳

MT

Repair open circuit or short to ground or short to power in harness or connectors.

SU BR

CHECK FUEL PUMP RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 11 and fuel pump relay terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

ST RS

OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

BT HA

7

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors M81, F36 쐌 Harness for open or short between ECM and fuel pump relay 䊳

Repair open circuit or short to ground or short to power in harness or connectors.

EC-1737

SC EL IDX

FUEL PUMP

VG33ER

Diagnostic Procedure (Cont’d)

8

CHECK FUEL PUMP RELAY

With CONSULT-II 1. Reconnect fuel pump relay, fuel pump harness connector and ECM harness connector. 2. Turn ignition switch “ON”. 3. Turn fuel pump relay “ON” and “OFF” in “ACTIVE TEST” mode with CONSULT-II and check operating sound.

SEF073Y

Without CONSULT-II Check continuity between terminals 3 and 5.

SEF511P

12V direct current supply between terminals 1 and 2 Continuity exists No current supply Continuity does not exist OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace fuel pump relay.

EC-1738

FUEL PUMP

VG33ER Diagnostic Procedure (Cont’d)

9

CHECK FUEL PUMP

1. Disconnect fuel pump harness connector. 2. Check resistance between terminals 1 and 2.

GI MA EM LC SEC316C

Resistance: 0.2 - 5.0Ω [at 25°C (77°F)] OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace fuel pump.

10

FE CL

CHECK INTERMITTENT INCIDENT

MT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

AT TF PD AX SU BR ST RS BT HA SC EL

EC-1739

IDX

POWER STEERING OIL PRESSURE SWITCH

VG33ER

Component Description

Component Description

NGEC1460

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.

LEC521

CONSULT-II Reference Value in Data Monitor Mode

NGEC1461

Specification data are reference values. MONITOR ITEM

PW/ST SIGNAL

CONDITION 쐌 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

NGEC1462

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

39

GY/R

ITEM

Power steering oil pressure switch

CONDITION

DATA (DC Voltage)

[Engine is running] 쐌 Steering wheel is being fully turned

0V

[Engine is running] 쐌 Steering wheel is not being turned

Approximately 5V

EC-1740

POWER STEERING OIL PRESSURE SWITCH

VG33ER Wiring Diagram

Wiring Diagram

NGEC1463

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEC677

EC-1741

EL IDX

POWER STEERING OIL PRESSURE SWITCH

VG33ER

Diagnostic Procedure

Diagnostic Procedure 1

NGEC1464

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

䊳

GO TO 2.

No

䊳

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.

SEF228Y

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Start engine. 2. Check voltage between ECM terminal 39 and ground.

SEF739U

MTBL0145

OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

EC-1742

POWER STEERING OIL PRESSURE SWITCH

VG33ER

Diagnostic Procedure (Cont’d)

4

CHECK POWER STEERING OIL PRESSURE SWITCH GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Disconnect power steering oil pressure switch harness connector.

GI MA EM LC

LEC521

3. Check harness continuity between switch terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power.

FE

OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair open circuit or short to power in harness or connectors.

5

CL MT

CHECK POWER STEERING OIL PRESSURE SWITCH INPUT SIGNAL CIRCUIT

AT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 39 and switch terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power.

TF

OK or NG

PD

OK

䊳

GO TO 6.

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

AX 6

CHECK POWER STEERING OIL PRESSURE SWITCH

1. Disconnect power steering oil pressure switch harness connector then start engine. 2. Check continuity between terminals 1 and 2.

SU BR ST RS SEC312C

BT HA

MTBL0254

SC

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace power steering oil pressure switch.

EL

EC-1743

IDX

POWER STEERING OIL PRESSURE SWITCH Diagnostic Procedure (Cont’d)

7

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1744

VG33ER

IACV-FICD SOLENOID VALVE

VG33ER Component Description

Component Description

NGEC1465

When the air conditioner is on, the IACV-FICD solenoid valve supplies additional air to adjust to the increased load.

GI MA EM LC

LEC515

ECM Terminals and Reference Value

NGEC1466

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 the ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

9

12

21

B/Y

P

G/R

ITEM

Ambient air temperature switch

Air conditioner relay

Air conditioner switch

CONDITION

DATA (DC Voltage)

FE CL

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is above 25°C (77°F) 쐌 Air conditioner is operating

0V

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is below 19°C (66°F) 쐌 Air conditioner is operating

BATTERY VOLTAGE (11 - 14V)

[Engine is running] 쐌 Idle speed 쐌 Ambient air temperature is below 19°C (66°F) 쐌 Air conditioner is not operating

Approximately 5V

[Engine is running] 쐌 Both A/C switch and blower fan switch are “ON”*

0 - 1V

[Engine is running] 쐌 A/C switch is “OFF”

BATTERY VOLTAGE (11 - 14V)

SU

[Engine is running] 쐌 Both A/C switch and blower fan switch are “ON” (Compressor operates)*

Approximately 0V

BR

[Engine is running] 쐌 Air conditioner switch is “OFF”

Approximately 5V

ST

*: Any mode except “OFF”, ambient air temperature is above 25°C (77°F).

MT AT TF PD AX

RS BT HA SC EL

EC-1745

IDX

IACV-FICD SOLENOID VALVE

VG33ER

Wiring Diagram

Wiring Diagram

NGEC1467

LEC678

EC-1746

IACV-FICD SOLENOID VALVE

VG33ER Diagnostic Procedure

Diagnostic Procedure 1

NGEC1468

CHECK OVERALL FUNCTION

GI

1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm (in “P” or “N” position) If NG, adjust idle speed. 3. Turn air conditioner switch and blower fan switch ON. 4. Recheck idle speed.

MA EM LC

FE SEF742U

850 rpm or more (in “P” or “N” position)

CL OK or NG

OK

䊳

INSPECTION END

NG

䊳

GO TO 2.

2

MT AT

CHECK AIR CONDITIONER FUNCTION

Check if air conditioner compressor functions normally. OK or NG OK

䊳

GO TO 3.

NG

䊳

Refer to “Symptom Table”, “TROUBLE DIAGNOSES”, HA-28.

TF PD AX SU BR ST RS BT HA SC EL

EC-1747

IDX

IACV-FICD SOLENOID VALVE

VG33ER

Diagnostic Procedure (Cont’d)

3

CHECK IACV-FICD SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn air conditioner switch and blower fan switch OFF. 2. Stop engine. 3. Disconnect IACV-FICD solenoid valve harness connector.

LEC515

4. Start engine, then turn air conditioner switch and blower fan switch ON. 5. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF680W

Voltage: Battery voltage OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. 쐌 Harness connectors F38, F102 쐌 Harness for open or short between IACV-FICD solenoid valve and harness connector F27 䊳

5

Repair harness or connectors.

CHECK IACV-FICD SOLENOID VALVE GROUND CIRCUIT-I

1. Turn ignition switch OFF. 2. Disconnect ambient air temperature switch harness connector. 3. Check harness continuity between ambient air temperature switch terminal 1 and body ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair open circuit or short to power in harness or connectors.

EC-1748

IACV-FICD SOLENOID VALVE

VG33ER Diagnostic Procedure (Cont’d)

6

CHECK IACV-FICD SOLENOID VALVE GROUND CIRCUIT-II

1. Check harness continuity between ambient air temperature switch terminal 2 and IACV-FICD solenoid valve terminal 1.

GI MA EM LC

SEF160X

Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

䊳

GO TO 8.

NG

䊳

GO TO 7.

7

CL

DETECT MALFUNCTIONING PART

MT

Check the following. 쐌 Harness connectors F38, F102 쐌 Harness connectors F36, M81 쐌 Harness connectors M65, E43 쐌 Diode-3 쐌 Harness for open or short between IACV-FICD solenoid valve and ambient air temperature switch 䊳

FE

AT TF

Repair open circuit or short to ground or short to power in harness or connectors.

PD AX SU BR ST RS BT HA SC EL

EC-1749

IDX

IACV-FICD SOLENOID VALVE

VG33ER

Diagnostic Procedure (Cont’d)

8

CHECK IACV-FICD SOLENOID VALVE

Disconnect IACV-FICD solenoid valve harness connector. 쐌 Check for clicking sound when applying 12V direct current to terminals.

SEF682W

쐌 Check plunger for seizing or sticking. 쐌 Check for broken spring.

SEF097K

OK or NG OK

䊳

GO TO 9.

NG

䊳

Replace IACV-FICD solenoid valve.

9

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1312. 䊳

INSPECTION END

EC-1750

MIL & DATA LINK CONNECTORS

VG33ER Wiring Diagram

Wiring Diagram

NGEC1469

GI MA EM LC

FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEC192A

EC-1751

EL IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

VG33ER

Fuel Pressure Regulator

Fuel Pressure Regulator

NGEC1470

2

Fuel pressure at idling kPa (kg/cm , psi) Vacuum hose is connected

Approximately 235 (2.4, 34)

Vacuum hose is disconnected

Approximately 294 (3.0, 43)

Idle Speed and Ignition Timing

NGEC1471

Base idle speed*1

No-load*4 (in “P” or N” position)

700±50 rpm

Target idle speed*2

No-load*4 (in “P” or N” position)

750±50 rpm

Air conditioner: ON

In “P” or N” position

850 rpm or more

Ignition timing*3

In “P” or N” position

10°±1° BTDC

Throttle position sensor idle position

*1: *2: *3: *4: 쐌 쐌 쐌

0.15 - 0.85V

Throttle position sensor harness connector disconnected or using CONSULT-II “WORK SUPPORT” mode Throttle position sensor harness connector connected Throttle position sensor harness connector disconnected Under the following conditions: Air conditioner switch: OFF Electric load: OFF (Lights, heater fan & rear window defogger) Steering wheel: Kept in straight-ahead position

Ignition Coil

NGEC1472

Primary voltage

12V

Primary resistance [at 20°C (68°F)]

Approximately 1.0Ω

Secondary resistance [at 20°C (68°F)]

Approximately 10 kΩ

Mass Air Flow Sensor Supply voltage

NGEC1473

Battery voltage (11 - 14)V

Output voltage at idle

1.0 - 1.7*V 3.3 - 4.8 g·m/sec at idle* 12.0 - 14.9 g·m/sec at 2,500 rpm*

Mass air flow (Using CONSULT-II or GST)

*: Engine is warmed up to normal operating temperature and running 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

Heated Oxygen Sensor 1 Heater Resistance [at 25°C (77°F)]

NGEC1474

NGEC1475

2.3 - 4.3Ω

Fuel Pump Resistance [at 25°C (77°F)]

NGEC1476

0.2 - 5.0Ω

IACV-AAC Valve Resistance [at 20°C (68°F)]

NGEC1477

Approximately 10.0Ω

EC-1752

SERVICE DATA AND SPECIFICATIONS (SDS)

VG33ER Injector

Injector

NGEC1478

Resistance [at 25°C (77°F)]

GI

10 - 14Ω

Throttle Position Sensor

NGEC1479

Voltage [at normal operating temperature, engine off, ignition switch ON, (throttle opener disengaged, if so equipped)]

Throttle valve conditions

Completely closed (a)

MA EM

0.15 - 0.85V

Partially open

LC

Between (a) and (b)

Completely open (b)

3.5 - 4.7V

Calculated Load Value

NGEC1480

FE

Calculated load value % (Using CONSULT or GST) At idle

18.0 - 26.0

At 2,500 rpm

18.0 - 21.0

Intake Air Temperature Sensor Temperature °C (°F)

CL NGEC1481

MT

Resistance kΩ

20 (68)

2.1 - 2.9

80 (176)

0.27 - 0.38

Heated Oxygen Sensor 2 Heater Resistance [at 25°C (77°F)]

AT TF NGEC1482

2.3 - 4.3Ω

PD

Crankshaft Position Sensor (OBD) Resistance [at 20°C (68°F)]

NGEC1483

AX

512 - 632Ω

Fuel Tank Temperature Sensor Temperature °C (°F)

NGEC1484

SU

Resistance kΩ

20 (68)

2.3 - 2.7

50 (122)

0.79 - 0.90

BR ST RS BT HA SC EL

EC-1753

IDX

NOTES

ACCELERATOR CONTROL, FUEL & EXHAUST SYSTEMS SECTION

FE

GI MA EM LC EC

CONTENTS PREPARATION ...............................................................2 Special Service Tool ....................................................2 Commercial Service Tool.............................................2 ACCELERATOR CONTROL SYSTEM ...........................3 Removal and Installation .............................................3 Adjusting Accelerator Wire ..........................................3

FUEL SYSTEM ................................................................4 Removal and Installation .............................................4 FUEL TANK ...............................................................5 FUEL PUMP AND FUEL LEVEL SENSOR ...................7 EXHAUST SYSTEM ........................................................9 Removal and Installation .............................................9

CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

PREPARATION Special Service Tool

Special Service Tool

NGFE0001

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description Loosening or tightening rear heated oxygen sensor a: 22 mm (0.87 in)

KV10114400 (J38365) Heated oxygen sensor wrench

NT636

Commercial Service Tool Tool name

NGFE0007

Description

(J-43897-18) (J-43897-12) Oxygen sensor thread cleaner

Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with anti-seize lubricant shown in Commercial Service Tools. a: J-43897-18 18mm diameter, for Zirconia Oxygen Sensor b: J-43897-12 12mm diameter, for Titania Oxygen Sensor

AEM488

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads.

Anti-seize lubricant Permatex姟 133AR or equivalent meeting MIL specification MIL-A-907

AEM489

FE-2

ACCELERATOR CONTROL SYSTEM Removal and Installation

Removal and Installation

NGFE0002

CAUTION: 쐌 When removing accelerator wire, make a mark to indicate lock nut’s initial position. 쐌 Check that throttle valve opens fully when accelerator pedal is fully depressed. Also check that it returns to idle position when pedal is released. 쐌 Check accelerator control parts for improper contact with any adjacent parts. 쐌 When connecting accelerator wire, be careful not to twist or scratch its inner wire. 쐌 Refer to EL-174, “ASCD Wire Adjustment”.

GI MA EM LC EC

CL MT AT WFE019

TF PD AX

Adjusting Accelerator Wire

NGFE0003

NOTE: Adjust accelerator wire with the engine warmed up to normal operating temperature and ignition switch turned to OFF. 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.

SU BR ST RS

SFE249AE

BT HA SC EL

FE-3

IDX

FUEL SYSTEM Removal and Installation

Removal and Installation

NGFE0004

WARNING: When replacing fuel line parts, be sure to observe the following: 쐌 Put a “CAUTION: INFLAMMABLE” sign in workshop. 쐌 Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. 쐌 Be sure to furnish the workshop with a CO2 fire extinguisher. CAUTION: 쐌 Before removing fuel line parts, carry out the following procedures: a) Put drained fuel in an explosion-proof container and put lid on securely. b) Release fuel pressure from fuel line. Refer to EC-57 (KA24DE), EC-644 (VG33E), EC-1217 (VG33ER) “Fuel Pressure Release”. c) Disconnect battery ground cable. 쐌 Remove quick connectors with commercial service tool. 쐌 Always replace O-ring with a new one. 쐌 Do not kink or twist hoses and tubes when installed. 쐌 Do not tighten hose clamps excessively to avoid damaging hoses. 쐌 Perform an inspection and installation of EVAP system parts as necessary. Refer to EC-40 (KA24DE), EC-626 (VG33E), EC-1199 (VG33ER), “Evaporative Emission System”. 쐌 For inspection and installation of ORVR system parts, refertoEC-45(KA24DE),EC-632(VG33E),EC-1205(VG33ER), “On-Board Refueling Vapor Recovery (ORVR)”. 쐌 After installation, run engine and check for fuel leaks at connections. 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on.

FE-4

FUEL SYSTEM Removal and Installation (Cont’d)

GI MA EM LC EC

CL MT AT WFE023

TF PD AX

FUEL TANK 1.

WFE041

NGFE0004S01

Release fuel pressure from fuel line. RefertoEC-57(KA24DE),EC-644(VG33E),EC-1217(VG33ER), “Fuel Pressure Release”. 2. Disconnect battery ground cable. 3. Remove back seat bottom. Refer to BT-38, “Removal and Installation”. 4. Remove inspection hole cover located under rear seat. 5. Drain fuel from fuel tank. 6. Disconnect electrical connectors. 7. Remove filler protector. 8. Remove the quick connectors as follows. 1) Put mating marks on the connectors for correct installation. 2) Hold the sides of the connector, push in tabs, and pull out the tube inserted in the retainer. CAUTION: 쐌 The tube can be removed when the push in tabs are completely depressed. 쐌 Do not use any tools to remove the quick connector. 쐌 Keep the connecting portions of the tubes and quick connectors clean.

SU BR ST RS BT HA SC EL

AFE108

FE-5

IDX

FUEL SYSTEM Removal and Installation (Cont’d)

9.

Disconnect filler hose, vent and evaporation hose at fuel tank side.

SFE421A

10. Remove fuel tank protector.

AFE096

11. Remove fuel tank mounting bolts while supporting fuel tank. 12. Remove fuel tank.

SFE423A

To install, reverse the removal procedure. Connect the quick connectors as follows. 쐌 Make sure the connectors are clean and undamaged. 쐌 Align push in tabs with retainer openings. 쐌 Insert tube into the center of the connector until you hear a click.

AFE110

After connecting quick connectors, make sure the connection is fully seated and locked in place as follows: 쐌 Pull on the fuel tube and connector to make sure they are properly connected. 쐌 Start the engine, increase engine speed and verify that there are no leaks.

AFE109

FE-6

FUEL SYSTEM Removal and Installation (Cont’d)

FUEL PUMP AND FUEL LEVEL SENSOR

NGFE0004S02

GI MA EM LC EC

CL MT AT WFE024

TF PD AX

1.

2. 3. 4. 5.

Release fuel pressure from fuel line. RefertoEC-57(KA24DE),EC-644(VG33E),EC-1217(VG33ER), “Fuel Pressure Release”. Disconnect battery ground cable. Remove back seat bottom. Refer to BT-38, “Removal and Installation”. Remove inspection hole cover located under rear seat. Disconnect electrical connectors.

SU BR ST RS

WFE041

6. 1) 2)

AFE095

Remove the quick connectors as follows. Put mating marks on the connectors for correct installation. Hold the sides of the connector, push in tabs, and pull out the tube inserted in the retainer. CAUTION: 쐌 The tube can be removed when the push in tabs are completely depressed. 쐌 Do not use any tools to remove the quick connector. 쐌 Keep the connecting portions of the tubes and quick connectors clean. 7. Remove the six screws.

FE-7

BT HA SC EL IDX

FUEL SYSTEM Removal and Installation (Cont’d)

8. 9.

Remove fuel level sensor retainer and fuel level sensor. Remove fuel pump with bracket while lifting the pawl of the fuel pump bracket upward. 10. Remove fuel level sensor assembly. Installation procedure is the reverse order of removal. 쐌 Install fuel level sensor as shown. CAUTION: 쐌 Tighten bolts to specified torque. : 2.0 - 2.5 N·m (0.20 - 0.26 kg-m, 17.4 - 22.6 in-lb) 쐌 Always replace O-ring with a new one. 쐌 Make sure the connectors are clean and undamaged. 쐌 After installation, run engine and check for leaks at connections.

FE-8

EXHAUST SYSTEM Removal and Installation

Removal and Installation

NGFE0005

CAUTION: 쐌 Always replace exhaust gaskets with new ones when reassembling. 쐌 With engine running, check all tube connections for exhaust gas leaks, and entire system for unusual noises. 쐌 Check to ensure that mounting brackets and mounting insulators are installed properly and free from undue stress. Improper installation could result in excessive noise or vibration. 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. 쐌 Do not over-torque the oxygen sensor. Doing so may cause damage to the oxygen sensor, resulting in the MIL coming on.

GI MA EM LC EC

CL MT AT TF PD AX SU BR ST RS BT HA SC EL

FE-9

IDX

EXHAUST SYSTEM Removal and Installation (Cont’d)

KA24DE Models

WFE052

FE-10

EXHAUST SYSTEM Removal and Installation (Cont’d)

VG33E 2WD Models

GI MA EM LC EC

CL MT AT TF PD AX SU BR ST RS BT HA SC WFE056

FE-11

EL IDX

EXHAUST SYSTEM Removal and Installation (Cont’d) 1. 2. 3. 4.

Gasket Front tube Heated oxygen sensor 2 (rear) (bank 1) Heated oxygen sensor 2 (rear) (bank 2)

5. 6. 7. 8.

Gasket Mounting rubber Mounting bracket Center muffler

FE-12

9. TWC (under floor) 10. Heat shield 11. Mass damper (A/T only)

EXHAUST SYSTEM Removal and Installation (Cont’d)

VG33E 4WD Models

GI MA EM LC EC

CL MT AT TF PD AX SU BR ST RS BT HA SC WFE057

FE-13

EL IDX

EXHAUST SYSTEM Removal and Installation (Cont’d) 1. 2. 3. 4.

Gasket Front tube Heated oxygen sensor 2 (rear) (bank 1) Heated oxygen sensor 2 (rear) (bank 2)

5. 6. 7. 8.

Gasket Mounting rubber Mounting bracket Center muffler

FE-14

9. TWC (under floor) 10. Heat shield 11. Mass damper (A/T only)

EXHAUST SYSTEM Removal and Installation (Cont’d)

VG33ER Models

GI MA EM LC EC

CL MT AT TF PD AX SU BR ST RS BT HA SC WFE053

FE-15

EL IDX

EXHAUST SYSTEM Removal and Installation (Cont’d) 1. 2. 3. 4.

Gasket Front tube Heated oxygen sensor 2 (rear) (bank 1) Heated oxygen sensor 2 (rear) (bank 2)

5. 6. 7. 8. 9.

Gasket Mounting rubber Mounting bracket Center muffler TWC (under floor)

FE-16

10. 11. 12. 13.

Mounting bracket (4WD) Mass damper (A/T only) Heat shield Mounting bracket (2WD)

CLUTCH SECTION

CL

GI MA EM LC EC

CONTENTS PRECAUTIONS ...............................................................2 Precautions ..................................................................2 PREPARATION ...............................................................3 Special Service Tools ..................................................3 Commercial Service Tools ...........................................3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................4 NVH Troubleshooting Chart.........................................4 CLUTCH ...................................................................4 CLUTCH SYSTEM - HYDRAULIC TYPE........................5 Components.................................................................5 Inspection and Adjustment ..........................................6 CLUTCH PEDAL INSPECTION AND ADJUSTMENT ...........................................................6 AIR BLEEDING PROCEDURE ....................................7

CLUTCH MASTER CYLINDER.......................................8 Components.................................................................8 Disassembly and Assembly.........................................8 Inspection.....................................................................8 OPERATING CYLINDER.................................................9 Components.................................................................9 Inspection.....................................................................9

CLUTCH RELEASE MECHANISM ...............................10 Components...............................................................10 Removal and Installation ...........................................10 Inspection...................................................................11 Lubrication .................................................................11 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL....................................................................12 Components...............................................................12 Inspection and Adjustment ........................................12 CLUTCH DISC.........................................................12 CLUTCH COVER AND FLYWHEEL...........................13 FLYWHEEL INSPECTION ........................................13 Installation..................................................................13 SERVICE DATA AND SPECIFICATIONS (SDS) .........15 Clutch Control System...............................................15 Clutch Master Cylinder (with clutch damper) ............15 Clutch Operating Cylinder .........................................15 Clutch Disc.................................................................15 Clutch Cover ..............................................................15 Clutch Pedal ..............................................................15

FE

MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

PRECAUTIONS Precautions

Precautions 쐌 쐌 쐌 쐌 쐌

SBR686C

NGCL0001

Recommended fluid is brake fluid “DOT 3”. Never 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. 쐌 Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic system. WARNING: After cleaning the clutch disc, wipe it with a dust collector. Do not use compressed air.

CL-2

PREPARATION Special Service Tools

Special Service Tools

NGCL0002

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

GI

Description

MA Installing clutch cover and clutch disc a: 15.9 mm (0.626 in) dia. b: 22.8 mm (0.898 in) dia. c: 55 mm (2.17 in)

ST20630000 (J26366) Clutch aligning bar

EM LC

NT405

Adjusting unevenness of diaphragm spring of clutch cover a: 150 mm (5.91 in) b: 25 mm (0.98 in)

ST20050240 ( — ) Diaphragm spring adjusting wrench

EC FE

NT404

Commercial Service Tools Tool name

NGCL0003

MT

Description

1 Flare nut crowfoot 2 Torque wrench

Removing and installing clutch piping a: 10 mm (0.39 in)

AT TF

NT360

Removing release bearing

Bearing puller

PD AX

NT077

SU Installing release bearing a: 52 mm (2.05 in) dia. b: 45 mm (1.77 in) dia.

Bearing drift

BR

NT474

ST RS BT HA SC EL

CL-3

IDX

Symptom Clutch grabs/chatters

Clutch pedal spongy 1 1

Clutch noisy

2 3 4

CL-4

CL-9

OPERATING CYLINDER PISTON CUP (Damaged)

CL-12 CL-12 CL-12 CL-12 CL-12 CL-12 CL-13 CL-13 CL-13 CL-13

CLUTCH DISC (Dirty or burned) CLUTCH DISC (Oily) CLUTCH DISC (Worn out) CLUTCH DISC (Hardened) CLUTCH DISC (Lack of spline grease) DIAPHRAGM SPRING (Damaged) DIAPHRAGM SPRING (Out of tip alignment) PRESSURE PLATE (Distortion) FLYWHEEL (Distortion)

RELEASE BEARING (Worn, dirty or damaged)

ENGINE MOUNTING (Loose)

CL-8

MASTER CYLINDER PISTON CUP (Damaged)

CLUTCH DISC (Lining broken)

1

CL-12

1

CLUTCH DISC (Runout is excessive)

Clutch does not disengage 2

CL-12

1 2

CLUTCH DISC (Out of true)

Clutch slips 2

EM-41 (KA24DE), EM-113 (VG33E & VG33ER) CL-10

CL-7

CLUTCH LINE (Air in line)

SUSPECTED PARTS (Possible cause) CL-6

Reference page

CLUTCH PEDAL (Free play out of adjustment)

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NGCL0027

NVH Troubleshooting Chart

Use the chart below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, repair or replace these parts.

NVH Troubleshooting Chart

5 5 5 5 5

NGCL0027S01

CLUTCH NGCL0027S0101

2 2 2

4 5

2 2

2

3

5 6 6 7

CLUTCH SYSTEM — HYDRAULIC TYPE Components

Components

NGCL0004

GI MA EM LC EC FE

MT AT TF PD AX SU BR ST WCL044

1. 2. 3. 4. 5. 6. 7. 8.

Clutch pedal bracket Clutch interlock switch Clutch master cylinder Fulcrum pin Bushing Clevis pin Clutch pedal Lock nut

9. 10. 11. 12. 13. 14. 15.

ASCD cancel switch Pedal stopper Snap pin Assist spring Clutch disc Clutch cover Release bearing

16. 17. 18. 19. 20. 21. 22.

Release bearing sleeve Withdrawal lever Operating cylinder Air bleeder Clutch damper Flare nut Bushing

RS BT HA SC EL

CL-5

IDX

CLUTCH SYSTEM — HYDRAULIC TYPE Inspection and Adjustment

Inspection and Adjustment

NGCL0005

CLUTCH PEDAL INSPECTION AND ADJUSTMENTNGCL0005S01 1.

a.

b. c.

d.

2. a. b. LCL052

3.

4.

a. b.

Check to see if the clutch pedal clevis pin floats freely in the bore of the clutch pedal. It should not be bound by the clevis or clutch pedal. If the pin is not free, check that the ASCD switch or pedal stopper bolt is not applying pressure to the clutch pedal causing the pin to bind. To adjust, loosen the ASCD switch or pedal stopper bolt lock nut and turn the ASCD switch or pedal stopper bolt. Tighten the lock nut. Verify that the clutch pedal clevis pin floats freely in the bore of the clutch pedal. It should not be bound by the clevis or clutch pedal. If the pin is still not free, remove the pin and check for deformation or damage. Replace the pin if necessary. Leave the pin removed for step 2. Check the clutch pedal stroke for free range of movement.. With the clutch pedal clevis pin removed, manually move the pedal up and down to determine if it moves freely. If any sticking is noted, replace the related pars (clutch pedal, pedal bracket, assist spring, bushing, etc.). Reassemble the pedal and re-verify that the clevis pin floats freely in the bore of the pedal.

Adust the clearance “C: while fully depressing the clutch pedal (with the clutch interlock switch) as shown. Clearance “C”: 0.1 - 1.0 mm (0.004 - 0.039 in) Check the clutch hydraulic system components (clutch master cylinder, clutch operationg cylinder, clutch withdrawal lever, clutch release bearing, etc.) for sticking or binding. If any sticking or binding is noted, repair or replace the releated parts as necessary. If the hydraulic system was necessary, bleed the clutch hydraulic system. Refer to “Air Bleeding Procedure”, CL-7.

SCL800

CL-6

CLUTCH SYSTEM — HYDRAULIC TYPE Inspection and Adjustment (Cont’d)

AIR BLEEDING PROCEDURE

SCL203-A

NGCL0005S02

Bleed air according to the following procedure. Bleed air from operating cylinder. 1. Fill the master cylinder reservoir tank with new brake fluid. 2. Connect a transparent vinyl hose to the air bleeder. 3. Slowly depress the clutch pedal to its full stroke length and release it completely. Repeat this operation several times at 2 to 3 second intervals. 4. Open the air bleeder with the clutch pedal fully depressed. 5. Close the air bleeder. 6. Release the clutch pedal and wait at least 5 seconds. 7. Repeat steps 3 through 6 above until air bubbles no longer appear in the brake fluid.

GI MA EM LC EC FE

MT AT TF PD AX SU BR ST RS BT HA SC EL

CL-7

IDX

CLUTCH MASTER CYLINDER Components

Components

NGCL0006

WCL041

Disassembly and Assembly 쐌 쐌

NGCL0007

Use a screwdriver to remove stopper ring while pushing push rod into cylinder. When installing stopper ring, tap in lightly while pushing push rod into cylinder.

Inspection

NGCL0008

Check the following items, and replace if necessary. 쐌 Rubbing surface of cylinder and piston, for uneven wear, rust, or damage 쐌 Piston with piston cup, for wear or damage 쐌 Return spring, for wear or damage 쐌 Reservoir, for deformation or damage

CL-8

OPERATING CYLINDER Components

Components

NGCL0009

GI MA EM LC EC FE

WCL042

MT

Inspection

NGCL0010

Check the following items, and replace if necessary. 쐌 Rubbing surface of cylinder and piston, for uneven wear, rust, or damage 쐌 Piston with piston cup, for wear or damage 쐌 Piston spring, for wear or damage 쐌 Dust cover, for cracks, deformation, or damage

AT TF PD AX SU BR ST RS BT HA SC EL

CL-9

IDX

CLUTCH RELEASE MECHANISM Components

Components

NGCL0013

WCL045

Removal and Installation 쐌

Remove release bearing.

쐌

Install release bearing with suitable drift.

쐌

Install retainer spring and holder spring.

CL145

WCL025

SCL217

CL-10

NGCL0014

CLUTCH RELEASE MECHANISM Inspection

Inspection

NGCL0015

Check the following items, and replace if necessary. 쐌 Release bearing, to see that it rolls freely and is free from noise, cracks, pitting, or wear. 쐌 Release sleeve and withdrawal lever rubbing surface, for wear, rust, or damage

GI MA EM LC EC

WCL043

FE

MT

Lubrication 쐌 쐌

NGCL0016

Apply recommended grease to contact surface and rubbing surface. Too much lubricant might damage clutch disc facing damage.

AT TF PD AX SU BR ST RS BT HA SC EL

CL-11

IDX

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL Components

Components

NGCL0018

WCL034

Inspection and Adjustment CLUTCH DISC

NGCL0019 NGCL0019S01

Check the following items, and replace if necessary. 쐌 Clutch disc, for burns, discoloration, oil, or grease leakage 쐌 Clutch disc, for wear of facing Wear limit of facing surface to rivet head: 0.3 mm (0.012 in)

ACL063

쐌

Clutch disc, for backlash of spline and runout of facing Maximum backlash of spline (at outer edge of disc): 1.0 mm (0.039 in) Runout of facing limit (at outer edge of disc): 1.0 mm (0.039 in) Distance of runout check point (from hub center): Model 240: 115 mm (4.53 in) Model 250: 120 mm (4.72 in)

ACL064

CL-12

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL Inspection and Adjustment (Cont’d)

CLUTCH COVER AND FLYWHEEL 쐌 쐌

NGCL0019S02

Check clutch cover, installed on vehicle, for uneven diaphragm spring toe height. Uneven limit: 0.7 mm (0.028 in) If out of limit, adjust the height with Tool.

GI MA EM LC

SCL466

FLYWHEEL INSPECTION

NGCL0019S03

CAUTION: Do not allow any magnetic materials to contact the ring gear teeth. 쐌 Inspect contact surface of flywheel for slight burns or discoloration. Clean flywheel with emery paper. 쐌 Check flywheel runout. Refer to EM-52 (KA24DE), orEM-124 (VG33E, VG33ER), “FLYWHEEL/DRIVE PLATE RUNOUT”.

EC FE

MT

AEM100

Installation 쐌 쐌 쐌 쐌

NGCL0020

Apply recommended grease to contact surface of splines. Too much lubricant may damage clutch disc facing. Insert Tool into clutch disc hub when installing clutch cover and disc. Be careful not to allow grease to contaminate clutch facing.

AT TF PD AX

WCL035

SU BR ST RS BT HA SC EL

CL-13

IDX

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL Installation (Cont’d)

쐌

Tighten bolts in numerical order, in two steps. KA24DE, VG33E models First step: : 10 - 20 N·m (1.0 - 2.0 kg-m, 8 - 14 ft-lb) Final step: : 22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 22 ft-lb) VG33ER model First step: : 10 - 20 N·m (1.0 - 2.0 kg-m, 8 - 14 ft-lb) Final step: : 34.3 - 44.1 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)

WCL037

WCL038

CL-14

SERVICE DATA AND SPECIFICATIONS (SDS) Clutch Control System

Clutch Control System

NGCL0028

Type of clutch control

GI

Hydraulic

Clutch Master Cylinder (with clutch damper)

NGCL0021

Inner diameter

MA

15.87 mm (5/8 in)

Clutch Operating Cylinder Inner diameter

EM NGCL0022

19.05 mm (3/4 in)

LC

Clutch Disc

NGCL0023

Unit: mm (in) Model

240

250

250

Engine

KA24DE

VG33E

VG33ER

240 x 150 x 3.5 (9.45 x 5.91 x 0.138)

250 x 160 x 3.5 (9.84 x 6.30 x 0.138)

250 x 160 x 3.5 (9.84 x 6.30 x 0.138)

7.75 - 8.25 (0.305 - 0.3248) with 4,903 N (500 kg, 1,103 lb)

8.1 - 8.5 (0.3189 - 0.3346) with 6,473 N (660 kg, 1,455 lb)

8.1 - 8.5 (0.3189 - 0.3346) with 4,903 N (500 kg, 1,103 lb)

Wear limit of facing surface to rivet head

0.3 (0.012)

0.3 (0.012)

0.3 (0.012)

Runout limit of facing

1.0 (0.039)

1.0 (0.039)

1.0 (0.039)

Distance of runout check point (from hub center)

115 (4.53)

120 (4.72)

120 (4.72)

Maximum backlash of spline (at outer edge of disc)

1.0 (0.039)

1.0 (0.039)

1.0 (0.039)

Facing size (Outer dia. x inner dia. x thickness)

Thickness of disc assembly with load

EC FE

MT AT TF

Clutch Cover

NGCL0024

Unit: mm (in) Engine

KA24DE

VG33E

VG33ER

Model

240

250

250

2WD

4,903 N (500 kg, 1,103 lb)

6,473 N (660 kg, 1,455 lb)

7,355 N (750 kg, 1,653 lb)

4WD

—

6,473 N (660 kg, 1,455 lb)

7,355 N (750 kg, 1,653 lb)

37.5 - 39.5 (1.476 - 1.555)

36.5 - 38.5 (1.437 - 1.516)

37 - 39 (1.457 - 1.535)

0.7 (0.028)

0.7 (0.028)

0.7 (0.028)

PD AX

Set-load Diaphragm spring height Uneven limit of diaphragm spring toe height

Clutch Pedal

BR NGCL0025

Unit: mm (in) Clearance “C” between pedal stopper bracket and clutch pedal position switch (with clutch pedal fully depressed.)

SU

ST

0.1 - 1.0 (0.004 - 0.039)

RS

*: Measured from surface of dash lower panel to pedal pad.

BT HA SC EL

CL-15

IDX

NOTES

MANUAL TRANSMISSION SECTION

MT

GI MA EM LC EC

CONTENTS FS5W71C PREPARATION ...............................................................3 Special Service Tools ..................................................3 Commercial Service Tools ...........................................5 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................6 NVH Troubleshooting Chart.........................................6 MANUAL TRANSMISSION..........................................6 DESCRIPTION .................................................................7 Cross-sectional View ...................................................7 ON-VEHICLE SERVICE ..................................................8 Replacing Rear Oil Seal ..............................................8 REMOVAL .................................................................8 INSTALLATION..........................................................8 Position Switch Check .................................................8 REMOVAL AND INSTALLATION ...................................9 Removal.......................................................................9 Installation..................................................................10 OVERHAUL ...................................................................11 Case Components .....................................................11 Gear Components .....................................................12 Shift Control Components .........................................13 DISASSEMBLY..............................................................14 Case Components .....................................................14 DISASSEMBLY ........................................................14 Shift Control Components .........................................14 DISASSEMBLY ........................................................14 Gear Components .....................................................15 DISASSEMBLY ........................................................15 INSPECTION..................................................................18 Shift Control Components .........................................18 INSPECTION ...........................................................18 Gear Components .....................................................18 INSPECTION ...........................................................18 ASSEMBLY....................................................................20 Gear Components .....................................................20 ASSEMBLY .............................................................20 Shift Control Components .........................................26 ASSEMBLY .............................................................26

FE

Case Components .....................................................27 ASSEMBLY .............................................................27 SERVICE DATA AND SPECIFICATIONS (SDS) .........30 General Specifications...............................................30 Gear End Play ...........................................................30 Clearance Between Baulk Ring and Gear ................31 2ND & 3RD BAULK RING ........................................31 Available Snap Rings ................................................31 MAIN DRIVE GEAR BEARING ..................................31 MAINSHAFT FRONT ................................................31 COUNTER DRIVE GEAR .........................................31 OD MAINSHAFT BEARING ......................................32 Available Shims .........................................................32 COUNTERSHAFT FRONT BEARING ........................32

CL

AT TF PD AX

FS5R30A PREPARATION .............................................................33 Special Service Tools ................................................33 Commercial Service Tool...........................................35 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................36 NVH Troubleshooting Chart.......................................36 MANUAL TRANSMISSION........................................36 DESCRIPTION ...............................................................37 Cross-sectional View - 2WD Model...........................37 Cross-sectional View - 4WD Model...........................38 ON-VEHICLE SERVICE ................................................39 Replacing Rear Oil Seal - 2WD Model .....................39 REMOVAL ...............................................................39 INSTALLATION........................................................39 Position Switch Check ...............................................40 REMOVAL AND INSTALLATION .................................41 Removal.....................................................................41 2WD MODEL ...........................................................41 4WD MODEL ...........................................................42 Installation..................................................................43 OVERHAUL ...................................................................44 Case Components .....................................................44 Gear Components .....................................................45

SU BR ST RS BT HA SC EL IDX

CONTENTS Shift Control Components .........................................47 DISASSEMBLY..............................................................48 Case Components .....................................................48 DISASSEMBLY ........................................................48 Shift Control Components .........................................49 DISASSEMBLY ........................................................49 Gear Components .....................................................50 DISASSEMBLY ........................................................50 INSPECTION..................................................................54 Shift Control Components .........................................54 INSPECTION ...........................................................54 Gear Components .....................................................54 INSPECTION ...........................................................54 ASSEMBLY....................................................................56 Gear Components .....................................................56 ASSEMBLY .............................................................56 Shift Control Components .........................................64 ASSEMBLY .............................................................64 Case Components .....................................................65

(Cont’d)

ASSEMBLY .............................................................65 SERVICE DATA AND SPECIFICATIONS (SDS) .........67 General Specifications...............................................67 Gear End Play ...........................................................67 Clearance Between Baulk Ring and Gear ................67 DOUBLE BAULK RING ............................................68 Distance between Rear Surface of Reverse Cone and Reverse Baulk Ring..................................68 Available Snap Ring ..................................................68 MAIN DRIVE GEAR SNAP RING ..............................68 MAINSHAFT FRONT SNAP RING .............................68 COUNTER GEAR REAR SNAP RING .......................69 Available C-ring .........................................................69 MAINSHAFT C-RING ...............................................69 Available Shim and Washer ......................................69

MT-2

TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER ............69 REVERSE IDLER REAR THRUST WASHER .............70

PREPARATION

FS5W71C Special Service Tools

Special Service Tools

NGMT0045

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (KentMoore No.) Tool name

Description

ST23810001 ( — ) Adapter setting plate

Fixing adapter plate with gear assembly a: 166 mm (6.54 in) b: 270 mm (10.63 in)

GI MA EM LC

NT407

Removing overdrive mainshaft bearing a: 447 mm (17.60 in) b: 100 mm (3.94 in)

KV32101330 (See J26349-A) Puller

EC FE CL

NT408

Pressing counter gear and mainshaft

KV31100401 ( — ) Transmission press stand

AT

NT068

Tightening mainshaft lock nut a: 100 mm (3.94 in) b: 41 mm (1.61 in)

ST22520000 (J26348) Wrench

TF PD

NT409

Removing and installing fork rod retaining pin a: 2.3 mm (0.091 in) dia. b: 4 mm (0.16 in) dia.

ST23540000 (J25689-A) Pin punch

AX SU

NT442

Removing and installing 1st gear bushing Removing main drive gear bearing a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia.

ST30031000 (J22912-01) Puller

BR ST RS

NT411

ST23860000 ( — Drift

Installing counter drive gear a: 38 mm (1.50 in) dia. b: 33 mm (1.30 in) dia.

)

BT HA

NT065

Installing counter gear front and rear end bearings a: 29 mm (1.14 in) dia. b: 23 mm (0.91 in) dia.

ST22360002 (J25679-01) Drift

SC EL

NT065

MT-3

IDX

PREPARATION

FS5W71C

Special Service Tools (Cont’d) Tool number (KentMoore No.) Tool name

Description

ST22350000 (J25678-01) Drift

Installing OD gear bushing a: 34 mm (1.34 in) dia. b: 28 mm (1.10 in) dia.

NT065

Installing front cover oil seal a: 44 mm (1.73 in) dia. b: 31 mm (1.22 in) dia.

ST23800000 (J25691-01) Drift

NT065

Installing rear oil seal a: 60 mm (2.36 in) dia. b: 47 mm (1.85 in) dia.

ST33400001 (J26082) Drift

NT086

Removing rear oil seal a: 250 mm (9.84 in) b: 160 mm (6.30 in)

ST33290001 (J34286) Puller

NT414

Installing mainshaft ball bearing a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia.

ST30720000 (J25405) Drift

NT115

Installing main drive gear bearing a: 71.5 mm (2.815 in) dia. b: 47.5 mm (1.870 in) dia.

ST30613000 (J25742-3) Drift

NT073

Installing counter rear bearing a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia.

ST33200000 (J26082) Drift

NT091

Removing and installing mainshaft bearing (Use with J-25726-B)

(J-26349-A) Bearing Remover and Puller Set

WMT065

MT-4

PREPARATION

FS5W71C Special Service Tools (Cont’d)

Tool number (KentMoore No.) Tool name

Description

GI

(J-34286) Rear Race Puller

Removing races

MA EM WMT066

LC Removing gears and bearing

(J-39856) Gear and Bearing Removal Kit

EC FE CL

WMT067

Commercial Service Tools Tool name

NGMT0046

Description

Puller

Removing counter bearings, counter drive and OD gears

AT TF

NT077

Installing countershaft rear end bearing a: 40 mm (1.57 in) dia. b: 30 mm (1.18 in) dia.

Drift

PD AX

NT074

SU BR ST RS BT HA SC EL

MT-5

IDX

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NGMT0047

FS5W71C

NVH Troubleshooting Chart

NVH Troubleshooting Chart

NGMT0047S01

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.

MANUAL TRANSMISSION

MT-11

MT-11

MT-13

MT-13

MT-12

MT-12

MT-12

MT-12

OIL SEAL (Worn or damaged)

CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)

SHIFT FORK (Worn)

GEAR (Worn or damaged)

BEARING (Worn or damaged)

BAULK RING (Worn or damaged)

INSERT SPRING (Damaged)

Reference page

GASKET (Damaged)

Refer to MA-38, “Checking M/T Oil”.

NGMT0047S0101

3

3

2

2

1

2

OIL (Oil level is high.)

OIL (Wrong oil.)

Noise

OIL (Oil level is low.)

SUSPECTED PARTS (Possible cause)

Oil leakage

3

1

Hard to shift or will not shift

1

1

2

2

Symptom Jumps out of gear

1

MT-6

2

2

NGMT0048

DESCRIPTION

FS5W71C Cross-sectional View

Cross-sectional View

NGMT0048S01

GI MA EM LC EC FE CL

AT TF PD AX SU BR ST RS BT HA SC SMT153D

MT-7

EL IDX

ON-VEHICLE SERVICE

FS5W71C

Replacing Rear Oil Seal

Replacing Rear Oil Seal

NGMT0028

REMOVAL 1. 2. 쐌

NGMT0028S01

Remove the propeller shaft. Refer to PD-8, “Removal and Installation”. Remove rear oil seal using Tool. Always replace with a new seal once it has been removed.

AMT079

INSTALLATION 1. 쐌 2.

NGMT0028S02

Install new oil seal until it stops. Apply multi-purpose grease to seal lip of oil seal before installing. Install any part removed.

SMT480CA

Position Switch Check 쐌

NGMT0029

Check continuity. Switch

Gear position

Continuity

Reverse

Yes

Except reverse

No

Neutral

Yes

Except neutral

No

Back-up lamp switch

Park/neutral position (PNP) switch

SMT981D

MT-8

NGMT0030

REMOVAL AND INSTALLATION

FS5W71C Removal

Removal

NGMT0030S01

GI MA EM LC EC FE CL

AT TF PD AX SU BR ST RS BT HA SC WMT030

MT-9

EL IDX

REMOVAL AND INSTALLATION

FS5W71C

Removal (Cont’d)

CAUTION: Before separating the transmission from the engine, remove the crankshaft position sensor (OBD) from the transmission. Be careful not to damage sensor edge or ring gear teeth. NOTE: To prevent oil spills, drain transmission oil before removing transmission or insert plug into rear oil seal after removing propeller shaft. 쐌 Be careful not to damage spline, sleeve yoke and rear oil seal when removing propeller shaft. 1. Remove the battery negative terminal. 2. Remove the crankshaft position sensor (OBD) from the transmission upper side. 3. Remove the clutch operating cylinder from the transmission. 4. Disconnect the vehicle speed sensor, back-up switch, and park/neutral position (PNP) switch harness connectors. 5. Remove the starter motor from the transmission. 6. Disconnect the exhaust hanger. 7. Remove the propeller shaft. Refer to PD-8, “Removal and Installation”.

8. Remove the shift lever. 9. Support the engine by placing a jack under the oil pan. 쐌 Do not place jack under oil pan drain plug. 10. Remove the transmission crossmember. 11. Separate the transmission from the engine. WARNING: Support manual transmission while removing it.

SMT099A

Installation 1.

AMT190

NGMT0030S02

Tighten bolts securing transmission.

Bolt No.

Tightening torque N·m (kg-m, ft-lb)


mm (in)

1

40 - 49 (4.0 - 5.0, 29 - 36)

65 (2.56)

2

40 - 49 (4.0 - 5.0, 29 - 36)

58 (2.28)

3*

16 - 21 (1.6 - 2.2, 12 - 15)

25 (0.98)

4

16 - 21 (1.6 - 2.2, 12 - 15)

16 (0.63)

*: With nut

2.

Installation is in the reverse order of removal.

MT-10

NGMT0031

OVERHAUL

FS5W71C Case Components

Case Components

NGMT0031S01

GI MA EM LC EC FE CL

AT TF PD AX SU BR ST RS BT HA SC WMT062

MT-11

EL IDX

OVERHAUL

FS5W71C

Gear Components

Gear Components

NGMT0031S02

WMT063

MT-12

OVERHAUL

FS5W71C Shift Control Components

Shift Control Components

NGMT0031S04

CAUTION: To avoid damage when replacing shift knob, remove shift lever with knob, as assembled.

GI MA EM LC EC FE CL

AT TF PD AX SU BR ST RS BT HA SC WMT040

EL

MT-13

IDX

DISASSEMBLY

FS5W71C

Case Components

Case Components DISASSEMBLY 1. a.

NGMT0032

쐌

Remove rear extension. Remove control housing, check ball, return spring plugs, select check plungers and return springs. Also remove reverse check plug, check spring and check ball. Be careful not to lose check balls.

b. c. d.

Drive out striking lever retaining pin. Remove striking lever from striking rod. Remove rear extension by lightly tapping on it.

2.

Remove front cover, gasket, counter gear front bearing shim and main drive gear ball bearing snap ring. Separate transmission case from adapter plate by lightly tapping on it.

SMT161D

AMT132

3.

AMT131

4. 쐌

Remove oil seal from front cover. Be careful not to damage mating surface of front cover.

SMT166D

Shift Control Components DISASSEMBLY 1. 2. 3.

NGMT0033

Set up Tool on adapter plate. Remove striking rod from adapter plate. Remove check ball plugs, check springs, and check balls.

SMT545A

MT-14

DISASSEMBLY

FS5W71C Shift Control Components (Cont’d)

4.

Drive out retaining pins. Then drive out fork rods and remove interlock balls.

GI MA EM LC

SMT984

Gear Components DISASSEMBLY 1. 쐌 쐌

NGMT0034

EC

Before disassembly, measure the end play of each gear. If end play is not within the specified limit, disassemble and inspect the parts. Replace any part which is worn or damaged. Refer to “Gear End Play”, MT-30.

FE

Mesh 2nd and reverse gear, then remove counter gear front bearing using a suitable puller. Remove snap ring, then remove sub-gear bracket, sub-gear spring and sub-gear.

AT

CL

SMT025

2. 3.

TF PD AX

SMT174A

4. 쐌 5.

Remove counter drive gear together with main drive gear assembly using a suitable puller. When removing main drive gear assembly, be careful not to drop pilot bearing or baulk ring. Remove snap ring, then remove 3rd and 4th synchronizer assembly and 3rd main gear.

SU BR ST RS

SMT162A

6. a.

Disassemble parts at rear of adapter plate as follows: Release staking on both counter gear and mainshaft lock nuts, then loosen both nuts. Mainshaft lock nut: Left-hand thread

BT HA SC EL

AMT133

MT-15

IDX

DISASSEMBLY

FS5W71C

Gear Components (Cont’d)

b. c. d.

e.

SMT547A

f. g. h. i. j. k. l.

Remove overdrive counter gear together with counter gear rear end bearing using a suitable puller. Remove reverse counter gear and spacer. Remove snap rings from reverse idler shaft, then remove reverse idler gear, thrust washers and reverse idler gear bearing. Remove snap ring and pull out overdrive mainshaft bearing, then remove snap ring. Remove mainshaft lock nut. Remove speedometer drive gear and steel ball. Remove thrust washer, steel roller, roller bearing and washer. Remove overdrive main gear, needle bearing and baulk ring (overdrive). Remove counter gear by tapping on rear end of counter gear. Press out overdrive gear bushing and overdrive & reverse synchronizer assembly. Remove reverse main gear and needle bearing.

m. Press out reverse gear bushing.

SMT554A

7. 쐌

Remove thrust washer, steel ball, 1st main gear and needle bearing. Be careful not to lose steel ball.

SMT383A

8.

Press out 1st gear bushing together with 2nd main gear using Tool. Remove 2nd gear needle bearing.

TM049A

MT-16

DISASSEMBLY

FS5W71C Gear Components (Cont’d)

9. a. b.

Remove main drive gear ball bearing. Remove snap ring. Remove main drive gear ball bearing.

GI MA EM LC

SMT420A

EC FE CL

AT TF PD AX SU BR ST RS BT HA SC EL

MT-17

IDX

INSPECTION

FS5W71C

Shift Control Components

Shift Control Components INSPECTION 쐌

NGMT0035

Check contact and sliding surfaces of fork rods for wear, scratches, projections and other damage.

SMT075C

Gear Components INSPECTION Gears and Shafts 쐌 쐌

NGMT0036 NGMT0036S01

Check shafts for cracks, wear and bending. Check gears for excessive wear, chips and cracks.

SMT386A

SMT550A

Synchronizers 쐌 쐌 쐌 쐌

NGMT0036S02

Check spline portion of coupling sleeves, synchronizer hubs, and gears for wear, chips, and cracks. Check baulk rings for cracks and deformation. Check shifting inserts for wear and deformation. Check insert spread springs for deformation.

SMT427C

MT-18

INSPECTION

FS5W71C Gear Components (Cont’d)

쐌 1) 쐌

Measure baulk ring wear. Measure clearance between baulk ring and gear. Refer to “Clearance Between Baulk Ring and Gear”, MT-31. If the clearance is less than the wear limit, replace baulk ring.

GI MA EM LC

SMT140

Bearings 쐌

NGMT0036S03

Make sure all bearings roll freely and are free from noise, cracks, pitting or wear.

EC FE CL

SMT418A

AT TF PD AX SU BR ST RS BT HA SC EL

MT-19

IDX

ASSEMBLY

FS5W71C

Gear Components

Gear Components ASSEMBLY

NGMT0037

AMT185

1. 2. 쐌 쐌 a.

Install bearings into case components. Assemble adapter plate parts. Install oil gutter on adapter plate and expand on rear side. Install bearing retainer. Insert reverse idler shaft, then install bearing retainer.

b.

Tighten each screw, then stake each one at two points.

3. a.

Install main drive gear ball bearing. Press main drive gear ball bearing.

SMT778C

SMT674C

SMT425A

MT-20

ASSEMBLY

FS5W71C Gear Components (Cont’d)

b.

Select and install proper main drive gear snap ring to achieve proper clearance of groove. Refer to “MAIN DRIVE GEAR BEARING”, MT-31. Allowable clearance of groove: 0 - 0.13 mm (0 - 0.0051 in)

GI MA EM LC

SMT170D

4. 쐌

Assemble synchronizers. Assemble the 1st and 2nd synchronizer.

EC FE CL

SMT054C

쐌

Check coupling sleeve and synchronizer hub orientation.

AT TF PD AX SU BR ST RS SMT206C

BT HA SC EL

MT-21

IDX

ASSEMBLY

FS5W71C

Gear Components (Cont’d)

쐌

Assemble the 3rd and 4th synchronizer.

쐌

Assemble the overdrive and reverse synchronizer.

5. a.

Assemble the front side components onto the mainshaft. Install 2nd main gear, needle bearing and 1st and 2nd synchronizer assembly, then press 1st gear bushing on mainshaft. Install 1st main gear.

WMT053

SMT207CA

b.

SMT752A

MT-22

ASSEMBLY

FS5W71C Gear Components (Cont’d)

c. 쐌

Install steel ball and 1st gear washer. Before installation, apply multi-purpose grease to steel ball and to both sides of the 1st gear washer.

GI MA EM LC

TM358

6. a.

Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft as follows: Press mainshaft assembly into adapter plate using Tool.

EC FE CL

TM439

b. c. 쐌

Press counter gear into adapter plate using Tool. Install 3rd main gear and needle bearing, then press 3rd and 4th synchronizer assembly onto mainshaft. Pay attention to the direction of 3rd and 4th synchronizer.

AT TF PD AX

SMT750

d.

e.

Install front mainshaft snap ring. Select proper front mainshaft snap ring to achieve proper clearance of groove. Refer to “MAINSHAFT FRONT”, MT-31. Allowable clearance of groove: 0 - 0.13 mm (0 - 0.0051 in) Apply gear oil to mainshaft pilot bearing and install it on mainshaft.

SU BR ST RS

TM441

f. 쐌

Press counter drive gear together with main drive gear using Tool. Pay attention to the direction of counter drive gear.

BT HA SC EL

SMT412C

MT-23

IDX

ASSEMBLY

FS5W71C

Gear Components (Cont’d)

g. i.

쐌

Install sub-gear components. Install sub-gear and sub-gear bracket on counter drive gear and then select proper snap ring that will minimize clearance of groove in counter gear. Refer to “COUNTER DRIVE GEAR”, MT-31. Do not install sub-gear spring at this time. Allowable clearance of groove: 0 - 0.18 mm (0 - 0.0071 in)

SMT201D

ii.

Remove snap ring, sub-gear bracket and sub-gear from counter gear. iii. Reinstall sub-gear, sub-gear spring, sub-gear bracket and snap ring.

SMT202D

h.

Press counter/gear front bearing onto counter gear using Tool.

7.

Install rear side components on mainshaft and counter gear as follows: Install sub-gear parts (sub-gear, sub-gear spring, sub-gear bracket, steel ball and snap ring) on the reverse idler gear. Install reverse idler gear to reverse idler shaft along with reverse idler thrust washer, snap rings and reverse idler gear bearing.

TM443

a. b.

AMT134

MT-24

ASSEMBLY

FS5W71C Gear Components (Cont’d)

c. 쐌

Install bushing, reverse main gear and overdrive and reverse synchronizer to mainshaft. Pay attention to the direction of synchronizer hub.

GI MA EM LC EC FE CL

SMT207CA

d. e. f.

g. h. 쐌

Install overdrive gear bushing to mainshaft using Tool. Install overdrive main gear and needle bearing to mainshaft. Install spacer, reverse counter gear and overdrive counter gear to counter/gear. OD main gear and OD counter gear should be handled as a matched set. Install washer, roller bearing, steel roller and thrust washer. Tighten mainshaft lock nut temporarily. Always use new lock nut.

i.

Install counter/gear rear end bearing using Tool.

쐌

AT TF PD AX

SMT531

SU BR ST RS

SMT043

8. 쐌

Mesh 2nd and reverse gears, then tighten mainshaft lock nut using Tool. Always use new lock nut. Mainshaft lock nut: : 137 - 167 N·m (14.0 - 17.0 kg-m, 101 - 123 ft-lb)

BT HA SC EL

SMT003A

MT-25

IDX

ASSEMBLY

FS5W71C

Gear Components (Cont’d)

쐌

9. 쐌

Use the chart shown at left to determine the proper reading torque. (Length of torque wrench vs. setting or reading torque) Reference: Formula to convert torque wrench indication to the true torque value: T = (0.1 m (0.33 ft) + L) /L × C If the specified torque is T kg-m (ft-lb), the torque wrench scale indication C is determined using the following formula. C = (T × L)/( 0.1 m (0.33 ft) + L) Tighten counter gear lock nut. Always use new lock nut. Counter gear lock nut: : 98 - 127 N·m (10.0 - 13.0 kg-m, 72 - 94 ft-lb)

SMT004A

10. Stake mainshaft lock nut and counter gear lock nut using a punch. 11. Measure gear end play. Refer to “DISASSEMBLY”, MT-15. 12. Install snap ring and OD mainshaft bearing, then snap ring. Refer to “OD MAINSHAFT BEARING”, MT-32. Allowable clearance: 0 - 0.14 mm (0 - 0.0055 in)

AMT145

Shift Control Components ASSEMBLY

NGMT0038

1.

Install fork rods, interlock plunger, interlock balls and check balls.

2.

Install 1st and 2nd shift fork, then drive in retaining pin.

SMT992-A

SMT989

MT-26

ASSEMBLY

FS5W71C Shift Control Components (Cont’d)

3.

Install 3rd and 4th shift fork, then drive in retaining pin.

GI MA EM LC

SMT990

4.

Install overdrive and reverse shift fork, then drive in retaining pin.

EC FE CL

SMT991

Case Components ASSEMBLY 1. 쐌

AT NGMT0039

Install front cover oil seal using Tool. Apply multi-purpose grease to seal lip.

TF PD AX

SMT036

2. 쐌

Apply sealant to mating surface of transmission case as shown in the figure at left. Use Genuine Anaerobic Liquid Gasket, or equivalent.

SU BR ST RS

SMT061C

3.

Slide gear assembly onto adapter plate by lightly tapping it using a soft hammer.

BT HA SC EL

SMT013

MT-27

IDX

ASSEMBLY

FS5W71C

Case Components (Cont’d)

4.

Install main drive gear ball bearing snap ring.

5.

Apply sealant to mating surface of adapter plate as shown at left. Use Genuine Anaerobic Liquid Gasket, or equivalent.

SMT672A

쐌

SMT062C

6. 7.

Place shift forks in neutral position. Install striking lever and rod onto adapter plate and align striking lever with shift brackets.

8. 쐌

Install rear extension. Tighten mounting bolts equally in a criss-cross pattern.

9.

Install striking lever retaining pin.

SMT801B

SMT180D

AMT132

MT-28

ASSEMBLY

FS5W71C Case Components (Cont’d)

10. Select counter gear front bearing shim. Refer to “COUNTERSHAFT FRONT BEARING”, MT-32. Allowable clearance (A) from bearing surface to transmission case: 0 - 0.16 mm (0 - 0.0063 in) 11. Install gasket and front cover.

GI MA EM LC

SMT205D

12. Install check ball, return springs, select check plungers and plugs. 13. Install control housing and gasket.

EC FE CL

SMT161D

AT TF PD AX SU BR ST RS BT HA SC EL

MT-29

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5W71C

General Specifications

General Specifications

NGMT0040

Applied model

KA24DE (2WD)

Transmission

FS5W71C

Number of speed

5

Shift pattern

MT-SDS-2

Synchromesh type

Warner 1st

3.592

2nd

2.246

3rd

1.415

4th

1.000

OD

0.821

Reverse

3.657

Gear ratio

Mainshaft (Number of teeth)

Countershaft gear (Number of teeth)

Drive

21

1st

33

2nd

28

3rd

26

OD

21

Reverse

36

Drive

32

1st

14

2nd

19

3rd

28

OD

39

Reverse

15

Reverse idler gear (Number of teeth)

21

Oil capacity
(US pt, Imp pt)

2.0 (4-1/4, 3-1/2) Reverse synchronizer

Remarks

Installed

Double cone synchronizer

2nd & 3rd

Sub-gear

Counter drive gear & reverse idler gear

Gear End Play

NGMT0041

Unit: mm (in) 1st gear

0.31 - 0.41 (0.0122 - 0.0161)

2nd gear

0.11 - 0.21 (0.0043 - 0.0083)

3rd gear

0.11 - 0.21 (0.0043 - 0.0083)

Overdrive gear

0.24 - 0.41 (0.0094 - 0.0161)

MT-30

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5W71C

Clearance Between Baulk Ring and Gear

Clearance Between Baulk Ring and Gear

NGMT0042

Unit: mm (in) 1st

1.20 - 1.60 (0.0473 - 0.0629)

Main drive

1.20 - 1.60 (0.0473 - 0.0629)

Overdrive

1.20 - 1.60 (0.0473 - 0.0629)

Reverse

1.10 - 1.55 (0.0433 - 0.0610)

MA

Standard

1st

0.80 (0.0315)

main drive

0.80 (0.0315)

Overdrive

0.80 (0.0315)

Reverse

0.70 (0.0276)

EM LC

Wear limit

2ND & 3RD BAULK RING

GI

EC NGMT0042S03

Unit: mm (in) Dimension

Standard

A

0.7 - 0.9 (0.028 - 0.035)

FE

Wear limit

CL 0.2 (0.008)

0.6 - 1.1 (0.024 - 0.043)

B

Available Snap Rings

NGMT0043

MAIN DRIVE GEAR BEARING

AT

NGMT0043S01

Unit: mm (in) Allowable clearance

TF

0 - 0.13 (0 - 0.0051) Thickness

Part number*

1.87 (0.0736)

32204-78001

1.94 (0.0764)

32204-78002

2.01 (0.0791)

32204-78003

PD AX

*Always check with the Parts Department for the latest parts information.

MAINSHAFT FRONT

NGMT0043S02

SU

Unit: mm (in) Allowable clearance

0 - 0.18 (0 - 0.0071)

BR

Thickness

Part number*

2.4 (0.094)

32263-V5200

2.5 (0.098)

32263-V5201

ST RS

*Always check with the Parts Department for the latest parts information.

COUNTER DRIVE GEAR

NGMT0043S03

Unit: mm (in) Allowable clearance

BT

0 - 0.13 (0 - 0.0051) Thickness

Part number*

1.4 (0.055)

32215-E9000

1.5 (0.059)

32215-E9001

1.6 (0.063)

32215-E9002

*Always check with the Parts Department for the latest parts information.

MT-31

HA SC EL IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5W71C

Available Snap Rings (Cont’d)

OD MAINSHAFT BEARING

NGMT0043S04

Unit: mm (in) Allowable clearance

0 - 0.14 (0 - 0.0055) Thickness

Part number*

1.1 (0.043)

32228-20100

1.2 (0.047)

32228-20101

1.3 (0.051)

32228-20102

1.4 (0.055)

32228-20103

*Always check with the Parts Department for the latest parts information.

Available Shims

NGMT0044

COUNTERSHAFT FRONT BEARING

NGMT0044S01

Unit: mm (in) Allowable clearance “A” 0 - 0.16 (0 - 0.0063)

SMT205D

“A”

Thickness of shim

4.52 - 4.71 (0.1780 - 0.1854)

Part number* Not necessary

4.42 - 4.51 (0.1741 - 0.1775)

0.1 (0.004)

32218-V5000

4.32 - 4.41 (0.1701 - 0.1736)

0.2 (0.008)

32218-V5001

4.22 - 4.31 (0.1662 - 0.1691)

0.3 (0.012)

32218-V5002

4.12 - 4.21 (0.1622 - 0.1657)

0.4 (0.016)

32218-V5003

4.02 - 4.11 (0.1583 - 0.1618)

0.5 (0.020)

32218-V5004

3.92 - 4.01 (0.1544 - 0.1578)

0.6 (0.024)

32218-V5005

*Always check with the Parts Department for the latest parts information.

MT-32

PREPARATION

FS5R30A Special Service Tools

Special Service Tools

NGMT0001

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

GI

Description

MA Removing and installing retaining pin a: 2.3 mm (0.091 in) dia. b: 4 mm (0.16 in) dia.

ST23540000 (J25689-A) Pin punch

EM LC

NT442

Removing 1st & 2nd synchronizer assembly Removing counter gear rear thrust bearing Removing main drive bearing a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia.

ST30031000 (J22912-01) Puller

EC FE

NT411

Removing rear oil seal a: 250 mm (9.84 in) b: 160 mm (6.30 in)

ST33290001 (J34286) Puller

CL

AT NT414

ST33230000 ( — Drift

Removing mainshaft and counter gear a: 51 mm (2.01 in) dia. b: 28.5 mm (1.122 in) dia.

)

TF PD AX

NT084

Removing counter gear front bearing (Use with KV38100300) a: 34 mm (1.34 in) dia. b: 28 mm (1.10 in) dia.

ST22350000 (J25678-01) Drift

SU BR

NT065

Removing counter gear front bearing (Use with ST22350000) Installing counter gear rear bearing a: 54 mm (2.13 in) dia. b: 32 mm (1.26 in) dia.

KV38100300 (J25523) Drift

ST RS

NT065

1 Removing mainshaft front bearing 2 Installing mainshaft front bearing a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia.

ST30720000 1 (J34286) 2 (J34331) Drift

BT HA

NT115

1 Installing counter gear front bearing 2 Installing front cover oil seal a: 44 mm (1.73 in) dia. b: 24.5 mm (0.965 in) dia.

ST33210000 1 (J25523) 2 (J25803-01) Drift

SC EL

NT084

MT-33

IDX

PREPARATION

FS5R30A

Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

ST30613000 (J25742-3) Drift

Installing main drive gear bearing a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia.

NT073

1 Removing counter gear rear bearing 2 Installing OD gear bushing 2 Removing and installing mainshaft rear bearing (4WD model) 2 Installing reverse cone 3 Installing reverse counter gear 4 Installing counter gear rear end bearing a: 40 mm (1.57 in) dia. b: 31 mm (1.22 in) dia.

ST37750000 1 (J34286) 2 (J34332) 3 (J34334) 4 (J25679-01) Drift NT065

Installing reverse hub Installing mainshaft rear bearing (2WD model) a: 45 mm (1.77 in) dia. b: 36 mm (1.42 in) dia.

ST22452000 (J34337) Drift

NT065

Installing rear oil seal a: 60 mm (2.36 in) dia. b: 47 mm (1.85 in) dia.

ST33400001 (J26082) Drift

NT086

Installing mainshaft and counter gear (Use with J34328)

(J26349-3) Puller leg

NT078

(J34328) Puller

Installing mainshaft and counter gear (Use with J26349-3)

NT079

Installing sub-gear snap ring a: 44.5 mm (1.752 in) dia. b: 38.5 mm (1.516 in) dia.

(J26092) Drift

NT065

Installing OD main gear Installing reverse gear bushing a: 44.5 mm (1.752 in) dia. b: 40.5 mm (1.594 in) dia.

(J34342) Drift

NT065

MT-34

PREPARATION

FS5R30A Special Service Tools (Cont’d)

Tool number (Kent-Moore No.) Tool name

Description

GI

ST33220000 (J25804-01) Drift

Installing mainshaft rear bearing a: 37 mm (1.46 in) dia. b: 22 mm (0.87 in) dia.

MA EM

NT084

LC

Removing and installing mainshaft bearing (Use with J-25726-B)

(J-26349-A) Bearing Remover and Puller Set

EC FE WMT065

CL

Removing races

(J-34286) Rear Race Puller

AT WMT066

TF

Removing gears and bearing

(J-39856) Gear and Bearing Removal Kit

PD AX WMT067

Commercial Service Tool Tool name

SU NGMT0002

Description

BR

Puller

Removing Removing Removing Removing

counter gear rear end bearing mainshaft rear bearing (2WD model) reverse synchronizer hub reverse counter gear

ST RS

NT077

BT HA SC EL

MT-35

IDX

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NGMT0023

FS5R30A

NVH Troubleshooting Chart

NVH Troubleshooting Chart

NGMT0023S01

Use the chart below to help you find the cause of the problem. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

MANUAL TRANSMISSION

MT-47

MT-45

MT-45

MT-45

MT-45

GEAR (Worn or damaged)

BEARING (Worn or damaged)

BAULK RING (Worn or damaged)

INSERT SPRING (Damaged)

1

SHIFT FORK (Worn)

1

MT-47

Hard to shift or will not shift

CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)

1

MT-47

3

O-RING (Worn or damaged)

Oil leakage

MT-44

2

OIL SEAL (Worn or damaged)

1

MT-44

OIL (Wrong)

Noise

OIL (Level low)

SUSPECTED PARTS (Possible cause)

GASKET (Damaged)

Reference page

OIL (Level too high)

Refer to MA-38, “Checking M/T Oil”.

NGMT0023S0101

3

3

2

2

2

2

2

Symptom Jumps out of gear

1

MT-36

2

2

NGMT0005

DESCRIPTION

FS5R30A Cross-sectional View — 2WD Model

Cross-sectional View — 2WD Model

NGMT0005S01

GI MA EM LC EC FE CL

AT TF PD AX SU BR ST RS BT HA SC WMT041

MT-37

EL IDX

DESCRIPTION

FS5R30A

Cross-sectional View — 4WD Model

Cross-sectional View — 4WD Model

NGMT0005S02

SMT320D

MT-38

ON-VEHICLE SERVICE

FS5R30A Replacing Rear Oil Seal — 2WD Model

Replacing Rear Oil Seal — 2WD Model REMOVAL 1. 2. 쐌

NGMT0003 NGMT0003S01

Remove the propeller shaft. Refer to PD-8, “Removal and Installation”. Remove rear oil seal using Tool. Always replace with a new seal once it has been removed.

GI MA EM LC

SMT479CA

INSTALLATION 1. 쐌 2.

NGMT0003S02

Install new oil seal until it stops. Apply multi-purpose grease to seal lip of oil seal before installing. Install any part removed.

EC FE CL

SMT480CA

AT TF PD AX SU BR ST RS BT HA SC EL

MT-39

IDX

ON-VEHICLE SERVICE

FS5R30A

Position Switch Check

Position Switch Check Switch

NGMT0004

Gear position

Continuity

Reverse

Yes

Except reverse

No

Neutral

Yes

Except neutral

No

Back-up lamp switch

Park/neutral position (PNP) switch

SMT981D

AMT205

MT-40

NGMT0006

REMOVAL AND INSTALLATION

FS5R30A Removal

Removal

NGMT0006S01

CAUTION: When removing the M/T assembly from engine, first remove the crankshaft position sensor (OBD) from the M/T assembly. Be careful not to damage sensor edge.

GI MA EM LC EC FE CL

AMT189

2WD MODEL

NGMT0006S0101

AT

Disconnect the battery negative terminal. Remove the shift lever with control housing from the transmission. Remove the crankshaft position sensor (OBD) from the upper side of the transmission case. Remove the clutch operating cylinder from the transmission. Tighten the clutch operating cylinder to the specified torque. Refer to CL-5, “CLUTCH SYSTEM”. Disconnect the vehicle speed sensor, back-up lamp switch, heated oxygen sensor (rear), and the park/neutral position (PNP) switch harness connectors. Remove the starter motor from the transmission. : 41 - 52 N·m (4.2 - 5.3 kg-m, 30 - 38 ft-lb) Remove propeller shaft. Refer to PD-8, “Removal”. Insert plug into rear oil seal after removing propeller shaft. Be careful not to damage spline, sleeve yoke and rear oil seal when removing propeller shaft. Remove the gussets from the transmission or engine.

TF

Remove exhaust tube mounting bracket from transmission. Refer to FE-9, “EXHAUST SYSTEM”. 10. Support manual transmission with a jack. 11. Remove rear mounting member. Tighten rear mounting member to the specified torque. Refer to EM-112, “ENGINE REMOVAL”. 12. Lower manual transmission as much as possible. WARNING: Support manual transmission while removing it.

BT

1. 2. 3. 4.

5.

6. 7. 쐌 쐌 8. 9.

PD AX SU BR ST RS

HA SC EL

SMT099A

MT-41

IDX

REMOVAL AND INSTALLATION

FS5R30A

Removal (Cont’d)

AMT203

4WD MODEL 1. 2.

NGMT0006S0102

Disconnect the battery negative terminal. Remove the shift lever from the transmission and the control lever from the transfer. 3. Remove the clutch operating cylinder from the transmission. Tighten the clutch operating cylinder to the specified torque. Refer to CL-5, “CLUTCH SYSTEM”. 4. Disconnect the vehicle speed sensor, back-up lamp switch, heated oxygen sensor (rear), and the park/neutral position (PNP) switch harness connectors. 5. Remove the starter motor from the transmission. : 41 - 52 N·m (4.2 - 5.3 kg-m, 30 - 38 ft-lb) 6. Remove the front and rear propeller shafts. Refer to PD-8, “Removal”. 쐌 Insert plug into rear oil seal after removing propeller shaft. 쐌 Be careful not to damage spline, sleeve yoke and rear oil seal when removing propeller shaft. 7. Remove the exhaust tube mounting bracket from the transmission. Refer to FE-9, “EXHAUST SYSTEM”. 8. Remove the front exhaust tubes and center pipe. 9. Remove the torsion bars and mounts. Refer to SU-12, “Removal”. 10. Remove the rear torsion bar crossmember. 11. Remove the gussets from the transmission or engine. 12. Support the manual transmission with a jack. 13. Remove the rear mounting member. Tighten the rear mounting member to the specified torque. Refer to EM-112, “ENGINE REMOVAL”. 14. Lower the manual transmission as much as possible. WARNING: Support the manual transmission together with the transfer, while removing it.

MT-42

REMOVAL AND INSTALLATION

FS5R30A Removal (Cont’d)

15. Remove the crankshaft position sensor (OBD) from the upper side of the transmission case. 16. Remove the transmission bolts. WARNING: Support the manual transmission together with the transfer, while removing it.

GI MA EM LC

SMT558A

Installation 쐌

NGMT0006S02

Tighten bolt securing transmission.

EC

Bolt No.

Tightening torque N·m (kg-m, ft-lb)


mm (in)

1

39 - 49 (4.0 - 5.0, 29 - 36)

65 (2.56)

2

39 - 49 (4.0 - 5.0, 29 - 36)

58 (2.28)

3

29 - 39 (3.0 - 4.0, 22 - 29)

20 (0.79)

4 (Starter spacer and cover plate)

29 - 39 (3.0 - 4.0, 22 - 29)

25 (0.98)

FE CL

WMT068

쐌

Installation is in the reverse order of removal.

AT TF PD AX SU BR ST RS BT HA SC EL

MT-43

IDX

NGMT0007

OVERHAUL

FS5R30A

Case Components

Case Components

NGMT0007S01

WMT060

MT-44

OVERHAUL

FS5R30A Gear Components

Gear Components

NGMT0007S02

GI MA EM LC EC FE CL

AT TF PD AX SU BR ST RS BT HA SC WMT064

MT-45

EL IDX

OVERHAUL

FS5R30A

Gear Components (Cont’d)

WMT048

MT-46

OVERHAUL

FS5R30A Shift Control Components

Shift Control Components

NGMT0007S03

GI MA EM LC EC FE CL

AT TF PD AX SU BR ST RS BT HA SC WMT061

MT-47

EL IDX

DISASSEMBLY

FS5R30A

Case Components

Case Components DISASSEMBLY 1.

NGMT0008

쐌

Remove check ball plug, check spring and check ball. Then remove interlock stopper. If interlock assembly is removed as a unit, the check ball can fall into transmission case. Be careful not to lose check ball.

2. 쐌

Remove control housing, return spring and check ball. Be careful not to lose check ball.

3.

Drive out retaining pin from striking arm.

4.

Remove rear extension (or OD gear case) together with striking arm by tapping lightly.

5.

Remove front cover and gasket.

쐌

SMT366A

SMT367A

SMT368A

SMT135C

SMT370A

MT-48

DISASSEMBLY

FS5R30A Case Components (Cont’d)

6.

Remove stopper ring and main drive bearing snap ring.

GI MA EM LC

SMT371A

7.

Remove transmission case by tapping lightly.

EC FE CL SMT372A

8.

Remove front cover oil seal.

AT TF PD AX SMT392A

Shift Control Components DISASSEMBLY 1. 2.

SU NGMT0009

Mount adapter plate on vise. Remove OD and reverse fork rod.

BR ST RS

SMT373A

3. 4.

Drive out retaining pin from striking lever. While pulling out striking rod, remove striking lever and striking interlock. Then remove 1st and 2nd, 3rd and 4th and reverse shift fork.

BT HA SC EL

SMT374A

MT-49

IDX

DISASSEMBLY

FS5R30A

Shift Control Components (Cont’d)

5. 6.

Drive out retaining pin from OD shift fork. Pull out OD fork rod and then remove OD shift fork.

SMT375A

Gear Components DISASSEMBLY 1. 쐌

NGMT0010

Before removing gears and shafts, measure each gear end play. Refer to “Gear End Play”, MT-67. If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft.

SMT376A

2. a.

Remove rear side components on mainshaft and counter gear. Remove reverse coupling sleeve.

b.

Remove mainshaft rear snap ring and counter gear rear snap ring. Remove C-ring holder and mainshaft C-rings from mainshaft. Use punch and hammer to remove C-rings.

SMT463A

c.

SMT377A

d. e. f.

Pull out counter gear rear end bearing. Remove reverse idler gear and reverse idler thrust washers. Pull out mainshaft rear bearing (2WD model).

SMT378A

MT-50

DISASSEMBLY

FS5R30A Gear Components (Cont’d)

g.

Pull out reverse main gear together with mainshaft spacer and reverse synchronizer hub. Then remove reverse gear needle bearings.

GI MA EM LC

SMT380A

h. i.

Pull out reverse counter gear. Remove OD coupling sleeve together with OD baulk ring, reverse baulk ring and spring inserts.

EC FE CL

SMT773A

j.

Pull out reverse gear bushing.

AT TF PD AX SMT770A

k.

Pull out OD counter gear together with reverse cone.

SU BR ST RS

SMT771A

3.

Press out mainshaft and counter gear alternately.

BT HA SC EL

MT-51

IDX

DISASSEMBLY

FS5R30A

Gear Components (Cont’d)

AMT174A

4. a. b. 쐌

Remove front side components on mainshaft. Remove 1st gear washer and steel ball. Remove 1st main gear and 1st gear needle bearing. Be careful not to lose steel ball.

c.

Press out 2nd main gear together with 1st gear bushing and 1st and 2nd synchronizer assembly. Remove mainshaft front snap ring.

SMT383A

d.

SMT482C

e.

Press out 3rd main gear together with 3rd and 4th synchronizer assembly and 3rd gear needle bearing.

SMT385A

MT-52

DISASSEMBLY

FS5R30A Gear Components (Cont’d)

5. a.

Remove front side components on counter gear. Remove counter gear rear thrust bearing.

GI MA EM LC

SMT404A

b.

Remove sub-gear components.

EC FE CL SMT470A

6. a. b.

Remove main drive gear bearing. Remove main drive gear snap ring. Press out main drive gear bearing.

AT TF PD AX

SMT420A

7.

Remove bearings from case components.

SU BR ST RS BT HA SC AMT173

MT-53

EL IDX

INSPECTION

FS5R30A

Shift Control Components

Shift Control Components INSPECTION 쐌

NGMT0011

Check contact surface and sliding surface for wear, scratches, projections or other damage.

SMT398A

Gear Components INSPECTION Gears and Shafts 쐌 쐌

NGMT0012 NGMT0012S01

Check shafts for cracks, wear or bending. Check gears for excessive wear, chips or cracks.

SMT386A

SMT423A

Synchronizers 쐌 쐌 쐌 쐌

NGMT0012S02

Check spline portion of coupling sleeves, hubs, and gears for wear or cracks. Check baulk rings for cracks or deformation. Check shifting inserts for wear or deformation. Check insert springs for deformation.

SMT427C

쐌 쐌

Measure wear of main drive, 1st and OD baulk rings. Refer to “Clearance Between Baulk Ring and Gear”, MT-67. If the clearance is smaller than the wear limit, replace baulk ring.

SMT140

MT-54

INSPECTION

FS5R30A Gear Components (Cont’d)

쐌 a) b)

SMT041B

쐌

Measure wear of 2nd and 3rd baulk rings. Place baulk rings in position on synchronizer cone. While holding baulk rings 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.

GI MA EM LC EC FE CL

SMT042B

쐌 a) b)

c)

Measure wear of reverse baulk ring. Place baulk ring in position on reverse cone. While holding baulk ring against reverse cone as far as it will go, measure dimension “A” with dial indicator. Dimension “A”: Standard 0.35 to 0.95 mm (0.0119 to 0.0295 in) Wear limit 1.1 mm (0.043 in) If dimension “A” is larger than the wear limit, replace baulk ring.

AT TF PD AX

SMT424A

Bearings 쐌

NGMT0012S03

Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

SU BR ST RS

SMT418A

BT HA SC EL

MT-55

IDX

ASSEMBLY

FS5R30A

Gear Components

Gear Components ASSEMBLY

NGMT0013

AMT172

1. 2. a.

Install bearings into case components. Install main drive gear bearing. Press main drive gear bearing.

b.

Select proper main drive gear snap ring to minimize clearance of groove. Refer to “MAIN DRIVE GEAR SNAP RING”, MT-68. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.003 in) Install selected snap ring on main drive gear.

SMT425A

c.

SMT426A

3. a. 쐌

Install components on counter gear. Install sub-gear components. When installing sub-gear snap ring, tap sub-gear snap ring into position on counter gear.

SMT577A

MT-56

ASSEMBLY

FS5R30A Gear Components (Cont’d)

b.

Install counter gear rear thrust bearing.

GI MA EM LC

SMT405A

4. a.

Install front side components on mainshaft. Assemble 1st and 2nd synchronizer.

EC FE CL

SMT614B

b.

Assemble 3rd and 4th synchronizer.

AT TF PD AX SMT615B

c. 쐌

Press on 3rd and 4th synchronizer assembly together with 3rd main gear and 3rd gear needle bearing. Pay attention to direction of synchronizer assembly.

SU BR ST RS

SMT399A

d.

e.

Select proper snap ring to minimize clearance of groove. Refer to “MAINSHAFT FRONT SNAP RING”, MT-68. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.003 in) Install selected snap ring on mainshaft.

BT HA SC EL

SMT400A

MT-57

IDX

ASSEMBLY

FS5R30A

Gear Components (Cont’d)

f.

Press on 1st and 2nd synchronizer assembly together with 2nd main gear and 2nd gear needle bearing.

g. h.

Press on 1st gear bushing using 1st gear washer. Install 1st main gear and needle bearing.

i. 쐌

Install steel ball and 1st gear washer. Apply multi-purpose grease to steel ball and 1st gear washer before installing.

5.

Select proper counter gear front bearing thrust washer when replacing transmission case, counter gear, counter gear rear thrust bearing or sub-gear components. Install counter gear with sub-gear components, counter gear front and rear bearing thrust washer on adapter plate. Remove counter gear front bearing thrust washer from transmission case. Place adapter plate and counter gear assembly in transmission case (case inverted).

SMT401A

SMT402A

SMT403A

a. b. c.

SMT427AA

MT-58

ASSEMBLY

FS5R30A Gear Components (Cont’d)

d. e. f. g.

Tighten adapter plate to transmission case using 2 bolts. Place dial indicator on rear end of counter gear. Move counter gear up and down and measure dial indicator deflection. Select proper thrust washer using table below as a guide. Refer to “TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER”, MT-69. Counter gear end play: 0.10 - 0.26 mm (0.0040 - 0.0102 in)

GI MA EM LC EC FE CL

SMT578A

6.

a. 쐌

Select proper reverse idler rear thrust washer when replacing rear extension (or OD gear case), reverse idler gear, reverse idler shaft or reverse idler front thrust washer. Install reverse idler gear, reverse idler needle bearings, reverse idler front thrust washers and reverse idler shaft into rear extension (or OD gear case). When replacing reverse idler rear thrust washer, install either A or B. Refer to “REVERSE IDLER REAR THRUST WASHER”, MT-70.

AT TF PD AX SU BR ST RS

AMT170

BT HA SC EL

MT-59

IDX

ASSEMBLY

FS5R30A

Gear Components (Cont’d)

b. c. d.

e.

Place dial indicator on front end of reverse idler shaft. Put straightedge on front surface of rear extension (or OD gear case) as a stopper of reverse idler shaft. Move reverse idler shaft up and down and measure reverse idler gear end play. Reverse idler gear end play: 0.30 - 0.53 mm (0.0119 - 0.0208 in) If not within specification, replace reverse idler rear thrust washer with the other (A or B) and check again.

SMT433A

7. a.

Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft. Mount adapter plate on vise and apply multi-purpose grease to counter gear rear bearing.

SMT438A

b. 쐌

Install mainshaft a little on mainshaft front bearing. To allow for installation of counter gear, do not install mainshaft completely.

c.

Install counter gear on counter gear rear bearing and install main drive gear, pilot bearing and spacer on mainshaft.

SMT440A

SMT441A

MT-60

ASSEMBLY

FS5R30A Gear Components (Cont’d)

쐌

When installing counter gear into counter gear rear bearing, push up on upper roller of counter gear rear bearing with screwdriver.

GI MA EM LC

SMT442A

d. e.

Install Tools (J26349-3) onto adapter plate and C-ring and C-ring holder on mainshaft. Install Tool (J34328) on mainshaft.

EC FE CL

SMT064C

f.

Install mainshaft and counter gear completely by extending length of (J26349-3).

AT TF PD AX

SMT579A

8. a.

Install rear side components on mainshaft and counter gear. Install OD gear bushing while pushing on the front of counter gear.

SU BR ST RS

SMT444A

b. 쐌 c. d.

Install OD main gear. Pay attention to direction of OD main gear. (B is wider than A as shown at left.) Install adapter plate with gear assembly onto transmission case. Install OD gear needle bearing and then install OD counter gear and reverse idler shaft.

BT HA SC EL

SMT580AA

MT-61

IDX

ASSEMBLY

FS5R30A

Gear Components (Cont’d)

e.

Install reverse gear bushing with speedometer drive gear (2WD model).

f.

Install reverse cone.

g.

Install insert springs and reverse baulk ring on OD coupling sleeve. Then install them and OD baulk ring on OD counter gear. Pay attention to direction of OD coupling sleeve.

SMT581A

SMT582A

쐌

SMT571AA

SMT583A

h. i.

Install reverse counter gear. Install reverse gear needle bearing and then install reverse main gear, reverse idler gear and reverse idler thrust washers.

SMT584A

MT-62

ASSEMBLY

FS5R30A Gear Components (Cont’d)

j. 쐌 k.

Install reverse hub. Pay attention to its direction. Install mainshaft spacer and mainshaft rear bearing (2WD model).

GI MA EM LC

SMT585A

l. Install counter gear rear end bearing. m. Separate adapter plate from transmission case and mount adapter plate on vise again.

EC FE CL

SMT485C

n.

Select proper mainshaft C-ring to minimize clearance of groove. Refer to “MAINSHAFT C-RING”, MT-69. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.003 in)

AT TF PD AX

SMT452A

o.

Install selected C-ring, C-ring holder and mainshaft rear snap ring.

SU BR ST RS

SMT454A

BT HA SC EL

MT-63

IDX

ASSEMBLY

FS5R30A

Gear Components (Cont’d)

p.

q.

Select proper counter gear rear snap ring to minimize clearance of groove. Refer to “COUNTER GEAR REAR SNAP RING”, MT-69. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.003 in) Install selected counter gear rear snap ring.

SMT453A

SMT455A

r. 쐌 s.

Install reverse coupling sleeve. Pay attention to its direction. Measure each gear end play as a final check. Refer to “DISASSEMBLY”, MT-50.

SMT456A

Shift Control Components ASSEMBLY 1. 2.

NGMT0014

Install OD fork rod and OD shift fork. Then install retaining pin into OD shift fork. Install 1st and 2nd, 3rd and 4th and reverse shift fork onto coupling sleeve.

SMT457A

3. 쐌

Install striking rod into hole of shift forks, striking lever and interlock and then install retaining pin into striking lever. Make sure that striking rod moves smoothly.

SMT374A

MT-64

ASSEMBLY

FS5R30A Case Components

Case Components ASSEMBLY 1. 쐌 2.

NGMT0015

쐌 3.

Install front cover oil seal. Apply multi-purpose grease to seal lip. Install selected counter gear front bearing shim onto transmission case. Apply multi-purpose grease. Apply sealant to mating surface of transmission case.

4. 5. 쐌

Install gear assembly onto transmission case. Install check spring and check ball into interlock stopper. Apply multi-purpose grease to check ball.

GI MA EM LC

SMT393A

EC FE CL

SMT588A

6. 쐌

Install interlock stopper assembly and then tighten check ball plug. Refer to “Shift Control Components”, MT-47. Apply sealant to thread of check ball plug.

AT TF PD AX

SMT460A

7.

Install stopper ring and main drive bearing snap ring.

SU BR ST RS

SMT371A

8. 쐌 9.

Install front cover and gasket. Refer to “Case Components”, MT-44. Apply sealant to thread of 3 bolts shown left. Apply sealant to mating surface of adapter plate.

BT HA SC EL

SMT459A

MT-65

IDX

ASSEMBLY

FS5R30A

Case Components (Cont’d)

10. Install OD gear case together with striking arm.

SMT461A

11. Install retaining pin into striking arm.

SMT368A

12. Install return spring and check ball and then install control housing. Refer to “Case Components”, MT-44. 쐌 Apply Genuine Anaerobic Liquid Gasket, or equivalent, to the mating surface of OD gear case.

SMT462A

13. Tighten control housing bolts. Bolt head size: A bolts 12 mm (0.47 in) B bolts 13 mm (0.51 in)

SMT572A

MT-66

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5R30A General Specifications

General Specifications

NGMT0016

GI

VG33E/VG33ER FS5R30A Transmission 2WD

MA

4WD

Number of speed

5

EM Shift pattern

LC MT-SDS-2

Synchromesh type

EC

Warner Number of teeth Gear ratio Mainshaft

Countershaft

—

22

32

1st

3.580

32

13

2nd

2.077

30

21

3rd

1.360

29

31

4th

1.000

—

—

OD

0.811

24

43

Reverse

3.636

30

12

Drive

Reverse idler gear Oil capacity
(US pt, Imp pt) Remarks

FE CL

AT TF

22 2.8 (5-7/8, 4-7/8) — 2WD model

5.1 (10-3/4, 9) — 4WD model

PD

2nd & 3rd double baulk ring type synchronizer

Gear End Play

NGMT0017

Unit: mm (in) Gear

AX

End play

1st main gear

0.23 - 0.33 (0.0091 - 0.0129)

2nd main gear

0.23 - 0.33 (0.0091 - 0.0129)

3rd main gear

0.06 - 0.16 (0.0024 - 0.0062)

OD counter gear

0.23 - 0.33 (0.0091 - 0.0129)

Reverse main gear

0.33 - 0.43 (0.0130 - 0.0169)

Counter gear

0.10 - 0.26 (0.0040 - 0.0102)

Reverse idler gear

0.30 - 0.53 (0.0119 - 0.0208)

SU BR ST RS

Clearance Between Baulk Ring and Gear

NGMT0018

BT

Unit: mm (in) Standard 1st

1.05 - 1.30 (0.0414 - 0.0511)

Main drive

1.05 - 1.30 (0.0414 - 0.0511)

OD

1.05 - 1.30 (0.0414 - 0.0511)

Wear limit

HA

0.7 (0.028)

SC EL

MT-67

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5R30A

Clearance Between Baulk Ring and Gear (Cont’d)

DOUBLE BAULK RING

NGMT0018S01

Unit: mm (in) VG33E model VG33ER model

2nd & 3rd baulk rings 1st, 2nd & 3rd baulk rings

SMT742C

Dimension

Standard

Wear limit

A

0.7 - 0.9 (0.028 - 0.035)

B

0.6 - 1.1 (0.024 - 0.043)

0.2 (0.008)

Distance between Rear Surface of Reverse Cone and Reverse Baulk Ring

NGMT0019

Unit: mm (in)

SMT428C

Dimension

Standard

Wear limit

A

0.35 to 0.95 (0.0119 to 0.0295)

1.1 (0.043)

Available Snap Ring

NGMT0020

MAIN DRIVE GEAR SNAP RING

NGMT0020S01

Unit: mm (in) Allowable clearance

0 - 0.1 (0 - 0.003)

Thickness

Part number

Thickness

Part number*

1.89 (0.0744)

32204-01G60

2.03 (0.0799)

32204-01G63

1.95 (0.0768)

32204-01G61

2.07 (0.0815)

32204-01G64

1.99 (0.0783)

32204-01G62

2.11 (0.0831)

32204-01G65

*Always check with the Parts Department for the latest parts information.

MAINSHAFT FRONT SNAP RING

NGMT0020S02

Unit: mm (in) Allowable clearance

0 - 0.1 (0 - 0.003)

Thickness

Part number

Thickness

Part number*

1.99 (0.0783)

32204-01G62

2.11 (0.0831)

32204-01G65

2.03 (0.0799)

32204-01G63

2.15 (0.0846)

32204-01G66

2.07 (0.0815)

32204-01G64

2.19 (0.0862)

32204-01G67

*Always check with the Parts Department for the latest parts information.

MT-68

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5R30A

Available Snap Ring (Cont’d)

COUNTER GEAR REAR SNAP RING

NGMT0020S03

Unit: mm (in) Allowable clearance

GI

0 - 0.1 (0 - 0.003)

Thickness

Part number

Thickness

Part number*

1.32 (0.0520)

32236-01G00

1.56 (0.0614)

32236-01G04

1.38 (0.0543)

32236-01G01

1.62 (0.0638)

32236-01G05

1.44 (0.0567)

32236-01G02

1.68 (0.0661)

32236-01G06

1.50 (0.0591)

32236-01G03

1.74 (0.0685)

32236-01G07

MA EM LC

*Always check with the Parts Department for the latest parts information.

Available C-ring

NGMT0021

MAINSHAFT C-RING

EC

NGMT0021S01

Unit: mm (in) Allowable clearance

FE

0 - 0.1 (0 - 0.003)

Thickness

Part number

Thickness

Part number*

2.63 (0.1035)

32348-01G15

3.19 (0.1256)

32348-01G07

2.70 (0.1063)

32348-01G00

3.26 (0.1283)

32348-01G08

2.77 (0.1091)

32348-01G01

3.33 (0.1311)

32348-01G09

2.84 (0.1118)

32348-01G02

3.40 (0.1339)

32348-01G10

2.91 (0.1146)

32348-01G03

3.47 (0.1366)

32348-01G11

2.98 (0.1173)

32348-01G04

3.54 (0.1394)

32348-01G12

3.05 (0.1201)

32348-01G05

3.61 (0.1421)

32348-01G13

3.12 (0.1228)

32348-01G06

3.68 (0.1449)

32348-01G14

CL

AT TF PD

*Always check with the Parts Department for the latest parts information.

Available Shim and Washer

NGMT0022 AX TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER NGMT0022S01

Unit: mm (in)

SU

Allowable clearance 0.10 - 0.26 (0.0040 - 0.0102) Dial indicator deflection

Thickness of proper washer

Part number*

0.93 - 1.02 (0.0367 - 0.0401)

0.80 (0.0315)

32218-01G00

1.01 - 1.10 (0.0398 - 0.0433)

0.88 (0.0346)

32218-01G11

1.09 - 1.18 (0.0430 - 0.0464)

0.96 (0.0378)

32218-01G12

1.17 - 1.26 (0.0461 - 0.0496)

1.04 (0.0409)

32218-01G13

1.25 - 1.34 (0.0493 - 0.0527)

1.12 (0.0441)

32218-01G14

1.33 - 1.42 (0.0524 - 0.0559)

1.20 (0.0472)

32218-01G04

1.41 - 1.50 (0.0556 - 0.0590)

1.28 (0.0504)

32218-01G15

1.49 - 1.58 (0.0587 - 0.0622)

1.36 (0.0535)

32218-01G16

1.57 - 1.66 (0.0619 - 0.0653)

1.44 (0.0567)

32218-01G17

BR ST RS BT HA

*Always check with the Parts Department for the latest parts information.

SC EL

MT-69

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

FS5R30A

Available Shim and Washer (Cont’d)

REVERSE IDLER REAR THRUST WASHER

=NGMT0022S02

Unit: mm (in) Allowable clearance 0.30 - 0.53 (0.0119 - 0.0208) Thickness

Part number*

A

1.97 (0.0776)

32284-01G10

B

2.07 (0.0815)

32284-01G11

*Always check with the Parts Department for the latest parts information.

MT-70

AUTOMATIC TRANSMISSION SECTION

AT

GI MA EM LC EC

CONTENTS TROUBLE DIAGNOSIS - INDEX ....................................4 Alphabetical & P No. Index for DTC ...........................4 PRECAUTIONS ...............................................................6 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............6 Precautions for On Board Diagnostic (OBD) System of A/T and Engine...........................................6 Precautions ..................................................................6 Service Notice or Precautions .....................................8 Wiring Diagrams and Trouble Diagnosis.....................9 PREPARATION .............................................................10 Special Service Tools ................................................10 OVERALL SYSTEM ......................................................12 A/T Electrical Parts Location .....................................12 Circuit Diagram ..........................................................13 Cross-sectional View .................................................14 Hydraulic Control Circuit............................................15 Shift Mechanism ........................................................16 Control System ..........................................................25 Control Mechanism....................................................26 Control Valve .............................................................31 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................33 Introduction ................................................................33 OBD-II Function for A/T System................................33 One or Two Trip Detection Logic of OBD-II ..............33 OBD-II Diagnostic Trouble Code (DTC) ....................33 Malfunction Indicator Lamp (MIL)..............................37 CONSULT-II ...............................................................37 Diagnostic Procedure Without CONSULT-II..............46 TROUBLE DIAGNOSIS - INTRODUCTION..................55 Introduction ................................................................55 Work Flow..................................................................59 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........62 A/T Fluid Check .........................................................62 Stall Test ....................................................................62 Line Pressure Test.....................................................65 Road Test...................................................................66

TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................84 Symptom Chart..........................................................84 TCM Terminals and Reference Value........................97 TROUBLE DIAGNOSIS FOR POWER SUPPLY........101 Wiring Diagram - AT - MAIN....................................101 Diagnostic Procedure ..............................................102 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH .......................................................................104 Description ...............................................................104 Wiring Diagram - AT - PNP/SW...............................106 Diagnostic Procedure ..............................................107 Component Inspection.............................................109 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT .......................................................................110 Description ...............................................................110 Wiring Diagram - AT - FTS ......................................112 Diagnostic Procedure ..............................................113 Component Inspection.............................................115 DTC P0720 VEHICLE SPEED SENSOR.A/T (REVOLUTION SENSOR) ...........................................116 Description ...............................................................116 Wiring Diagram - AT - VSSA/T ................................118 Diagnostic Procedure ..............................................119 Component Inspection.............................................120 DTC P0725 ENGINE SPEED SIGNAL .......................121 Description ...............................................................121 Wiring Diagram - AT - ENGSS ................................122 Diagnostic Procedure ..............................................123 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION ....................................................................125 Description ...............................................................125 Wiring Diagram - AT - 1ST ......................................128 Diagnostic Procedure ..............................................129 Component Inspection.............................................130 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION ....................................................................131 Description ...............................................................131 Wiring Diagram - AT - 2ND......................................134

FE CL MT

TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS Diagnostic Procedure ..............................................135 Component Inspection.............................................135 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION ....................................................................137 Description ...............................................................137 Wiring Diagram - AT - 3RD......................................140 Diagnostic Procedure ..............................................141 Component Inspection.............................................142 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION ....................................................................143 Description ...............................................................143 Wiring Diagram - AT - 4TH ......................................147 Diagnostic Procedure ..............................................148 Component Inspection.............................................151 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE......................................................152 Description ...............................................................152 Wiring Diagram - AT - TCV......................................154 Diagnostic Procedure ..............................................155 Component Inspection.............................................156 DTC P0744 IMPROPER LOCK-UP OPERATION ......157 Description ...............................................................157 Wiring Diagram - AT - TCCSIG ...............................159 Diagnostic Procedure ..............................................160 Component Inspection.............................................163 DTC P0745 LINE PRESSURE SOLENOID VALVE ...164 Description ...............................................................164 Wiring Diagram - AT - LPSV....................................166 Diagnostic Procedure ..............................................167 Component Inspection.............................................168 DTC P0750 SHIFT SOLENOID VALVE A ..................169 Description ...............................................................169 Wiring Diagram - AT - SSV/A ..................................171 Diagnostic Procedure ..............................................172 Component Inspection.............................................173 DTC P0755 SHIFT SOLENOID VALVE B ..................174 Description ...............................................................174 Wiring Diagram - AT - SSV/B ..................................176 Diagnostic Procedure ..............................................177 Component Inspection.............................................178 DTC P1705 THROTTLE POSITION SENSOR ...........179 Description ...............................................................179 Wiring Diagram - AT - TPS......................................182 Diagnostic Procedure ..............................................183 Component Inspection.............................................187 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE..........................................................................188 Description ...............................................................188 Wiring Diagram - AT - OVRCSV..............................190 Diagnostic Procedure ..............................................191 Component Inspection.............................................192

(Cont’d)

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) ....193 Description ...............................................................193 Wiring Diagram - AT - BA/FTS ................................195 Diagnostic Procedure ..............................................196 Component Inspection.............................................198 DTC VEHICLE SPEED SENSOR.MTR .......................199 Description ...............................................................199 Wiring Diagram - AT - VSSMTR..............................201 Diagnostic Procedure ..............................................202 DTC TURBINE REVOLUTION SENSOR (VG33ER ONLY) ..........................................................................203 Description ...............................................................203 Wiring Diagram - AT - TRSA/T ................................205 Diagnostic Procedure ..............................................206 Component Inspection.............................................207 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM)...........................................................................208 Description ...............................................................208 Diagnostic Procedure ..............................................209 DTC CONTROL UNIT (EEP ROM) .............................210 Description ...............................................................210 Diagnostic Procedure ..............................................211 TROUBLE DIAGNOSES FOR SYMPTOMS ...............212 Wiring Diagram - AT - NONDTC .............................212 1. O/D OFF Indicator Lamp Does Not Come On....215 2. Engine Cannot Be Started In P and N Position..217 3. In ″P″ Position, Vehicle Moves Forward Or Backward When Pushed .........................................218 4. In N Position, Vehicle Moves ..............................219 5. Large Shock. N -> R Position .............................221 6. Vehicle Does Not Creep Backward In R Position ....................................................................223 7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position ....................................................................226 8. Vehicle Cannot Be Started From D1 ...................229 9. A/T Does Not Shift: D1 -> D2 Or Does Not Kickdown: D4 -> D2..................................................232 10. A/T Does Not Shift: D2 -> D3.............................235 11. A/T Does Not Shift: D3 -> D4 .............................238 12. A/T Does Not Perform Lock-up .........................241 13. A/T Does Not Hold Lock-up Condition ..............243 14. Lock-up Is Not Released...................................245 15. Engine Speed Does Not Return To Idle (Light Braking D4 -> D3).....................................................246 16. Vehicle Does Not Start From D1 .......................248 17. A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch ON -> OFF .....................249 18. A/T Does Not Shift: D3 -> 22, When Selector Lever D -> 2 Position ..............................................250 19. A/T Does Not Shift: 22 -> 11, When Selector Lever 2 -> 1 Position ...............................................251

AT-2

CONTENTS 20. Vehicle Does Not Decelerate By Engine Brake........................................................................252 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks) ........................................................252 A/T SHIFT LOCK SYSTEM.........................................260 Description ...............................................................260 Wiring Diagram - SHIFT -........................................261 Diagnostic Procedure ..............................................262 Component Check ...................................................264 KEY INTERLOCK CABLE ..........................................265 Components.............................................................265 Removal...................................................................265 Installation................................................................266 ON-VEHICLE SERVICE ..............................................267 Control Valve Assembly and Accumulators.............267 Revolution Sensor Replacement .............................268 Turbine Revolution Sensor Replacement (VG33ER only).........................................................268 Rear Oil Seal Replacement.....................................268 Parking Components Inspection..............................269 Park/Neutral Position (PNP) Switch Adjustment .....270 Manual Control Linkage Adjustment........................270 REMOVAL AND INSTALLATION ...............................271 Removal...................................................................271 Installation................................................................272 OVERHAUL .................................................................274 Components.............................................................274 Oil Channel ..............................................................276 Locations of Needle Bearings, Thrust Washers and Snap Rings .......................................................277 DISASSEMBLY............................................................278 REPAIR FOR COMPONENT PARTS .........................289 Oil Pump ..................................................................289

(Cont’d)

Control Valve Assembly...........................................293 Control Valve Upper Body .......................................299 Control Valve Lower Body .......................................304 Reverse Clutch ........................................................306 High Clutch ..............................................................310 Forward and Overrun Clutches ...............................312 Low & Reverse Brake..............................................316 Forward Clutch Drum Assembly..............................320 Rear Internal Gear and Forward Clutch Hub ..........322 Band Servo Piston Assembly ..................................325 Parking Pawl Components ......................................329 ASSEMBLY..................................................................331 Assembly (1)............................................................331 Adjustment ...............................................................339 Assembly (2)............................................................341 SERVICE DATA AND SPECIFICATIONS (SDS) .......348 General Specifications.............................................348 Shift Schedule..........................................................348 Stall Revolution........................................................348 Line Pressure...........................................................349 Return Springs.........................................................349 Accumulator O-ring..................................................350 Clutches and Brakes ...............................................350 Oil Pump and Low One-way Clutch ........................353 Total End Play..........................................................353 Reverse Clutch Drum End Play ..............................353 Removal and Installation .........................................353 Shift Solenoid Valves...............................................353 Solenoid Valves .......................................................353 A/T Fluid Temperature Sensor.................................354 Turbine Revolution Sensor ......................................354 Revolution Sensor ...................................................354 Dropping Resistor ....................................................354

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-3

IDX

TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC

Alphabetical & P No. Index for DTC

NGAT0179

ALPHABETICAL INDEX FOR DTC

NGAT0179S01

DTC Items (CONSULT-II screen terms)

CONSULT-II GST*1

Reference page

A/T 1ST GR FNCTN

P0731

AT-125

A/T 2ND GR FNCTN

P0732

AT-131

A/T 3RD GR FNCTN

P0733

AT-137

A/T 4TH GR FNCTN

P0734

AT-143

A/T TCC S/V FNCTN

P0744

AT-157

ATF TEMP SEN/CIRC

P0710

AT-110

ENGINE SPEED SIG

P0725

AT-121

L/PRESS SOL/CIRC

P0745

AT-164

O/R CLTCH SOL/CIRC

P1760

AT-188

PNP SW/CIRC

P0705

AT-104

SFT SOL A/CIRC*2

P0750

AT-169

SFT SOL B/CIRC*2

P0755

AT-174

TCC SOLENOID/CIRC

P0740

AT-152

TP SEN/CIRC A/T*2

P1705

AT-179

VEH SPD SEN/CIR AT*3

P0720

AT-116

*1: These numbers are prescribed by SAE J2012. *2: When the fail-safe operation occurs, the MIL illuminates. *3: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time.

AT-4

TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC (Cont’d)

P NO. INDEX FOR DTC

=NGAT0179S02

DTC Items (CONSULT-II screen terms)

CONSULT-II GST*1

GI Reference page

MA

P0705

PNP SW/CIRC

AT-104

P0710

ATF TEMP SEN/CIRC

AT-110

P0720

VEH SPD SEN/CIR AT*3

AT-116

P0725

ENGINE SPEED SIG

AT-121

P0731

A/T 1ST GR FNCTN

AT-125

P0732

A/T 2ND GR FNCTN

AT-131

P0733

A/T 3RD GR FNCTN

AT-137

P0734

A/T 4TH GR FNCTN

AT-143

P0740

TCC SOLENOID/CIRC

AT-152

P0744

A/T TCC S/V FNCTN

AT-157

P0745

L/PRESS SOL/CIRC

AT-164

P0750

SFT SOL A/CIRC*2

AT-169

P0755

SFT SOL B/CIRC*2

AT-174

P1705

TP SEN/CIRC A/T*2

AT-179

P1760

O/R CLTCH SOL/CIRC

AT-188

*1: These numbers are prescribed by SAE J2012. *2: When the fail-safe operation occurs, the MIL illuminates. *3: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time.

EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-5

IDX

PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGAT0001

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 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), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

Precautions for On Board Diagnostic (OBD) System of A/T and Engine

NGAT0002

The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the driver of a malfunction causing emission deterioration. CAUTION: 쐌 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 MIL to light up. 쐌 Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MIL to light up due to an open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) 쐌 Be sure to route and secure the harnesses properly after work. Interference of the harness with a bracket, etc. may cause the MIL to light up due to a short circuit. 쐌 Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MIL to light up due to a malfunction of the fuel injection system, etc. 쐌 Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and ECM before returning the vehicle to the customer.

Precautions 쐌

NGAT0003

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-6

PRECAUTIONS Precautions (Cont’d)

쐌

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.

GI MA EM LC

AAT470A

쐌

Before replacing TCM, perform TCM input/output signal inspection and make sure whether TCM functions properly or not. Refer to “TCM INSPECTION TABLE”, AT-97.

EC FE CL MT

MEF040DA

쐌

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.

TF PD AX

SAT964I

쐌

쐌 쐌 쐌 쐌 쐌 쐌 쐌

쐌

Before proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. Disassembly should be done in a clean work area. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transmission. Place disassembled parts in order for easier and proper assembly. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly. Gaskets, seals and O-rings should be replaced any time the transmission is disassembled. It is very important to perform functional tests whenever they are indicated. The valve body contains precision parts and requires extreme care when parts are removed and serviced. Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent springs and small parts from becoming scattered or lost. Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.

AT-7

SU BR ST RS BT HA SC EL IDX

PRECAUTIONS Precautions (Cont’d)

쐌

쐌 쐌 쐌 쐌

Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings and seals, or hold bearings and washers in place during assembly. Do not use grease. Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling. Replace ATF cooler if excessive foreign material is found in oil pan or clogging strainer. Refer to “ATF COOLER SERVICE”, AT-9. After overhaul, refill the transmission with new ATF. When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque converter and ATF cooling system. Always follow the procedures when changing A/T fluid. Refer to MA-40, “Changing A/T Fluid”.

Service Notice or Precautions FAIL-SAFE

NGAT0004 NGAT0004S01

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 in third gear, even with a shift lever position of 1, 2 or D. The customer may complain of sluggish or poor acceleration. When the ignition key is turned ON following Fail-Safe operation, O/D OFF indicator lamp blinks for about 8 seconds. Refer to “TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)”, AT-47. The blinking of the O/D OFF 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-59. 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.

TORQUE CONVERTER SERVICE

NGAT0004S04

The torque converter should be replaced under any of the following conditions: 쐌 External leaks in the hub weld area. 쐌 Converter hub is scored or damaged. 쐌 Converter pilot is broken, damaged or fits poorly into crankshaft. 쐌 Steel particles are found after flushing the cooler and cooler lines. 쐌 Pump is damaged or steel particles are found in the converter. 쐌 Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses have been made. (Converter clutch material may be glazed.) 쐌 Converter is contaminated with engine coolant containing antifreeze. 쐌 Internal failure of stator roller clutch. 쐌 Heavy clutch debris due to overheating (blue converter). 쐌 Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are worn or damaged — indicates that lining material came from converter. The torque converter should not be replaced if: 쐌 The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles. 쐌 The threads in one or more of the converter bolt holes are damaged.

AT-8

PRECAUTIONS Service Notice or Precautions (Cont’d)

쐌 쐌

Transmission failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate lining material in unit and inside the fluid filter. Vehicle has been exposed to high mileage (only). The exception may be where the torque converter clutch dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic, such as taxi, delivery or police use.

ATF COOLER SERVICE

GI MA

NGAT0004S02

Replace ATF cooler if excessive foreign material is found in oil pan or clogging strainer. Replace radiator lower tank (which includes ATF cooler) with a new one and flush cooler line using cleaning solvent and compressed air.

EM

OBD-II SELF-DIAGNOSIS

LC

NGAT0004S03

쐌

A/T self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through the blinking pattern of the O/D OFF indicator or the malfunction indicator lamp (MIL). Refer to “SELF-DIAGNOSTIC RESULT TEST MODE” the table on AT-38 for the indicator used to display each self-diagnostic result. 쐌 The self-diagnostic results indicated by the MIL are automatically stored in both the ECM and TCM memories. Always perform the procedure “HOW TO ERASE DTC” on AT-35 to complete the repair and avoid unnecessary blinking of the MIL. 쐌 The following self-diagnostic items can be detected using ECM self-diagnostic results mode* only when the O/D OFF indicator lamp does not indicate any malfunctions. − Park/neutral position (PNP) switch − A/T 1st, 2nd, 3rd, or 4th gear function − A/T TCC S/V function (lock-up) *: For details of OBD-II, refer to EC-660 (VG33E only) or EC-1232 (VG33ER only), “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”. 쐌 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-6, “Description”.

Wiring Diagrams and Trouble Diagnosis

EC FE CL MT

TF PD

NGAT0005

When you read wiring diagrams, refer to the following: 쐌 Refer to GI-10, “HOW TO READ WIRING DIAGRAMS”. 쐌 Refer to EL-10, “POWER SUPPLY ROUTING” for power distribution circuit. When you perform trouble diagnosis, refer to the following: 쐌 Refer to GI-33, “How to Follow Test Groups in Trouble Diagnoses”. 쐌 Refer to GI-22, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.

AX SU BR ST RS BT HA SC EL

AT-9

IDX

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 (Kent-Moore No.) Tool name ST2505S001 (J34301-C) Oil pressure gauge set 1 ST25051001 ( — ) Oil pressure gauge 2 ST25052000 ( — ) Hose 3 ST25053000 ( — ) Joint pipe 4 ST25054000 ( — ) Adapter 5 ST25055000 ( — ) Adapter

Description Measuring line pressure

NT097

Disassembling and assembling A/T a: 182 mm (7.17 in) b: 282 mm (11.10 in) c: 230 mm (9.06 in) d: 100 mm (3.94 in)

ST07870000 (J37068) Transmission case stand

NT421

Checking one-way clutch in torque converter

KV31102100 (J37065) Torque converter oneway clutch check tool

NT098

Removing oil pump assembly a: 179 mm (7.05 in) b: 70 mm (2.76 in) c: 40 mm (1.57 in) dia. d: M12 x 1.75P

ST25850000 (J25721-A) Sliding hammer

NT422

Removing and installing clutch return springs a: 320 mm (12.60 in) b: 174 mm (6.85 in)

KV31102400 (J34285 and J34285-87) Clutch spring compressor

NT423

AT-10

NGAT0006

PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

GI

ST33200000 (J26082) Drift

Installing oil pump housing oil seal Installing rear oil seal a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia.

MA EM

NT091

Selecting oil pump cover bearing race and oil pump thrust washer

(J34291) Shim setting gauge set

LC EC FE

NT101

CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-11

IDX

OVERALL SYSTEM A/T Electrical Parts Location

A/T Electrical Parts Location

NGAT0007

WAT547

AT-12

OVERALL SYSTEM Circuit Diagram

Circuit Diagram

NGAT0008

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC WAT541

AT-13

EL IDX

OVERALL SYSTEM Cross-sectional View

Cross-sectional View

NGAT0010

SAT125BA

AT-14

OVERALL SYSTEM Hydraulic Control Circuit

Hydraulic Control Circuit

NGAT0011

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC WAT371

AT-15

EL IDX

OVERALL SYSTEM Shift Mechanism

Shift Mechanism

NGAT0012

The automatic transmission uses compact, dual planetary gear systems to improve power-transmission efficiency, simplify construction and reduce weight. It also employs an optimum shift control and superwide gear ratios. They improve starting performance and acceleration during medium and high-speed operation. Two one-way clutches are also employed: one is used for the forward clutch and the other for the low clutch. These one-way clutches, combined with four accumulators, reduce shifting shock to a minimum.

CONSTRUCTION

NGAT0012S01

SAT509I

1. 2. 3. 4. 5. 6. 7. 8.

Torque converter clutch piston Torque converter Oil pump Input shaft Brake band Reverse clutch High clutch Front pinion gear

9. 10. 11. 12. 13. 14. 15. 16.

Front sun gear Front internal gear Front planetary carrier Rear sun gear Rear pinion gear Rear internal gear Rear planetary carrier Forward clutch

AT-16

17. 18. 19. 20. 21. 22. 23.

Forward one-way clutch Overrun clutch Low one-way clutch Low & reverse brake Parking pawl Parking gear Output shaft

OVERALL SYSTEM Shift Mechanism (Cont’d)

FUNCTION OF CLUTCH AND BRAKE Clutch and brake components

=NGAT0012S02

Abbr.

Function

GI

Reverse clutch 6

R/C

To transmit input power to front sun gear 9.

High clutch 7

H/C

To transmit input power to front planetary carrier 11.

Forward clutch 16

F/C

To connect front planetary carrier 11 with forward one-way clutch 17.

Overrun clutch 18

O/C

To connect front planetary carrier 11 with rear internal gear 14.

Brake band 5

B/B

To lock front sun gear 9.

Forward one-way clutch 17

F/O.C

When forward clutch 16 is engaged, to stop rear internal gear 14 from rotating in opposite direction against engine revolution.

Low one-way clutch 19

L/O.C

To stop front planetary carrier 11 from rotating in opposite direction against engine revolution.

Low & reverse brake 20

L & R/B

To lock front planetary carrier 11.

Shift position

High clutch

Forward clutch

Overrun clutch

Band servo 2nd apply

3rd release

4th apply

EC FE

NGAT0012S03

Forward oneway clutch

EM LC

CLUTCH AND BAND CHART Reverse clutch

MA

Low Low & onereverse Lock-up way brake clutch

Remarks

CL MT

PARK POSITION

P 쎻

R

REVERSE POSITION

쎻

NEUTRAL POSITION

N 1st

쎻

*1D

2nd

쎻

*1A

쎻

*1A

*2C

C

*3C

C

D*4 3rd

쎻

쎻

4th

쎻

C

1st

쎻

D

2nd

쎻

A

1st

쎻

쎻

2nd

쎻

쎻

2

B

쎻

B

*5쎻

쎻

Automatic shift 1k2

B

B B

쎻

Automatic shift 1k2k3k 4

쎻

1 B

B

쎻

Locks (held stationary) in 1st speed 1g2

*1: Operates when overdrive control switch is being set in OFF position. *2: Oil pressure is applied to both 2nd “apply” side and 3rd “release” side of band servo piston. However, brake band does not contract because oil pressure area on the “release” side is greater than that on the “apply” side. *3: Oil pressure is applied to 4th “apply” side in condition *2 above, and brake band contracts. *4: A/T will not shift to 4th when overdrive control switch is set in OFF position. *5: Operates when overdrive control switch is OFF. 쎻 : Operates. A: Operates when throttle opening is less than 3/16, activating engine brake. B: Operates during “progressive” acceleration. C: Operates but does not affect power transmission. D: Operates when throttle opening is less than 3/16, but does not affect engine brake.

AT-17

PD

B

B

B

TF

AX SU BR ST RS BT HA SC EL IDX

OVERALL SYSTEM Shift Mechanism (Cont’d)

POWER TRANSMISSION P and N Positions 쐌 쐌

=NGAT0012S04 NGAT0012S0401

P position Similar to the N position, no control members operate. The parking pawl interconnected with the select lever engages with the parking gear to mechanically hold the output shaft so that the power train is locked. N position No control members operate. Power from the input shaft is not transmitted to the output shaft since the clutch does not operate.

SAT039J

AT-18

OVERALL SYSTEM Shift Mechanism (Cont’d)

11 Position

=NGAT0012S0406

Forward clutch Forward one-way clutch Overrun clutch Low and reverse brake

As overrun clutch engages, rear internal gear is locked by the operation of low and reverse brake. This is different from that of D1 and 21.

Engine brake

Overrun clutch always engages, therefore engine brake can be obtained when decelerating.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SAT100J

SC EL

AT-19

IDX

OVERALL SYSTEM Shift Mechanism (Cont’d)

D1 and 21 Positions

=NGAT0012S0402

Forward one-way clutch Forward clutch Low one-way clutch

Rear internal gear is locked to rotate counterclockwise because of the functioning of these three clutches. (Start-up at D1)

Overrun clutch engagement conditions (Engine brake)

D1: Overdrive control switch in OFF Throttle opening less than 3/16 21: Throttle opening less than 3/16 At D1 and 21 positions, engine brake is not activated due to free turning of low one-way clutch.

SAT096J

AT-20

OVERALL SYSTEM Shift Mechanism (Cont’d)

D2, 22 and 12 Positions Forward clutch Forward one-way clutch Brake band

Overrun clutch engagement conditions

=NGAT0012S0403

Rear sun gear drives rear planetary carrier and combined front internal gear. Front internal gear now rotates around front sun gear accompanying front planetary carrier. As front planetary carrier transfers the power to rear internal gear through forward clutch and forward one-way clutch, this rotation of rear internal gear increases the speed of rear planetary carrier compared with that of the 1st speed. D2: Overdrive control switch in OFF Throttle opening less than 3/16 22: Throttle opening less than 3/16 12: Always engaged

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC SAT097J

EL

AT-21

IDX

OVERALL SYSTEM Shift Mechanism (Cont’d)

D3 Position

=NGAT0012S0404

High clutch Forward clutch Forward one-way clutch

Input power is transmitted to front planetary carrier through high clutch. And front planetary carrier is connected to rear internal gear by operation of forward clutch and forward one-way clutch. This rear internal gear rotation and another input (the rear sun gear) accompany rear planetary carrier to turn at the same speed.

Overrun clutch engagement conditions

D3: Overdrive control switch in OFF Throttle opening less than 3/16

SAT098J

AT-22

OVERALL SYSTEM Shift Mechanism (Cont’d)

D4 (O/D) Position

=NGAT0012S0405

High clutch Brake band Forward clutch (Does not affect power transmission)

Input power is transmitted to front carrier through high clutch. This front planetary carrier turns around the sun gear which is fixed by brake band and makes front internal gear (output) turn faster.

Engine brake

At D4 position, there is no one-way clutch in the power transmission line and engine brake can be obtained when decelerating.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SAT099J

SC EL

AT-23

IDX

OVERALL SYSTEM Shift Mechanism (Cont’d)

R Position

=NGAT0012S0407

Reverse clutch Low and reverse brake

Front planetary carrier is stationary because of the operation of low and reverse brake. Input power is transmitted to front sun gear through reverse clutch, which drives front internal gear in the opposite direction.

Engine brake

As there is no one-way clutch in the power transmission line, engine brake can be obtained when decelerating.

SAT101J

AT-24

OVERALL SYSTEM Control System

Control System

=NGAT0013

OUTLINE

NGAT0013S01

The automatic transmission senses vehicle operating conditions through various sensors. It always controls the optimum shift position and reduces shifting and lock-up shocks. SENSORS PNP switch Throttle position sensor Closed throttle position switch Wide open throttle position switch Engine speed signal A/T fluid temperature sensor Revolution sensor Vehicle speed sensor Overdrive control switch ASCD control unit Stoplamp switch (VG33ER only) Turbine revolution sensor (VG33ER only)

TCM

왘

Shift control Line pressure control Lock-up control Overrun clutch control Timing control Fail-safe control Self-diagnosis CONSULT-II communication line Duet-EA control

CONTROL SYSTEM

GI MA

ACTUATORS

EM 왘

Shift solenoid valve A Shift solenoid valve B Overrun clutch solenoid valve Torque converter clutch solenoid valve Line pressure solenoid valve O/D OFF indicator lamp

LC EC FE

NGAT0013S02

CL MT

TF PD AX SU BR ST RS WAT495

BT HA SC EL

AT-25

IDX

OVERALL SYSTEM Control System (Cont’d)

TCM FUNCTION

=NGAT0013S03

The function of the TCM is to: 쐌 Receive input signals sent from various switches and sensors. 쐌 Determine required line pressure, shifting point, lock-up operation, and engine brake operation. 쐌 Send required output signals to the respective solenoids.

INPUT/OUTPUT SIGNAL OF TCM

NGAT0013S04

Sensors and solenoid valves

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.

A/T fluid temperature sensor

Detects transmission fluid temperature and sends a signal to TCM.

Revolution sensor

Detects output shaft rpm and sends a signal to TCM.

Vehicle speed sensor

Used as an auxiliary vehicle speed sensor. Sends a signal when revolution sensor (installed on transmission) malfunctions.

Overdrive control switch

Sends a signal, which prohibits a shift to “D4” (overdrive) position, to the TCM.

ASCD control unit

Sends the cruise signal and “D4” (overdrive) cancellation signal from ASCD control unit to TCM.

Turbine revolution sensor (VG33ER only)

Sends the input shaft revolution signal.

Stoplamp switch (VG33ER only)

Sends the lock-up release signal to the TCM at the time of D4 (lock-up).

Shift solenoid valve A/B

Selects shifting point suited to driving conditions 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.

Overrun clutch solenoid valve

Controls an “engine brake” effect suited to driving conditions in relation to a signal sent from TCM.

O/D OFF indicator lamp

Shows TCM faults, when A/T control components malfunction.

Control Mechanism LINE PRESSURE CONTROL

NGAT0180 NGAT0180S01

TCM has the various line pressure control characteristics to meet the driving conditions. An ON-OFF duty signal is sent to the line pressure solenoid valve based on TCM characteristics. Hydraulic pressure on the clutch and brake is electronically controlled through the line pressure solenoid valve to accommodate engine torque. This results in smooth shift operation.

AT-26

OVERALL SYSTEM Control Mechanism (Cont’d)

Normal Control

NGAT0180S0101

The line pressure to throttle opening characteristics is set for suitable clutch operation.

GI MA EM LC

SAT003J

Back-up Control (Engine brake)

NGAT0180S0102

If the selector lever is shifted to “2” position while driving in D4 (OD) or D3, great driving force is applied to the clutch inside the transmission. Clutch operating pressure (line pressure) must be increased to deal with this driving force.

EC FE CL MT

SAT004J

During Shift Change

NGAT0180S0103

The line pressure is temporarily reduced corresponding to a change in engine torque when shifting gears (that is, when the shift solenoid valve is switched for clutch operation) to reduce shifting shock.

TF PD AX

SAT005J

At Low Fluid Temperature 쐌

NGAT0180S0104

Fluid viscosity and frictional characteristics of the clutch facing change with fluid temperature. Clutch engaging or band-contacting pressure is compensated for, according to fluid temperature, to stabilize shifting quality.

SU BR ST RS

쐌

The line pressure is reduced below 60°C (140°F) to prevent shifting shock due to low viscosity of automatic transmission fluid when temperature is low.

BT HA SC EL

SAT006J

AT-27

IDX

OVERALL SYSTEM Control Mechanism (Cont’d)

쐌

Line pressure is increased to a maximum irrespective of the throttle opening when fluid temperature drops to −10°C (14°F). This pressure rise is adopted to prevent a delay in clutch and brake operation due to extreme drop of fluid viscosity at low temperature.

SAT007J

SHIFT CONTROL

NGAT0180S02

The shift is regulated entirely by electronic control to accommodate vehicle speed and varying engine operations. This is accomplished by electrical signals transmitted by the revolution sensor and throttle position sensor. This results in improved acceleration performance and fuel economy.

Control of Shift Solenoid Valves A and B

NGAT0180S0201

The TCM activates shift solenoid valves A and B according to signals from the throttle position sensor and revolution sensor to select the optimum gear position on the basis of the shift schedule memorized in the TCM. The shift solenoid valve performs simple ON-OFF operation. When set to ON, the drain circuit closes and pilot pressure is applied to the shift valve. [Relation between shift solenoid valves A and B and gear positions] SAT008J

Gear position Shift solenoid valve D1, 21, 11

D2, 22, 12

D3

D4 (OD)

N-P

A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

ON (Closed)

B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Control of Shift Valves A and B

NGAT0180S0202

SAT047J

AT-28

OVERALL SYSTEM Control Mechanism (Cont’d)

Pilot pressure generated by the operation of shift solenoid valves A and B is applied to the end face of shift valves A and B. The drawing above shows the operation of shift valve B. When the shift solenoid valve is “ON”, pilot pressure applied to the end face of the shift valve overcomes spring force, moving the valve upward.

MA

LOCK-UP CONTROL

NGAT0180S03

The torque converter clutch piston in the torque converter is locked to eliminate torque converter slip to increase power transmission efficiency. The solenoid valve is controlled by an ON-OFF duty signal sent from the TCM. The signal is converted to oil pressure signal which controls the torque converter clutch piston.

Conditions for Lock-up Operation

ON

Selector lever Gear position Vehicle speed sensor Throttle position sensor Closed throttle position switch A/T fluid temperature sensor

EM LC

NGAT0180S0301

When vehicle is driven in 4th gear position, vehicle speed and throttle opening are detected. If the detected values fall within the lock-up zone memorized in the TCM, lock-up is performed. Overdrive control switch

GI

OFF

EC FE

“D” position D4

D3

More than set value Less than set opening

CL MT

OFF More than 40°C (104°F)

TF PD AX Torque Converter Clutch Solenoid Valve Control

NGAT0180S0302

The torque converter clutch solenoid valve is controlled by the TCM. The plunger closes the drain circuit during the OFF period, and opens the circuit during the ON period. If the percentage of OFF-time increases in one cycle, the pilot pressure drain time is reduced and pilot pressure remains high. The torque converter clutch piston is designed to slip to adjust the ratio of ON-OFF, thereby reducing lock-up shock.

SU BR ST RS

SAT010J

OFF-time INCREASING " Amount of drain DECREASING " Pilot pressure HIGH " Lock-up RELEASING

BT HA SC EL

SAT011J

AT-29

IDX

OVERALL SYSTEM Control Mechanism (Cont’d)

Torque Converter Clutch Control Valve OperationNGAT0180S0303

SAT048J

Lock-up Released The OFF-duration of the torque converter clutch solenoid valve is long, and pilot pressure is high. The pilot pressure pushes the end face of the torque converter clutch control valve in combination with spring force to move the valve to the left. As a result, converter pressure is applied to chamber A (torque converter clutch piston release side). Accordingly, the torque converter clutch piston remains unlocked. Lock-up Applied When the OFF-duration of the torque converter clutch solenoid valve is short, pilot pressure drains and becomes low. Accordingly, the control valve moves to the right by the pilot pressure of the other circuit and converter pressure. As a result, converter pressure is applied to chamber B, keeping the torque converter clutch piston applied. Also smooth lock-up is provided by transient application and release of the lock-up.

OVERRUN CLUTCH CONTROL (ENGINE BRAKE CONTROL)

NGAT0180S04

Forward one-way clutch is used to reduce shifting shocks in downshifting operations. This clutch transmits engine torque to the wheels. However, drive force from the wheels is not transmitted to the engine because the one-way clutch rotates idle. This means the engine brake is not effective. The overrun clutch operates when the engine brake is needed.

Overrun Clutch Operating Conditions Gear position D position

D1, D2, D3 gear position

2 position

21, 22 gear position

1 position

11, 12 gear position

NGAT0180S0401

Throttle opening Less than 3/16 At any position

SAT014J

AT-30

OVERALL SYSTEM Control Mechanism (Cont’d)

Overrun Clutch Solenoid Valve Control

NGAT0180S0402

The overrun clutch solenoid valve is operated by an ON-OFF signal transmitted by the TCM to provide overrun clutch control (engine brake control). When this solenoid valve is ON, the pilot pressure drain port closes. When it is OFF, the drain port opens. During the solenoid valve ON pilot pressure is applied to the end face of the overrun clutch control valve.

GI MA EM LC

SAT015J

Overrun Clutch Control Valve Operation

NGAT0180S0403

When the solenoid valve is ON, pilot pressure A is applied to the overrun clutch control valve. This pushes up the overrun clutch control valve. The line pressure is then shut off so that the clutch does not engage. When the solenoid valve is OFF, pilot pressure A is not generated. At this point, the overrun clutch control valve moves downward by spring force. As a result, overrun clutch operation pressure is provided by the overrun clutch reducing valve. This causes the overrun clutch to engage. In the 1 position, the overrun clutch control valve remains pushed down so that the overrun clutch is engaged at all times.

EC FE CL MT

TF PD AX SAT049J

Control Valve

NGAT0181

FUNCTION OF CONTROL VALVE

SU

NGAT0181S01

Valve name

Function

BR

쐌 Pressure regulator valve 쐌 Pressure regulator plug 쐌 Pressure regulator sleeve plug

Regulate oil discharged from the oil pump to provide optimum line pressure for all driving conditions.

Pressure modifier valve

Used as a signal supplementary valve to the pressure regulator valve. Regulates pressure-modifier pressure (signal pressure) which controls optimum line pressure for all driving conditions.

RS

Modifier accumulator piston

Smooths hydraulic pressure regulated by the pressure modifier valve to prevent pulsations.

BT

Pilot valve

Regulates line pressure to maintain a constant pilot pressure level which controls lock-up mechanism, overrun clutch, 3-2 timing required for shifting.

Accumulator control valve Accumulator control sleeve

Regulate accumulator back-pressure to pressure suited to driving conditions.

Manual valve

Directs line pressure to oil circuits corresponding to select positions. Hydraulic pressure drains when the shift lever is in Neutral.

ST

HA SC EL

AT-31

IDX

OVERALL SYSTEM Control Valve (Cont’d) Valve name

Function

Shift valve A

Simultaneously switches three oil circuits using output pressure of shift solenoid valve A to meet driving conditions (vehicle speed, throttle opening, etc.). Provides automatic downshifting and up-shifting (1st , 2nd , 3rd , 4th gears/4th , 3rd , 2nd , 1st gears) in combination with shift valve B.

Shift valve B

Simultaneously switches three oil circuits using output pressure of shift solenoid valve B in relation to driving conditions (vehicle speed, throttle opening, etc.). Provides automatic downshifting and up-shifting (1st , 2nd , 3rd , 4th gears/4th , 3rd , 2nd , 1st gears) in combination with shift valve A.

Shuttle shift valve S

Switches hydraulic circuits to provide 3-2 timing control and overrun clutch control in relation to the throttle opening. Inactivates the overrun clutch to prevent interlocking in 4th gear when the throttle is wide open.

Overrun clutch control valve

Switches hydraulic circuits to prevent engagement of the overrun clutch simultaneously with application of the brake band in 4th gear. (Interlocking occurs if the overrun clutch engages during D4 gear operation.)

4-2 relay valve

Memorizes that the transmission is in 4th gear. Prevents the transmission from downshifting from 4th gear to 3rd and then to 2nd in combination with 4-2 sequence valve and shift valves A and B when downshifting from 4th to 2nd gear.

4-2 sequence valve

Prevents band servo pressure from draining before high clutch operating pressure and band servo releasing pressure drain (from the same circuit) during downshifting from 4th to 2nd gear.

Servo charger valve

An accumulator and a one-way orifice are used in the 2nd gear band servo oil circuit to dampen shifting shock when shifting from 1st to 2nd gear. To maintain adequate flow rate when downshifting from 4th or 3rd gear to 2nd gear, the servo charger valve directs 2nd gear band servo hydraulic pressure to the circuit without going through the one-way orifice when downshifting from 3rd or a higher gear.

3-2 timing valve

Prevents a late operation of the brake band when shifting selector lever from D to 1 or 2 position while driving in D3.

1 reducing valve

Reduces low & reverse brake pressure to dampen engine-brake shock when downshifting from the 1 position 2nd gear to 1st gear.

Overrun clutch reducing valve

Reduces oil pressure directed to the overrun clutch and prevents engine-brake shock. In 1 and 2 positions, line pressure acts on the overrun clutch reducing valve to increase the pressure-regulating point, with resultant engine brake capability.

Torque converter relief valve

Prevents an excessive rise in torque converter pressure.

Torque converter clutch control valve, torque converter clutch control plug and torque converter clutch control sleeve

Activate or inactivate the lock-up function. Also provide smooth lock-up through transient application and release of the lock-up system.

Shuttle shift valve D

Switches hydraulic circuits so that output pressure of the torque converter clutch solenoid valve acts on the lock-up valve in the D position of 2nd, 3rd and 4th gears. (In the D position 1st gear, lock-up is inhibited.) 쐌 Lock-up control is not affected in D position 2nd, 3rd or 4th gears, unless output pressure of the torque converter clutch solenoid valve is generated by a signal from the control unit.

AT-32

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Introduction

Introduction

NGAT0014

The A/T system has two self-diagnostic systems. The first is the emission-related on board diagnostic system (OBD-II) performed by the TCM in combination with the ECM. The malfunction is indicated by the MIL (malfunction indicator lamp) and is stored as a DTC in the ECM memory but not the TCM memory. The second is the TCM original self-diagnosis indicated by the O/D OFF indicator lamp. The malfunction is stored in the TCM memory. The detected items are overlapped with OBD-II self-diagnostic items. For detail, refer to “SELF-DIAGNOSTIC RESULT TEST MODE”, AT-38.

OBD-II Function for A/T System

GI MA EM

NGAT0182

The ECM provides emission-related on board diagnostic (OBD-II) functions for the A/T system. One function is to receive a signal from the TCM used with OBD-related parts of the A/T system. The signal is sent to the ECM when a malfunction occurs in the corresponding OBD-related part. The other function is to indicate a diagnostic result by means of the MIL (malfunction indicator lamp) on the instrument panel. Sensors, switches and solenoid valves are used as sensing elements. The MIL automatically illuminates in One or Two Trip Detection Logic when a malfunction is sensed in relation to A/T system parts.

One or Two Trip Detection Logic of OBD-II ONE TRIP DETECTION LOGIC

LC EC FE

NGAT0015 NGAT0015S01

If a malfunction is sensed during the first test drive, the MIL will illuminate and the malfunction will be stored in the ECM memory as a DTC. The TCM is not provided with such a memory function.

CL MT

TWO TRIP DETECTION LOGIC

NGAT0015S02

When a malfunction is sensed during the first test drive, it is stored in the ECM memory as a 1st trip DTC (diagnostic trouble code) or 1st trip freeze frame data. At this point, the MIL will not illuminate. — First Trip If the same malfunction that was experienced during the first test drive is sensed during the second test drive, the MIL will illuminate. — Second Trip A/T-related parts for which the MIL illuminates during the first or second test drive are listed below.

TF

MIL Items One trip detection Shift solenoid valve A — DTC: P0750 (1108)

X

Shift solenoid valve B — DTC: P0755 (1201)

X

Throttle position sensor or switch — DTC: P1705 (1206)

X

Except above

PD

Two trip detection

AX SU

X

The “trip” in the “One or Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during vehicle operation.

OBD-II Diagnostic Trouble Code (DTC) HOW TO READ DTC AND 1ST TRIP DTC

NGAT0016

BR ST

NGAT0016S01

DTC and 1st trip DTC can be read by the following methods. ( with CONSULT-II or GST) CONSULT-II or GST (Generic Scan Tool) Examples: P0705, P0710, P0720, P0725, etc. These DTCs are prescribed by SAE J2012. (CONSULT-II also displays the malfunctioning component or system.) 쐌 1st trip DTC No. is the same as DTC No. 쐌 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 and 1st trip DTC is shown below. 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.

AT-33

RS BT HA SC EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD-II Diagnostic Trouble Code (DTC) (Cont’d)

SAT014K

If the DTC is being detected currently, the time data will be “0”.

SAT015K

If a 1st trip DTC is stored in the ECM, the time data will be “[1t]”.

SAT016K

Freeze Frame Data and 1st Trip Freeze Frame Data

NGAT0016S0101

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-682 (VG33E only) or EC-1254 (VG33ER only), “CONSULT-II”. 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/MIL on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data.

AT-34

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD-II Diagnostic Trouble Code (DTC) (Cont’d) Priority 1

Items Freeze frame data

2 3

Misfire — DTC: P0300 - P0306 (0701, 0603 - 0608) Fuel Injection System Function — DTC: P0171 (0115), P0172 (0114), P0174 (0209), P0175 (0210)

GI MA

Except the above items (Includes A/T related items) 1st trip freeze frame data

EM Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased.

LC

HOW TO ERASE DTC

NGAT0016S02

The diagnostic trouble code can be erased by CONSULT-II, GST or ECM DIAGNOSTIC TEST MODE as described following. 쐌 If the battery terminal is disconnected, the diagnostic trouble code will be lost within 24 hours. 쐌 When you erase the DTC, using CONSULT-II or GST is easier and quicker than switching the mode selector on the ECM. The following emission-related diagnostic information is cleared from the ECM memory when erasing DTC related to OBD-II. For details, refer to EC-661 (VG33E only) or EC-1246 (VG33ER only), “How to Erase Emissionrelated Diagnostic Information”. 쐌 Diagnostic trouble codes (DTC) 쐌 1st trip diagnostic trouble codes (1st trip DTC) 쐌 Freeze frame data 쐌 1st trip freeze frame data 쐌 System readiness test (SRT) codes 쐌 Test values

HOW TO ERASE DTC (WITH CONSULT-II)

EC FE CL MT

TF NGAT0016S03

쐌 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 “A/T”. 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.)

PD AX SU BR ST RS BT HA SC EL

AT-35

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD-II Diagnostic Trouble Code (DTC) (Cont’d)

SAT286K

HOW TO ERASE DTC (WITH GST)

NGAT0016S04

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-II SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)”. Refer to “OBD-II SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)”, AT-46. (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-695 (VG33E only) or EC-1198 (VG33ER only), “Generic Scan Tool (GST)”.

HOW TO ERASE DTC (NO TOOLS)

NGAT0016S05

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 “TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)”, AT-47. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.)

AT-36

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator Lamp (MIL)

Malfunction Indicator Lamp (MIL) 1. 쐌

2. SAT964I

NGAT0183

The malfunction indicator lamp will light up when the ignition switch is turned ON without the engine running. This is for checking the lamp. If the malfunction indicator lamp does not light up, refer to EL-94 “Circuit Diagram” or EC-675 (VG33E only) or EC-1247 (VG33ER only), “Description”. (OrrefertoEC-1171(VG33Eonly)orEC-1751(VG33ERonly),“MIL & DATA LINK CONNECTORS”.) When the engine is started, the malfunction indicator lamp should go off. If the lamp remains on, the on board diagnostic system has detected an emission-related (OBD-II) malfunction. For detail, refer to EC-660 (VG33E only) or EC-1232 (VG33ER only), “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”.

GI MA EM LC EC FE CL MT

CONSULT-II

NGAT0184

After performing “SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)” (AT-38), place check marks for results on the “Diagnostic Worksheet”, AT-57. Reference pages are provided following the items. NOTICE: 1) The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each solenoid). Check for time difference between actual shift timing and the CONSULT-II display. If the difference is noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical parts using applicable diagnostic procedures. 2) Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service Manual may differ slightly. This occurs because of the following reasons: 쐌 Actual shift schedule has more or less tolerance or allowance, 쐌 Shift schedule indicated in Service Manual refers to the point where shifts start, and 쐌 Gear position displayed on CONSULT-II indicates the point where shifts are completed. 3) Shift solenoid valve “A” or “B” is displayed on CONSULT-II at the start of shifting. Gear position is displayed upon completion of shifting (which is computed by TCM). 4) Additional CONSULT-II information can be found in the Operation Manual supplied with the CONSULT-II unit.

TF PD AX SU BR ST RS BT HA SC EL

AT-37

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II) NGAT0184S01 1.

Turn on CONSULT-II and touch “ENGINE” for OBD-II detected items or touch “A/T” for TCM self-diagnosis. If A/T is not displayed, check TCM power supply and ground circuit. Refer to “Wiring Diagram—AT—MAIN”, AT-101. If result is NG, refer to EL-10, “POWER SUPPLY ROUTING”.

2.

Touch “SELF-DIAG RESULTS”. 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.

SAT014K

SAT987J

SELF-DIAGNOSTIC RESULT TEST MODE

NGAT0184S02

TCM self-diagnosis

OBD-II (DTC)

Available by O/D OFF indicator lamp or “A/T” on CONSULT-II

Available by malfunction indicator lamp*2, “ENGINE” on CONSULT-II or GST

—

P0705

쐌 TCM does not receive the proper voltage signal from the sensor.

X

P0720

쐌 TCM does not receive the proper voltage signal from the sensor.

X

—

—

P0731*1

—

P0732*1

—

P0733*1

Detected items (Screen terms for CONSULT-II, “SELFDIAG RESULTS” test mode) Malfunction is detected when ...

“A/T”

“ENGINE”

PNP switch circuit —

PNP SW/CIRC

Revolution sensor VHCL SPEED SEN·A/T

VEH SPD SEN/CIR AT

Vehicle speed sensor (Meter) VHCL SPEED SEN·MTR A/T 1st gear function —

— 쐌 A/T cannot be shifted to the 1st gear position even if electrical A/T 1ST GR FNCTN circuit is good.

A/T 2nd gear function —

A/T 2ND GR FNCTN

A/T 3rd gear function —

쐌 TCM does not receive the correct voltage signal (based on the gear position) from the switch.

A/T 3RD GR FNCTN

쐌 A/T cannot be shifted to the 2nd gear position even if electrical circuit is good. 쐌 A/T cannot be shifted to the 3rd gear position even if electrical circuit is good.

AT-38

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) TCM self-diagnosis

OBD-II (DTC)

Detected items (Screen terms for CONSULT-II, “SELFDIAG RESULTS” test mode)

GI Malfunction is detected when ...

“A/T”

“ENGINE”

A/T 4th gear function —

A/T 4TH GR FNCTN

A/T TCC S/V function (lock-up) —

A/T TCC S/V FNCTN

SFT SOL A/CIRC

SFT SOL B/CIRC

쐌 TCM detects an improper voltage drop when it tries to operate the solenoid valve.

Shift solenoid valve B SHIFT SOLENOID/V B

Overrun clutch solenoid valve OVERRUN CLUTCH S/V

O/R CLUCH SOL/ CIRC

T/C clutch solenoid valve T/C CLUTCH SOL/V

TCC SOLENOID/ CIRC

Line pressure solenoid valve LINE PRESSURE S/V

쐌 A/T cannot perform lock-up even if electrical circuit is good.

쐌 TCM detects an improper voltage drop when it tries to operate the solenoid valve.

Shift solenoid valve A SHIFT SOLENOID/V A

쐌 A/T cannot be shifted to the 4th gear position even if electrical circuit is good.

L/PRESS SOL/ CIRC

쐌 TCM detects an improper voltage drop when it tries to operate the solenoid valve. 쐌 TCM detects an improper voltage drop when it tries to operate the solenoid valve. 쐌 TCM detects an improper voltage drop when it tries to operate the solenoid valve.

Available by O/D OFF indicator lamp or “A/T” on CONSULT-II

Available by malfunction indicator lamp*2, “ENGINE” on CONSULT-II or GST

—

P0734*1

—

P0744*1

X

ENGINE SPEED SIG A/T fluid temperature sensor BATT/FLUID TEMP SEN

ATF TEMP SEN/ CIRC

Turbine revolution sensor (VG33ER only) TURBINE REV

—

CL X

P0755

X

P1760

TF X

P0740

X

P0745

CONTROL UNIT (ROM)

PD AX SU

P1705

쐌 TCM does not receive the proper voltage signal from the ECM.

X

P0725

쐌 TCM receives an excessively low or high voltage from the sensor.

X

P0710

쐌 TCM does not receive the proper voltage signal from the sensor.

X

—

ST RS BT HA

—

—

—

SC 쐌 TCM memory (ROM) is malfunctioning.

TCM (ROM)

MT

BR

쐌 TCM memory (RAM) is malfunctioning.

TCM (RAM) CONTROL UNIT (RAM)

P0750

TP SEN/CIRC A/T

Engine speed signal

LC

FE

X THROTTLE POSI SEN

EM

EC

쐌 TCM receives an excessively low or high voltage from the sensor.

Throttle position sensor Throttle position switch

MA

—

AT-39

—

—

EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) TCM self-diagnosis

OBD-II (DTC)

Available by O/D OFF indicator lamp or “A/T” on CONSULT-II

Available by malfunction indicator lamp*2, “ENGINE” on CONSULT-II or GST

—

—

X

—

X

X

Detected items (Screen terms for CONSULT-II, “SELFDIAG RESULTS” test mode) Malfunction is detected when ...

“A/T”

“ENGINE” 쐌 TCM memory (EEPROM) is malfunctioning.

TCM EEPROM CONT UNIT (EEPROM)

— 쐌 This is not a malfunction message (Whenever shutting off a power supply to the control unit, this message appears on the screen.)

Initial start

INITIAL START

—

No failure (NO DTC IS DETECTED FURTHER TESTING MAY BE REQUIRED**)

쐌 No failure has been detected.

X: Applicable —: Not applicable if another malfunction is assigned to MIL. *1: These malfunctions cannot be displayed by MIL *2: Refer to EC-675 (VG33E only) or EC-1247 (VG33ER only), “Malfunction Indicator Lamp (MIL)”.

DATA MONITOR MODE (A/T)

NGAT0184S03

Monitor item Item

Display

Vehicle speed sensor 1 (A/T) (Revolution sensor)

VHCL/S SE·A/T [km/h] or [mph]

Vehicle speed sensor 2 (Meter)

VHCL/S SE·MTR [km/h] or [mph]

Throttle position sensor

A/T fluid temperature sensor

TCM input signals

X

THRTL POS SEN [V]

Main signals

—

BATTERY VOLT [V]

Engine speed

ENGINE SPEED [rpm]

쐌 Vehicle speed computed from signal of vehicle speed sensor is displayed.

—

X

—

쐌 Throttle position sensor signal voltage is displayed.

X

—

쐌 A/T fluid temperature sensor signal voltage is displayed. 쐌 Signal voltage lowers as fluid temperature rises.

X

—

쐌 Source voltage of TCM is displayed.

X

X

AT-40

Remarks

쐌 Vehicle speed computed When racing engine in “N” from signal of revolution or “P” position with vehicle sensor is displayed. stationary, CONSULT-II data may not indicate 0 km/h (0 mph).

X

FLUID TEMP SE [V]

Battery voltage

Description

쐌 Engine speed, computed from engine speed signal, is displayed.

Vehicle speed display may not be accurate under approx. 10 km/h (6 mph). It may not indicate 0 km/h (0 mph) when vehicle is stationary.

Engine speed display may not be accurate under approx. 800 rpm. It may not indicate 0 rpm even when engine is not running.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Monitor item Item

Display

Turbine revolution sensor (VG33ER only)

TURBINE REV [rpm]

Overdrive control switch

OVERDRIVE SW [ON/OFF]

P/N position switch

R position switch

D position switch

2 position switch

1 position switch

ASCD cruise signal

TCM input signals

X

X

Closed throttle position switch

—

쐌 ON/OFF state computed from signal of overdrive control SW is displayed.

Error may occur under approx. 800 rpm and will not indicate 0 rpm even if engine is not running.

GI MA EM LC

X

—

R POSITION SW [ON/OFF]

X

—

쐌 ON/OFF state computed from signal of R position SW is displayed.

FE

D POSITION SW [ON/OFF]

X

—

쐌 ON/OFF state computed from signal of D position SW is displayed.

CL

—

쐌 ON/OFF status, computed from signal of 2 position SW, is displayed.

—

쐌 ON/OFF status, computed from signal of 1 position SW, is displayed.

—

쐌 Status of ASCD cruise signal is displayed. ON ... Cruising state OFF ... Normal running state

쐌 This is displayed even when no ASCD is mounted.

쐌 Status of ASCD O/D release signal is displayed. ON ... O/D released OFF ... O/D not released

쐌 This is displayed even when no ASCD is mounted.

—

쐌 ON/OFF status, computed from signal of kickdown SW, is displayed.

쐌 This is displayed even when no kickdown switch is equipped.

—

쐌 ON/OFF status, computed from signal of closed throttle position SW, is displayed.

2 POSITION SW [ON/OFF]

1 POSITION SW [ON/OFF]

X

X

ASCD-CRUISE [ON/OFF]

ASCD-O/D CUT [ON/OFF]

KICKDOWN SW [ON/OFF]

CLOSED THL/SW [ON/OFF]

Wide open throttle position W/O THRL/P-SW switch [ON/OFF]

Stop lamp switch (VG33ER only)

—

쐌 Turbine revolution computed from signal of turbine revolution sensor is displayed.

Remarks

쐌 ON/OFF state computed from signal of P/N position SW is displayed.

X

Kickdown switch

Description

PN POSI SW [ON/OFF]

X

ASCD-O/D cut signal

Main signals

X

X

X

—

—

쐌 ON/OFF status, computed from signal of wide open throttle position SW, is displayed.

—

쐌 ON/OFF status is displayed ON...Brake pedal switch is depressed. OFF...Brake pedal switch is released.

BRAKE SW [ON/OFF] X

AT-41

EC

MT

TF PD AX SU BR ST RS BT HA SC EL IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Monitor item Item

Gear position

Selector lever position

Vehicle speed

Throttle position

Line pressure duty

Display

—

X

쐌 Gear position data used for computation by TCM, is displayed.

—

X

쐌 Selector lever position data, used for computation by TCM, is displayed.

—

X

쐌 Vehicle speed data, used for computation by TCM, is displayed.

X

쐌 Throttle position data, 쐌 A specific value used for used for computation by control is displayed if TCM, is displayed. fail-safe is activated due to error.

X

쐌 Control value of line pressure solenoid valve, computed by TCM from each input signal, is displayed.

X

쐌 Control value of torque converter clutch solenoid valve, computed by TCM from each input signal, is displayed.

X

쐌 Control value of shift solenoid valve A, computed by TCM from each input signal, is displayed.

X

쐌 Control value of shift solenoid valve B, computed by TCM from each input signal, is displayed.

—

X

쐌 Control value of overrun clutch solenoid valve computed by TCM from each input signal is displayed.

—

X

쐌 Control status of O/D OFF indicator lamp is displayed.

SLCT LVR POSI

THROTTLE POSI [/8]

—

LINE PRES DTY [%] —

Torque converter clutch solenoid valve duty

TCC S/V DUTY [%] —

Shift solenoid valve A

SHIFT S/V A [ON/OFF] —

Shift solenoid valve B

SHIFT S/V B [ON/OFF] —

Overrun clutch solenoid valve

Self-diagnosis display lamp (O/D OFF indicator lamp)

OVERRUN/C S/V [ON/OFF]

SELF-D DP LMP [ON/OFF]

Remarks

Main signals

GEAR

VEHICLE SPEED [km/h] or [mph]

Description

TCM input signals

X: Applicable —: Not applicable

AT-42

쐌 A specific value used for control is displayed if fail-safe is activated due to error.

Control value of solenoid is displayed even if solenoid circuit is disconnected. The “OFF” signal is displayed if solenoid circuit is shorted.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

DTC WORK SUPPORT MODE WITH CONSULT-II CONSULT-II Setting Procedure 1. 2.

NGAT0184S04 NGAT0184S0401

Turn ignition switch OFF. Connect CONSULT-II to Data Link Connector. Data link connector for CONSULT-II is located in the lower instrument panel on driver side.

GI MA EM LC

LEC104A

3. 4.

Turn ignition switch ON Touch “START”.

EC FE CL MT

SAT586J

5.

Touch “A/T”.

TF PD AX SAT014K

6.

Touch “DTC WORK SUPPORT”.

SU BR ST RS

SAT971J

7.

Touch select item menu (1ST, 2ND, etc.).

BT HA SC EL

SAT018K

AT-43

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

8.

Touch “START”.

9.

Perform driving test according to “DTC CONFIRMATION PROCEDURE” in “TROUBLE DIAGNOSIS FOR DTC”.

쐌

When testing conditions are satisfied, CONSULT-II screen changes from “OUT OF CONDITION” to “TESTING”.

SAT589J

SAT019K

SAT591J

10. Stop vehicle. If “NG” appears on the screen, malfunction may exist. Go to “DIAGNOSTIC PROCEDURE”.

SAT592J

SAT593J

AT-44

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

11. Perform test drive to check gear shift feeling in accordance with instructions displayed.

GI MA EM LC

SAT594J

12. Touch “YES” or “NO”.

EC FE CL MT

SAT595J

13. CONSULT-II procedure ended. If “NG” appears on the screen, a malfunction may exist. Go to “DIAGNOSTIC PROCEDURE”.

TF PD AX SAT596J

SU BR ST RS SAT593J

DTC WORK SUPPORT MODE DTC work support item

1ST GR FNCTN P0731

NGAT0184S05

Description Following items for “A/T 1st gear function (P0731)” can be confirmed. 쐌 Self-diagnosis status (whether the diagnosis is being conducted or not) 쐌 Self-diagnosis result (OK or NG)

BT

Check item 쐌 쐌 쐌 쐌

HA Shift solenoid valve A Shift solenoid valve B Each clutch Hydraulic control circuit

SC EL

AT-45

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) DTC work support item

Description

Check item

2ND GR FNCTN P0732

Following items for “A/T 2nd gear function (P0732)” can be confirmed. 쐌 Self-diagnosis status (whether the diagnosis is being conducted or not) 쐌 Self-diagnosis result (OK or NG)

쐌 Shift solenoid valve B 쐌 Each clutch 쐌 Hydraulic control circuit

3RD GR FNCTN P0733

Following items for “A/T 3rd gear function (P0733)” can be confirmed. 쐌 Self-diagnosis status (whether the diagnosis is being conducted or not) 쐌 Self-diagnosis result (OK or NG)

쐌 Shift solenoid valve A 쐌 Each clutch 쐌 Hydraulic control circuit

4TH GR FNCTN P0734

Following items for “A/T 4th gear function (P0734)” can be confirmed. 쐌 Self-diagnosis status (whether the diagnosis is being conducted or not) 쐌 Self-diagnosis result (OK or NG)

쐌 쐌 쐌 쐌 쐌 쐌

TCC S/V FNCTN P0744

Following items for “A/T TCC S/V function (lock-up) (P0744)” can be confirmed. 쐌 Self-diagnosis status (whether the diagnosis is being conducted or not) 쐌 Self-diagnosis result (OK or NG)

쐌 Torque converter clutch solenoid valve 쐌 Each clutch 쐌 Hydraulic control circuit

Shift solenoid valve A Shift solenoid valve B Overrun clutch solenoid valve Line pressure solenoid valve Each clutch Hydraulic control circuit

Diagnostic Procedure Without CONSULT-II

NGAT0207

OBD-II SELF-DIAGNOSTIC PROCEDURE (WITH NGAT0207S01 GST) Refer to EC-695 (VG33E only) or EC-1267 (VG33ER only), “Generic Scan Tool (GST)”.

OBD-II SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)

NGAT0207S02

Refer to EC-675 (VG33E only) or EC-1247 (VG33ER only), “Malfunction Indicator Lamp (MIL)”.

AT-46

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d)

TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS) NGAT0207S03 1

CHECK O/D OFF INDICATOR LAMP

GI

1. Selector lever in P position. Start the engine. Warm engine to normal operating temperature. 2. Turn ignition switch to OFF position. 3. Wait at least 5 seconds.

MA EM LC EC SAT967I

4. Turn ignition switch to ON position. (Do not start engine.) 5. Does O/D OFF indicator lamp come on for about 2 seconds?

FE CL MT

TF WAT496

PD

Yes or No

AX

Yes

䊳

GO TO 2.

No

䊳

Go to “1. O/D OFF Indicator Lamp Does Not Come On”, AT-215.

SU BR ST RS BT HA SC EL

AT-47

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d)

2

JUDGEMENT PROCEDURE STEP 1

1. 2. 3. 4. 5.

Turn ignition switch to OFF position. Turn ignition switch to ACC position. Move selector lever from P to D position. Turn ignition switch to ON position. Do not start engine. Depress and hold overdrive control switch in OFF position (the O/D OFF indicator lamp will be ON) until directed to release the switch. If O/D OFF indicator lamp does not come on, go to step 3 in test no. 3 “DIAGNOSTIC PROCEDURE” ( AT-253). 6. Turn ignition switch to OFF position.

SAT968I

7. Turn ignition switch to ON position (Do not start engine). 8. Release the overdrive control switch (the O/D OFF indicator lamp will be OFF). 쐌 Wait for more than 2 seconds after ignition switch ON. 9. Move selector lever to 2 position. 10. Depress and release the overdrive control switch (the O/D OFF indicator lamp will be ON). 11. Depress and hold the overdrive control switch (the O/D OFF indicator lamp will be OFF) until directed to release the switch.

SAT969I

䊳

GO TO 3.

AT-48

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d)

3 1. 2. 3. 4. 5.

JUDGEMENT PROCEDURE STEP 2 Move selector lever to 1 position. Release the overdrive control switch. Depress and release the overdrive control switch (the O/D OFF indicator lamp will be ON). Depress and release the overdrive control switch (the O/D OFF indicator lamp will be OFF). Depress and hold the overdrive control switch (the O/D OFF indicator lamp will be ON) until directed to release the switch.

GI MA EM LC EC FE

SAT970I

CL

6. Depress accelerator pedal fully and release. 7. Release the overdrive control switch (the O/D OFF indicator lamp will begin to flash ON and OFF).

MT

TF PD SAT981F

GO TO 4.

AX

CHECK SELF-DIAGNOSIS CODE

SU

䊳

4

Check O/D OFF indicator lamp. Refer to “JUDGEMENT OF SELF-DIAGNOSIS CODE”, AT-50.

BR ST RS BT WAT496

䊳

HA

DIAGNOSIS END

SC EL

AT-49

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d)

JUDGEMENT OF SELF-DIAGNOSIS CODE (VG33E ONLY) NGAT0207S04 O/D OFF indicator lamp: 1st judgement flicker is longer than others.

All judgement flickers are same.

SAT437F

All circuits that can be confirmed by self-diagnosis are OK.

Revolution sensor circuit is short-circuited or disconnected. ⇒ Go to VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) , AT-116.

2nd judgement flicker is longer than others.

3rd judgement flicker is longer than others.

SAT436F

SAT439F

SAT441F

Vehicle speed sensor circuit is short-circuited or disconnected. ⇒ Go to VEHICLE SPEED SENSOR·MTR, AT-199.

Throttle position sensor circuit is short-circuited or disconnected. ⇒ Go to THROTTLE POSITION SENSOR , AT-179.

4th judgement flicker is longer than others.

5th judgement flicker is longer than others.

SAT445F

Shift solenoid valve B circuit is short-circuited or disconnected. SAT443F ⇒ Go to SHIFT SOLENOID VALVE B , AT-174. Shift solenoid valve A circuit is short-circuited or disconnected. ⇒ Go to SHIFT SOLENOID VALVE A , AT-169.

AT-50

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d) O/D OFF indicator lamp:

GI

7th judgement flicker is longer than others.

6th judgement flicker is longer than others.

MA EM LC SAT447F

SAT449F

Overrun clutch solenoid valve circuit is short-circuited or disconnected. ⇒ Go to OVERRUN CLUTCH SOLENOID VALVE (DTC: 1203), AT-188.

Torque converter clutch solenoid valve circuit is short-circuited or disconnected. ⇒ Go to TORQUE CONVERTER CLUTCH SOLENOID VALVE , AT-152.

8th judgement flicker is longer than others.

9th judgement flicker is longer than others.

EC FE CL MT

SAT453F

Engine speed signal circuit is short-circuited or disconnected. SAT451F ⇒ Go to ENGINE SPEED SIGNAL AT-121. A/T fluid temperature sensor is disconnected or TCM power source circuit is damaged. ⇒ Go to A/T FLUID TEMPERATURE SENSOR AND TCM POWER SOURCE, AT-193.

PD AX

Flickers as shown below.

10th judgement flicker is longer than others.

TF

SU BR ST SAT457F SAT455F

Line pressure solenoid valve circuit is short-circuited or disconnected. ⇒ Go to LINE PRESSURE SOLENOID VALVE , AT-164.

Battery power is low. Battery has been disconnected for a long time. Battery is connected conversely. (When reconnecting TCM connectors. — This is not a problem.)

RS BT HA SC EL

AT-51

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d) O/D OFF indicator lamp: Lamp comes on.

SAT367J

PNP switch, overdrive control switch or throttle position switch circuit is disconnected or TCM is damaged. ⇒ Go to 21. TCM Self-diagnosis Does Not Activate PNP, OVERDRIVE CONTROL AND THROTTLE POSITION SWITCHES), AT-252. t1 = 2.5 seconds

t2 = 2.0 seconds

t3 = 1.0 second

t4 = 1.0 second

JUDGEMENT OF SELF-DIAGNOSIS CODE (VG33ER ONLY) NGAT0207S05 O/D OFF indicator lamp: 1st judgement flicker is longer than others.

All judgement flickers are same.

LAT426

All circuits that can be confirmed by self-diagnosis are OK.

Revolution sensor circuit is short-circuited or disconnected. ⇒ Go to “DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)”, AT-116.

2nd judgement flicker is longer than others.

3rd judgement flicker is longer than others.

LAT425

LAT427

Vehicle speed sensor circuit is short-circuited or disconnected. ⇒ Go to “DTC VEHICLE SPEED SENSOR·MTR”, AT-199.

LAT428

Throttle position sensor circuit is short-circuited or disconnected. ⇒ Go to “DTC P1705 THROTTLE POSITION SENSOR”, AT-179.

AT-52

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d) O/D OFF indicator lamp: 4th judgement flicker is longer than others.

GI

5th judgement flicker is longer than others.

MA EM LC LAT430

Shift solenoid valve B circuit is short-circuited or disconnected. LAT429 ⇒ Go to “DTC P0755 SHIFT SOLENOID VALVE B”, AT-174. Shift solenoid valve A circuit is short-circuited or disconnected. ⇒ Go to “DTC P0750 SHIFT SOLENOID VALVE A”, AT-169. 7th judgement flicker is longer than others.

6th judgement flicker is longer than others.

EC FE CL MT

LAT432

LAT431

Overrun clutch solenoid valve circuit is short-circuited or disconnected. ⇒ Go to “DTC P1760 OVERRUN CLUTCH SOLENOID VALVE”, AT-188.

Torque converter clutch solenoid valve circuit is short-circuited or disconnected. ⇒ Go to “DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE”, AT-152.

8th judgement flicker is longer than others.

9th judgement flicker is longer than others.

TF PD AX SU BR

LAT434

Engine speed signal circuit is short-circuited or disconnected. LAT433 ⇒ Go to “DTC P0725 ENGINE SPEED SIGNAL”, AT-121. A/T fluid temperature sensor is disconnected or TCM power source circuit is damaged. ⇒ Go to “DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)”, AT-193.

ST RS BT HA SC EL

AT-53

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d) O/D OFF indicator lamp: 11th judgement flicker is longer than others.

10th judgement flicker is longer than others.

SAT455F

Line pressure solenoid valve circuit is short-circuited or disconLAT435 nected. ⇒ Go to “DTC P0745 LINE PRESSURE SOLENOID VALVE”, ⇒ Go to “DTC TURBINE REVOLUTION SENSOR”, AT-164. AT-164. Lamp comes on.

Flickers as shown below.

SAT457F

Battery power is low. SAT367J Battery has been disconnected for a long time. PNP switch, overdrive control switch or throttle position switch Battery is connected conversely. circuit is disconnected or TCM is damaged. (When reconnecting TCM connectors. — This is not a problem.) ⇒ Go to “21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks), AT-252. t1 = 2.5 seconds

t2 = 2.0 seconds

t3 = 1.0 second

t4 = 1.0 second

AT-54

TROUBLE DIAGNOSIS — INTRODUCTION Introduction

AAT473A

SAT632I

NGAT0019

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 A/T 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 A/T 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 A/T system. The A/T system must be in good operating condition and be free of valve seizure, solenoid valve malfunction, etc. It is much more difficult to diagnose a 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 “Work Flow”, AT-59. 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 should be used. Refer to “Diagnostic Worksheet”, AT-57. 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.

GI MA EM LC EC FE CL MT

TF PD AX

SEF234G

SU BR ST RS BT HA SC EL

AT-55

IDX

TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d)

DIAGNOSTIC WORKSHEET Information From Customer KEY POINTS WHAT ..... Vehicle & A/T 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

쏔 Continuous 쏔 Intermittent (

Symptoms

쏔 Vehicle does not move. 쏔 No up-shift

(쏔 Any position

(쏔 1st , 2nd

쏔 No down-shift

times a day) 쏔 Particular position)

쏔 2nd , 3rd

(쏔 O/D , 3rd

쏔 3rd , O/D)

쏔 3rd , 2nd

쏔 2nd , 1st)

쏔 Lockup malfunction 쏔 Shift point too high or too low. 쏔 Shift shock or slip

(쏔 N , D

쏔 Lockup 쏔 Any drive position)

쏔 Noise or vibration 쏔 No kickdown 쏔 No pattern select 쏔 Others ( O/D OFF indicator lamp

Malfunction indicator lamp (MIL)

)

Blinks for about 8 seconds. 쏔 Continuously lit

쏔 Not lit

쏔 Continuously lit

쏔 Not lit

AT-56

=NGAT0019S01 NGAT0019S0101

TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d)

Diagnostic Worksheet

=NGAT0019S0102

1.

쏔 Read the Fail-safe Remarks and listen to customer complaints.

AT-8

2.

쏔 CHECK A/T FLUID

AT-62

쏔 Leakage (Follow specified procedure) 쏔 Fluid condition 쏔 Fluid level 3.

GI MA

Perform STALL TEST and LINE PRESSURE TEST.

AT-62, AT-65

EM

쏔 Stall test — Mark possible damaged components/others. 쏔 쏔 쏔 쏔 쏔

LC

쏔 Low & reverse brake 쏔 Low one-way clutch 쏔 Engine 쏔 Line pressure is low 쏔 Clutches and brakes except high clutch and brake band are OK

Torque converter one-way clutch Reverse clutch Forward clutch Overrun clutch Forward one-way clutch

EC FE

쏔 Line pressure test — Suspected parts: 4.

쏔 Perform all ROAD TEST and mark required procedures.

AT-66

4-1. Check before engine is started.

AT-67

쏔 SELF-DIAGNOSTIC PROCEDURE - Mark detected items.

MT

쏔 PNP switch, AT-104. 쏔 A/T fluid temperature sensor, AT-110. 쏔 Vehicle speed sensor·A/T (Revolution sensor), AT-116. 쏔 Engine speed signal, AT-121. 쏔 Torque converter clutch solenoid valve, AT-152. 쏔 Line pressure solenoid valve, AT-164. 쏔 Shift solenoid valve A, AT-169. 쏔 Shift solenoid valve B, AT-174. 쏔 Throttle position sensor, AT-179. 쏔 Overrun clutch solenoid valve, AT-188. 쏔 A/T fluid temperature sensor and TCM power source, AT-193. 쏔 PNP, overdrive control and throttle position switches, AT-252. 쏔 Vehicle speed sensor·MTR, AT-199. 쏔 Control unit (RAM), control unit (ROM), AT-208. 쏔 Control unit (EEP ROM), AT-210. 쏔 Battery 쏔 Others 4-2. Check at idle 쏔 쏔 쏔 쏔 쏔 쏔 쏔

1. 2. 3. 4. 5. 6. 7.

TF PD AX SU AT-69

O/D OFF Indicator Lamp Does Not Come On, AT-215. Engine Cannot Be Started In P And N Position, AT-217. In P Position, Vehicle Moves Forward Or Backward When Pushed, AT-218. In N Position, Vehicle Moves, AT-219. Large Shock. N , R Position, AT-221. Vehicle Does Not Creep Backward In R Position, AT-223. Vehicle Does Not Creep Forward In D, 2 Or 1 Position, AT-226.

CL

BR ST RS BT HA SC EL

AT-57

IDX

TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d) 4.

4-3. Cruise test

AT-70 AT-74

Part-1 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔

8. Vehicle Cannot Be Started From D1, AT-229. 9. A/T Does Not Shift: D1, D2 Or Does Not Kickdown: D4, D2, AT-232. 10. A/T Does Not Shift: D2,D3, AT-235. 11. A/T Does Not Shift: D3,D4, AT-238. 12. A/T Does Not Perform Lock-up, AT-241. 13. A/T Does Not Hold Lock-up Condition, AT-243. 14. Lock-up Is Not Released, AT-245. 15. Engine Speed Does Not Return To Idle (Light Braking D4, D3), AT-246.

Part-2 쏔 쏔 쏔 쏔

AT-78

9. A/T Does Not Shift: D1, D2 Or Does Not Kickdown: D4, D2, AT-232. 10. A/T Does Not Shift: D2,D3, AT-235. 11. A/T Does Not Shift: D3,D4, AT-238. 16. Vehicle Does Not Start From D1, AT-248.

Part-3 쏔 쏔 쏔 쏔 쏔 쏔 쏔

AT-80

17. A/T Does Not Shift: D4,D3 When Overdrive Control Switch ON , OFF, AT-249 15. Engine Speed Does Not Return To Idle (Engine Brake In D3), AT-246. 18. A/T Does Not Shift: D3,22, When Selector Lever D , 2 Position, AT-250. 15. Engine Speed Does Not Return To Idle (Engine Brake In 22), AT-246. 19. A/T Does Not Shift: 22,11, When Selector Lever 2 , 1 Position, AT-251. 20. Vehicle Does Not Decelerate By Engine Brake, AT-252. SELF-DIAGNOSTIC PROCEDURE — Mark detected items. 쏔 PNP switch, AT-104. 쏔 A/T fluid temperature sensor, AT-110. 쏔 Vehicle speed sensor·A/T (Revolution sensor), AT-116. 쏔 Engine speed signal, AT-121. 쏔 Torque converter clutch solenoid valve, AT-152. 쏔 Line pressure solenoid valve, AT-164. 쏔 Shift solenoid valve A, AT-169. 쏔 Shift solenoid valve B, AT-174. 쏔 Throttle position sensor, AT-179. 쏔 Overrun clutch solenoid valve, AT-188. 쏔 A/T fluid temperature sensor and TCM power source, AT-193. 쏔 PNP, overdrive control and throttle position switches, AT-252. 쏔 Vehicle speed sensor·MTR, AT-199. 쏔 Turbine revolution sensor (VG33ER only), AT-203. 쏔 Control unit (RAM), control unit (ROM), AT-208. 쏔 Control unit (EEP ROM), AT-210. 쏔 Battery 쏔 Others

5.

쏔 For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts.

AT-38

6.

쏔 Perform all ROAD TEST and re-mark required procedures.

AT-66

7.

쏔 Perform DTC CONFIRMATION PROCEDURE for following MIL indicating items and check out NG items. Refer to EC-661 (VG33E only) or EC-1233 (VG33ER only), “Emission-related Diagnostic Information”.

EC-661 (VG33E only) or EC-1233 (VG33ER only)

쏔 쏔 쏔 쏔 쏔

DTC DTC DTC DTC DTC

(P0731, (P0732, (P0733, (P0734, (P0744,

1103) A/T 1st gear function, AT-125. 1104) A/T 2nd gear function, AT-131. 1105) A/T 3rd gear function, AT-137. 1106) A/T 4th gear function, AT-143. 1107) A/T TCC S/V function (lock-up), AT-157.

8.

쏔 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-84

9.

쏔 Erase DTC from TCM and ECM memories.

AT-35

AT-58

TROUBLE DIAGNOSIS — INTRODUCTION Work Flow

Work Flow HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR

NGAT0020 NGAT0020S01

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. Refer to “INFORMATION FROM CUSTOMER”, AT-56 and “DIAGNOSTIC WORKSHEET, AT-57 to perform the best troubleshooting possible.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-59

IDX

TROUBLE DIAGNOSIS — INTRODUCTION Work Flow (Cont’d)

WORK FLOW CHART

NGAT0020S02

WAT372

*1: *2: *3: *4: *5: *6:

AT-56 AT-57 AT-8 AT-62 AT-62, 65 AT-66

*7: *8: *9: *10: *11: *12:

*13: *14: *15: *16: *17: *18:

AT-37 AT-33 AT-50 AT-104 AT-210 AT-212

AT-60

AT-252 AT-84 AT-35 AT-105 AT-210 EC-661 (VG33E), EC-1233

TROUBLE DIAGNOSIS — INTRODUCTION Work Flow (Cont’d) (VG33ER)

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-61

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION A/T Fluid Check

A/T Fluid Check

NGAT0021

FLUID LEAKAGE CHECK 1. 2. 3. 4.

NGAT0021S01

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. Check for fresh leakage.

FLUID CONDITION CHECK

NGAT0021S02

Fluid color

SAT638A

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 tacky

Oxidation — Over or under filling, — Overheating

FLUID LEVEL CHECK

NGAT0021S03

Refer to MA-39, “Checking A/T Fluid”.

Stall Test STALL TEST PROCEDURE 1. 2.

NGAT0022 NGAT0022S01

Check A/T fluid and engine oil levels. If necessary, add fluid and oil. Drive vehicle for approx. 10 minutes or until engine oil and ATF reach operating temperature. ATF operating temperature: 50 - 80°C (122 - 176°F)

SAT647B

3. 4. 쐌

Set parking brake and block wheels. Install a tachometer where it can be seen by driver during test. It is good practice to put a mark on point of specified engine rpm on indicator.

SAT513G

AT-62

TROUBLE DIAGNOSIS — BASIC INSPECTION Stall Test (Cont’d)

5. 6. 7. 쐌

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: 2,440 - 2,640 rpm

GI MA EM LC

SAT514G

8. 9. 쐌 10.

Move selector lever to N position. Cool off ATF. Run engine at idle for at least one minute. Repeat steps 5 through 9 with selector lever in 2, 1 and R positions.

EC FE CL MT

SAT771B

JUDGEMENT OF STALL TEST

NGAT0022S02

The test result and possible damaged components relating to each result are shown in the illustration. In order to pinpoint the possible damaged components, follow the “Work Flow” shown in AT-59. NOTE: Stall revolution is too high in D or 2 position: 쐌 Slippage occurs in 1st gear but not in 2nd and 3rd gears. ..... Low one-way clutch slippage 쐌 Slippage occurs at the following gears: 1st through 3rd gears in D position and engine brake functions. 1st and 2nd gears in 2 position and engine brake functions with accelerator pedal released (fully closed throttle). ..... Forward clutch or forward one-way clutch slippage Stall revolution is too high in R position: 쐌 Engine brake does not function in 1 position. ..... Low & reverse brake slippage 쐌 Engine brake functions in 1 position. ..... Reverse clutch slippage Stall revolution within specifications: 쐌 Vehicle does not achieve speed of more than 80 km/h (50 MPH). ..... One-way clutch seizure in torque converter housing CAUTION: Be careful since automatic fluid temperature increases abnormally. 쐌 Slippage occurs in 3rd and 4th gears in D position. ..... High clutch slippage 쐌 Slippage occurs in 2nd and 4th gear in D position. ..... Brake band slippage Stall revolution less than specifications: 쐌 Poor acceleration during starts. ..... One-way clutch seizure in torque converter

AT-63

TF PD AX SU BR ST RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION Stall Test (Cont’d)

SAT392H

AT-64

TROUBLE DIAGNOSIS — BASIC INSPECTION Line Pressure Test

Line Pressure Test LINE PRESSURE TEST PORTS 쐌 쐌

NGAT0023 NGAT0023S03

Location of line pressure test ports. Always replace line pressure plugs as they are self-sealing bolts.

GI MA EM LC

SAT209GA

LINE PRESSURE TEST PROCEDURE 1. 2.

NGAT0023S01

Check A/T fluid and engine oil levels. If necessary, add fluid and oil. Drive vehicle for approx. 10 minutes or until engine oil and ATF reach operating temperature. ATF operating temperature: 50 - 80°C (122 - 176°F)

EC FE CL MT

SAT647B

3.

Install pressure gauge to corresponding line pressure port.

TF PD AX SAT518GB

SU BR ST RS SAT519GB

4. 쐌

Set parking brake and block wheels. Continue to depress brake pedal fully while line pressure test is being performed at stall speed.

BT HA SC EL

SAT513G

AT-65

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION Line Pressure Test (Cont’d)

5. 쐌

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 “Line Pressure”, AT-349.

SAT493G

JUDGEMENT OF LINE PRESSURE TEST Judgement

NGAT0023S02

Suspected parts

Line pressure is low in all positions.

쐌 쐌 쐌 쐌 쐌 쐌

Line pressure is low in particular position.

쐌 Fluid pressure leakage between manual valve and particular clutch 쐌 For example, line pressure is: — Low in R and 1 positions, but — Normal in D and 2 positions. Then, fluid leakage exists at or around low and reverse brake circuit. Refer to “CLUTCH AND BAND CHART”, AT-17.

Line pressure is high.

쐌 쐌 쐌 쐌 쐌 쐌 쐌

Maladjustment of throttle position sensor Fluid temperature sensor damaged Line pressure solenoid valve sticking Short circuit of line pressure solenoid valve circuit Pressure modifier valve sticking Pressure regulator valve or plug sticking Open in dropping resistor circuit

Line pressure is low.

쐌 쐌 쐌 쐌 쐌 쐌

Maladjustment of throttle position sensor Line pressure solenoid valve sticking Short circuit of line pressure solenoid valve circuit Pressure regulator valve or plug sticking Pressure modifier valve sticking Pilot valve sticking

At idle

At stall speed

Oil pump wear Control piston damage Pressure regulator valve or plug sticking Spring for pressure regulator valve damaged Fluid pressure leakage between oil strainer and pressure regulator valve Clogged strainer

Road Test DESCRIPTION 쐌 쐌 a) b) c)

NGAT0024 NGAT0024S01

The purpose of this test is to determine overall performance of the A/T and analyze causes of problems. The road test consists of the following three parts: Check before engine is started Check at idle Cruise test

SAT786A

AT-66

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

쐌 쐌

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 DIAGNOSES FOR SYMPTOMS”, AT-33 to AT-50 and AT-212 to AT-252.

GI MA EM LC

SAT496G

1. CHECK BEFORE ENGINE IS STARTED 1

NGAT0024S02

EC

CHECK O/D OFF INDICATOR LAMP

1. Park vehicle on flat surface. 2. Move selector lever to P position. 3. Turn ignition switch to OFF position. Wait at least 5 seconds.

FE CL MT

TF SAT967I

4. Turn ignition switch to ON position. (Do not start engine.) 5. Does O/D OFF indicator lamp come on for about 2 seconds?

PD AX SU BR

WAT496

Yes or No Yes

䊳

GO TO 2.

No

䊳

Go to “1. O/D OFF Indicator Lamp Does Not Come On”, AT-215.

ST RS BT HA SC EL

AT-67

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

2

CHECK O/D OFF INDICATOR LAMP

Does O/D OFF indicator lamp flicker for about 8 seconds?

WAT496

Yes or No Yes

䊳

Perform self-diagnosis. Refer to “TCM SELF-DIAGNOSIS PROCEDURE (NO TOOLS)”, AT-47.

No

䊳

GO TO 3.

3

CHECK NG ITEM

1. Turn ignition switch to OFF position. 2. Perform self-diagnosis and note NG items. Refer to “TCM SELF-DIAGNOSIS PROCEDURE (NO TOOLS)”, AT-47. 䊳

Go to “2. CHECK AT IDLE”, AT-69.

AT-68

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

2. CHECK AT IDLE 1 1. 2. 3. 4. 5.

=NGAT0024S03

CHECK ENGINE START

GI

Park vehicle on flat surface. Turn ignition switch to OFF position. Move selector lever to P or N position. Turn ignition switch to start position. Is engine started?

MA EM

Yes or No Yes

䊳

GO TO 2.

No

䊳

Go to “2. Engine Cannot Be Started In P and N Position”, AT-217.

2 1. 2. 3. 4.

LC EC

CHECK ENGINE START Turn ignition switch to OFF position. Move selector lever to D, 1, 2 or R position. Turn ignition switch to start position. Is engine started?

FE CL

Yes or No Yes

䊳

Go to “2. Engine Cannot Be Started In P and N Position”, AT-217.

No

䊳

GO TO 3.

3 1. 2. 3. 4. 5.

MT

CHECK VEHICLE MOVE Turn ignition switch to OFF position. Move selector lever to P position. Release parking brake. Push vehicle forward or backward. Does vehicle move when it is pushed forward or backward?

TF PD AX SU BR SAT796A

Yes or No Yes

䊳

Go to “3. In P Position, Vehicle Moves Forward Or Backward When Pushed”, AT-218.

No

䊳

GO TO 4.

4 1. 2. 3. 4. 5.

ST RS

CHECK VEHICLE MOVE

BT

Apply parking brake. Move selector lever to N position. Turn ignition switch to START position and start engine. Release parking brake. Does vehicle move forward or backward? Yes or No

Yes

䊳

Go to “4. In N Position, Vehicle Moves”, AT-219.

No

䊳

GO TO 5.

HA SC EL

AT-69

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

5

CHECK SHIFT SHOCK

1. Apply foot brake. 2. Move selector lever to R position. 3. Is there large shock when changing from N to R position?

SAT082J

Yes or No Yes

䊳

Go to “5. Large Shock. N , R Position”, AT-221.

No

䊳

GO TO 6.

6

CHECK VEHICLE MOVE

1. Release foot brake for several seconds. 2. Does vehicle creep backward when foot brake is released? Yes or No Yes

䊳

GO TO 7.

No

䊳

Go to “6. Vehicle Does Not Creep Backward In R Position”, AT-223.

7

CHECK VEHICLE MOVE

1. Move selector lever to D, 2 and 1 position and check if vehicle creeps forward. 2. Does vehicle creep forward in all three positions? Yes or No Yes

䊳

Go to “3. Cruise test”, AT-70.

No

䊳

Go to “7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position”, AT-226.

3. CRUISE TEST 쐌

With CONSULT-II 쐌 쐌

NGAT0024S04

Check all items listed in Parts 1 through 3. NGAT0024S0401

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-70

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

CONSULT-II Setting Procedure 1. 2.

NGAT0024S0402

Turn ignition switch OFF. Connect “CONSULT-II” to Data Link Connector. Data link connector is located in the lower instrument panel on driver side.

GI MA EM LC

LEC104A

3. 4.

Turn ignition switch ON. Touch “START”.

EC FE CL MT

SAT586J

5.

Touch “A/T”.

TF PD AX SAT014K

6.

Touch “DATA MONITOR”.

SU BR ST RS

SAT971J

7. 8.

Touch “MAIN SIGNALS” or “TCM INPUT SIGNALS”. See “Numerical Display”, “Barchart Display” or “Line Graph Display”.

BT HA SC EL

SAT175K

AT-71

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

9.

Touch “SETTING” to set recording condition (“AUTO TRIG” or “MANU TRIG”) and touch “BACK”. 10. Touch “START”.

SAT973J

11. When performing cruise test, touch “RECORD”.

SAT134K

12. After finishing cruise test part 1, touch “STOP”.

SAT135K

13. Touch “STORE” and touch “BACK”.

SAT987J

SAT974J

AT-72

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

14. 15. 16. 17.

Touch “DISPLAY”. Touch “PRINT”. Check the monitor data printed out.. Continue cruise test part 2 and 3.

GI MA EM LC

SAT975J

Without CONSULT-II 쐌

NGAT0024S0403

Throttle position sensor can be checked by measuring voltage across terminals 41 and 42 of TCM.

EC FE CL MT

AAT474A

TF PD AX SU BR ST RS BT HA SC EL

AT-73

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

Cruise Test — Part 1 1

=NGAT0024S0404

CHECK STARTING GEAR (D1) POSITION

1. Drive vehicle for approx. 10 minutes to warm engine oil and ATF up to operating temperature. ATF operating temperature: 50 - 80°C (122 - 176°F) 2. Park vehicle on flat surface. 3. Set overdrive control switch to ON position. 4. Move selector lever to P position.

SAT001J

5. Start engine. 6. Move selector lever to D position.

SAT952I

7. Accelerate vehicle by constantly depressing accelerator pedal halfway.

SAT953I

8. Does vehicle start from D1? Read gear position. Yes or No Yes

䊳

GO TO 2.

No

䊳

Go to “8. Vehicle Cannot Be Started From D1”, AT-229.

AT-74

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

2

CHECK SHIFT UP (D1 TO D2)

Does A/T shift from D1 to D2 at the specified speed? Read gear position, throttle opening and vehicle speed. Specified speed when shifting from D1 to D2: Refer to Shift schedule, AT-348.

GI MA EM LC EC SAT954I

Yes or No Yes

䊳

GO TO 3.

No

䊳

Go to “9. A/T Does Not Shift: D1 , D2 or Does Not Kickdown: D4 , D2”, AT-232.

3

FE CL

CHECK SHIFT UP (D2 TO D3)

MT

Does A/T shift from D2 to D3 at the specified speed? Read gear position, throttle opening and vehicle speed. Specified speed when shifting from D2 to D3: Refer to Shift schedule, AT-348.

TF PD AX SAT955I

Yes or No Yes

䊳

GO TO 4.

No

䊳

Go to “10. A/T Does Not Shift: D2 , D3”, AT-235.

SU BR ST RS BT HA SC EL

AT-75

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

4

CHECK SHIFT UP (D3 TO D4)

Does A/T shift from D3 to D4 at the specified speed? Read gear position, throttle opening and vehicle speed. Specified speed when shifting from D3 to D4: Refer to Shift schedule, AT-348.

SAT956I

Yes or No Yes

䊳

GO TO 5.

No

䊳

Go to “11. A/T Does Not Shift: D3 , D4”, AT-238.

5

CHECK LOCK-UP (D4 TO D4 L/U)

Does A/T perform lock-up at the specified speed? Read vehicle speed, throttle position when lock-up duty becomes 94%. Specified speed when lock-up occurs: Refer to Shift schedule, AT-348.

SAT957I

Yes or No Yes

䊳

GO TO 6.

No

䊳

Go to “12. A/T Does Not Perform Lock-up”, AT-241.

6

CHECK HOLD LOCK-UP

Does A/T hold lock-up condition for more than 30 seconds? Yes or No Yes

䊳

GO TO 7.

No

䊳

Go to “13. A/T Does Not Hold Lock-up Condition”, AT-243.

AT-76

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

7

CHECK LOCK-UP OFF (D4 L/U TO D4)

1. Release accelerator pedal. 2. Is lock-up released when accelerator pedal is released?

GI MA EM LC SAT958I

EC

Yes or No Yes

䊳

GO TO 8.

No

䊳

Go to “14. Lock-up Is Not Released”, AT-245.

8

FE CL

CHECK SHIFT DOWN (D4 TO D3)

1. Decelerate vehicle by applying foot brake lightly. 2. Does engine speed return to idle smoothly when A/T is shifted from D4 to D3? Read gear position and engine speed.

MT

TF PD SAT959I

Yes or No Yes

䊳

1. Stop vehicle. 2. Go to “Cruise test — Part 2”, AT-78.

No

䊳

Go to “15. Engine Speed Does Not Return To Idle (Light Braking D4, D3)”, AT-246.

AX SU BR ST RS BT HA SC EL

AT-77

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

Cruise Test — Part 2 1

CHECK STARTING GEAR (D1) POSITION

1. 2. 3. 4.

Confirm overdrive control switch is in ON position. Confirm selector lever is in D position. Accelerate vehicle by half throttle again. Does vehicle start from D1? Read gear position.

=NGAT0024S0405

SAT495G

Yes or No Yes

䊳

GO TO 2.

No

䊳

Go to “16. Vehicle Does Not Start From D1”, AT-248.

2

CHECK SHIFT UP AND SHIFT DOWN (D3 TO D4 TO D2)

1. Accelerate vehicle to 80 km/h (50 MPH) as shown in illustration. 2. Release accelerator pedal and then quickly depress it fully. 3. Does A/T shift from D4 to D2 as soon as accelerator pedal is depressed fully? Read gear position and throttle position.

SAT404H

Yes or No Yes

䊳

GO TO 3.

No

䊳

Go to “9. A/T Does Not Shift: D3 , D4 Or Does Not Kickdown: D4 , D2”, AT-232.

AT-78

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

3

CHECK SHIFT UP (D2 TO D3)

Does A/T shift from D2 to D3 at the specified speed? Read gear position, throttle position and vehicle speed. Specified speed when shifting from D2 to D3: Refer to Shift schedule, AT-348.

GI MA EM LC EC SAT960I

Yes or No Yes

䊳

GO TO 4.

No

䊳

Go to “10. A/T Does Not Shift: D2 , D3”, AT-235.

4

FE CL

CHECK SHIFT UP (D3 TO D4) AND ENGINE BRAKE

MT

Release accelerator pedal after shifting from D2 to D3. Does A/T shift from D3 to D4 and does vehicle decelerate by engine brake? Read gear position, throttle position and vehicle speed.

TF PD AX SAT405H

SU

Yes or No Yes

䊳

1. Stop vehicle. 2. Go to “Cruise test — Part 3”, AT-80.

No

䊳

Go to “11. A/T Does Not Shift: D3 , D4”, AT-238.

BR ST RS BT HA SC EL

AT-79

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

Cruise Test — Part 3 1

=NGAT0024S0406

VEHICLE SPEED D4 POSITION

1. Confirm overdrive control switch is in ON position. 2. Confirm selector lever is in D position. 3. Accelerate vehicle using half-throttle to D4.

SAT812A

䊳

2

GO TO 2.

CHECK SHIFT DOWN (D4 TO D3)

1. Release accelerator pedal. 2. Set overdrive control switch to OFF position while driving in D4. 3. Does A/T shift from D4 to D3 (O/D OFF)? Read gear position and vehicle speed.

SAT999I

Yes or No Yes

䊳

GO TO 3.

No

䊳

Go to “17. A/T Does Not Shift: D4 , D3, When Overdrive Control Switch ON , OFF, AT-249.

AT-80

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

3

CHECK ENGINE BRAKE

Does vehicle decelerate by engine brake?

GI MA EM LC SAT999I

EC

Yes or No

FE

Yes

䊳

GO TO 4.

No

䊳

Go to “15. Engine Speed Does Not Return To Idle (Light Braking D4 , D3)”, AT-246.

CL 4

CHECK SHIFT DOWN (D3 TO D2)

1. Move selector lever from D to 2 position while driving in D3 (O/D OFF). 2. Does A/T shift from D3 (O/D OFF) to 22? Read gear position.

MT

TF PD AX SAT791GA

Yes or No Yes

䊳

GO TO 5.

No

䊳

Go to “18. A/T Does Not Shift: D3 , D2, When Selector Lever “D” , “2” Position”, AT-250.

SU BR ST RS BT HA SC EL

AT-81

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

5

CHECK ENGINE BRAKE

Does vehicle decelerate by engine brake?

SAT791GA

Yes or No Yes

䊳

GO TO 6.

No

䊳

Go to “15. Engine Speed Does Not Return To Idle (Light Braking D4 , D3)”, AT-246.

6

CHECK SHIFT DOWN (22 TO 11)

1. Move selector lever from 2 to 1 position while driving in 22. 2. Does A/T shift from 22 to 11 position?

SAT778B

Yes or No Yes

䊳

GO TO 7.

No

䊳

Go to “19. A/T Does Not Shift: 22 , 11, When Selector lever 2 , 1 Position”, AT-251.

AT-82

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

7

CHECK ENGINE BRAKE

Does vehicle decelerate by engine brake?

GI MA EM LC SAT778B

EC

Yes or No Yes

䊳

1. Stop vehicle. 2. Perform self-diagnosis. Refer to TCM Self-Diagnosis Procedure (No Tools), AT-47.

No

䊳

Go to “20. Vehicle Does Not Decelerate By Engine Brake”, AT-252.

FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-83

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart

Symptom Chart

NGAT0026

Numbers are arranged in order of inspection. Perform inspections starting with number one and work up. Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only 1. Throttle position sensor (Adjustment)

EC-701

2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR

Torque converter is not locked up.

ON vehicle

OFF vehicle

No Lock-up Engagement/ TCC Inoperative

AT-270

4. Engine speed signal

AT-121

5. A/T fluid temperature sensor

AT-110

6. Line pressure test

AT-65

7. Torque converter clutch solenoid valve

AT-152

8. Control valve assembly

AT-267

9. Torque converter

AT-278

1. Fluid level

AT-62 EC-701

EC-1273

3. Line pressure test

AT-65

4. Torque converter clutch solenoid valve

AT-152

5. Line pressure solenoid valve

AT-164

6. Control valve assembly

AT-267

7. Torque converter

AT-278

1. Throttle position sensor (Adjustment) Lock-up point is extremely ON vehicle high or low. AT-241

Shift Shock

AT-116, 199

ON vehicle

OFF vehicle

Sharp shock in shifting from N to D position.

EC-1273

3. Park/neutral position (PNP) switch adjustment

2. Throttle position sensor (Adjustment) Torque converter clutch piston slip.

VG33ER only

EC-701

EC-1273

2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR

AT-116, 199

3. Torque converter clutch solenoid valve

AT-152

4. Control valve assembly

AT-267

1. Engine idling rpm

EC-648

EC-1220

2. Throttle position sensor (Adjustment)

EC-701

EC-1273

3. Line pressure test

AT-65

4. A/T fluid temperature sensor

AT-110

5. Engine speed signal

AT-121

6. Line pressure solenoid valve

AT-164

7. Control valve assembly

AT-267

8. Accumulator N-D

AT-267

ON vehicle

9. Turbine revolution sensor

—

AT-203

OFF vehicle 10. Forward clutch

AT-84

AT-312

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only 1. Throttle position sensor (Adjustment)

Too sharp a shock in change from D1 to D2.

ON vehicle

OFF vehicle

ON vehicle

EC-701

GI

EC-1273

2. Line pressure test

AT-65

3. Accumulator servo release

AT-267

4. Control valve assembly

AT-267

5. A/T fluid temperature sensor

AT-110

6. Brake band

AT-341

1. Throttle position sensor (Adjustment) Too sharp a shock in change from D2 to D3.

VG33ER only

EC-701

MA EM LC EC-1273

2. Line pressure test

AT-65

3. Control valve assembly

AT-267

4. High clutch

AT-310

5. Brake band

AT-341

EC FE

OFF vehicle 1. Throttle position sensor (Adjustment)

Shift Shock Too sharp a shock in change from D3 to D4.

ON vehicle

EC-701

CL EC-1273

2. Line pressure test

AT-65

3. Control valve assembly

AT-267

4. Brake band

AT-341

5. Overrun clutch

AT-312

MT

OFF vehicle Gear change shock felt during deceleration by ON vehicle releasing accelerator pedal.

1. Throttle position sensor (Adjustment)

Large shock changing from 12 to 11 in 1 position.

EC-701

EC-1273

2. Line pressure test

AT-65

3. Overrun clutch solenoid valve

AT-188

4. Control valve assembly

AT-267

ON vehicle

1. Control valve assembly

AT-267

ON vehicle

2. Low & reverse brake

AT-316

TF PD AX SU BR ST RS BT HA SC EL

AT-85

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only

Too high a gear change point from D1 to D2, from ON vehicle D2 to D3, from D3 to D4. AT-232, 235, 238 Gear change directly from ON vehicle D1 to D3 occurs. OFF vehicle Improper Shift Timing

Too high a change point from D4 to D3, from D3 to D2, from D2 to D1.

2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR

EC-701

EC-1273

AT-116, 199

3. Shift solenoid valve A

AT-169

4. Shift solenoid valve B

AT-174

1. Fluid level

AT-62

2. Accumulator servo release

AT-267

3. Brake band

AT-341

1. Throttle position sensor (Adjustment)

EC-701

EC-1273

ON vehicle

Kickdown does not operate when ON vehicle depressing pedal in D4 within kickdown vehicle speed.

Improper Shift Timing

1. Throttle position sensor (Adjustment)

VG33ER only

Kickdown operates or engine overruns when ON vehicle depressing pedal in D4 beyond kickdown vehicle speed limit. Gear change from 22 to 23 ON vehicle in 2 position. Gear change from 11 to 12 ON vehicle in 1 position.

2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR 1. Throttle position sensor (Adjustment) 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR

AT-116, 199

EC-701

EC-1273

AT-116, 199

3. Shift solenoid valve A

AT-169

4. Shift solenoid valve B

AT-174

1. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR 2. Throttle position sensor (Adjustment)

AT-116, 199 EC-701

EC-1273

3. Shift solenoid valve A

AT-169

4. Shift solenoid valve B

AT-174

1. Park/neutral position (PNP) switch adjustment

AT-270

1. Park/neutral position (PNP) switch adjustment

AT-270

2. Manual control linkage adjustment

AT-270

AT-86

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only 1. Fluid level EC-701

EC-1273

3. Overrun clutch solenoid valve

AT-188

4. Shift solenoid valve A

AT-169

5. Line pressure solenoid valve

AT-164

6. Control valve assembly

AT-267

7. Low & reverse brake

AT-316

8. Overrun clutch

AT-312

1. Fluid level

AT-62

ON vehicle

2. Throttle position sensor (Adjustment)

No Down Shift

ON vehicle

EC-701

LC EC

EC-1273

3. Shift solenoid valve A

AT-169

4. Shift solenoid valve B

AT-174

5. Control valve assembly

AT-267

6. High clutch

AT-310

7. Brake band

AT-341

1. Fluid level

AT-62

MA EM

OFF vehicle

Failure to change gear from D3 to D2 or from D4 to D2.

GI

AT-62

2. Throttle position sensor (Adjustment) Failure to change gear from D4 to D3.

VG33ER only

FE CL MT

OFF vehicle

2. Throttle position sensor (Adjustment) Failure to change gear from D2 to D1 or from D3 to D1.

ON vehicle

OFF vehicle

EC-701

EC-1273

3. Shift solenoid valve A

AT-169

4. Shift solenoid valve B

AT-174

5. Control valve assembly

AT-267

6. Low one-way clutch

AT-320

7. High clutch

AT-310

8. Brake band

AT-341

TF PD AX SU BR ST RS BT HA SC EL

AT-87

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only 1. Park/neutral position (PNP) switch adjustment 2. Throttle position sensor (Adjustment)

Failure to change from D3 to 22 when changing lever into 2 position. AT-246

ON vehicle

VG33ER only

AT-270 EC-701

EC-1273

3. Overrun clutch solenoid valve

AT-188

4. Shift solenoid valve B

AT-174

5. Shift solenoid valve A

AT-169

6. Control valve assembly

AT-267

7. Manual control linkage adjustment

AT-270

8. Brake band

AT-341

9. Overrun clutch

AT-312

1. Park/neutral position (PNP) switch adjustment

AT-270

OFF vehicle

No Down Shift

Does not change from 12 to 11 in 1 position.

ON vehicle

2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR

AT-116, 199

3. Shift solenoid valve A

AT-169

4. Control valve assembly

AT-267

5. Overrun clutch solenoid valve

AT-188

6. Overrun clutch

AT-312

7. Low & reverse brake

AT-316

1. Park/neutral position (PNP) switch adjustment

AT-270

2. Manual control linkage adjustment

AT-270

3. Shift solenoid valve A

AT-169

4. Control valve assembly

AT-267

OFF vehicle

Failure to change gear from D1 to D2.

ON vehicle

5. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR OFF vehicle No Up Shift

Failure to change gear from D2 to D3.

ON vehicle

AT-116, 199

6. Brake band

AT-341

1. Park/neutral position (PNP) switch adjustment

AT-270

2. Manual control linkage adjustment

AT-270

3. Shift solenoid valve B

AT-174

4. Control valve assembly

AT-267

5. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR

AT-116, 199

6. High clutch

AT-310

7. Brake band

AT-341

OFF vehicle

AT-88

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only

Failure to change gear from D3 to D4.

ON vehicle

1. Park/neutral position (PNP) switch adjustment

AT-270

2. Manual control linkage adjustment

AT-270

3. Shift solenoid valve A

AT-169

4. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR

OFF vehicle

6. Brake band

AT-341

A/T does not shift to D4 when driving with overdrive control switch ON.

3. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR ON vehicle

EM

AT-116, 199 AT-110

2. Park/neutral position (PNP) switch adjustment

GI MA

5. A/T fluid temperature sensor

1. Throttle position sensor (Adjustment) No Up Shift

VG33ER only

EC-701

LC EC EC-1273

AT-270

FE

AT-116, 199

CL

4. Shift solenoid valve A

AT-169

5. Overrun clutch solenoid valve

AT-188

6. Control valve assembly

AT-267

7. A/T fluid temperature sensor

AT-110

8. Line pressure solenoid valve

AT-164

9. Brake band

AT-341

10. Overrun clutch

AT-312

1. Manual control linkage adjustment

AT-270

2. Line pressure test

AT-65

3. Line pressure solenoid valve

AT-164

4. Control valve assembly

AT-267

5. Reverse clutch

AT-306

6. High clutch

AT-310

7. Forward clutch

AT-312

8. Overrun clutch

AT-312

9. Low & reverse brake

AT-316

1. Manual control linkage adjustment

AT-270

2. Low one-way clutch

AT-320

MT

TF

OFF vehicle

Vehicle will ON vehicle not run in R position (but runs in D, 2 and 1 positions). Clutch slips. Slips/Will Not Very poor acceleration. OFF vehicle Engage AT-223

Vehicle will not run in D ON vehicle and 2 positions (but runs in 1 and OFF vehicle R positions).

PD AX SU BR ST RS BT HA SC EL

AT-89

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only

ON vehicle Vehicle will not run in D, 1, 2 positions (but runs in R position). Clutch slips. Very poor acceleration. AT-226 OFF vehicle

1. Fluid level

AT-62

2. Line pressure test

AT-65

3. Line pressure solenoid valve

AT-164

4. Control valve assembly

AT-267

5. Accumulator N-D

AT-267

6. Reverse clutch

AT-306

7. High clutch

AT-310

8. Forward clutch

AT-312

9. Forward one-way clutch

AT-322

10. Low one-way clutch

AT-320

1. Fluid level

AT-62

2. Manual control linkage adjustment

AT-270

3. Throttle position sensor (Adjustment) ON vehicle Clutches or brakes slip somewhat in Slips/Will Not starting. Engage

OFF vehicle

ON vehicle No creep at all. AT-223, 226 OFF vehicle

Almost no shock or clutches slip- ON vehicle ping in change from D1 to D2. OFF vehicle

VG33ER only

EC-701

EC-1273

4. Line pressure test

AT-65

5. Line pressure solenoid valve

AT-164

6. Control valve assembly

AT-267

7. Accumulator N-D

AT-267

8. Forward clutch

AT-312

9. Reverse clutch

AT-306

10. Low & reverse brake

AT-316

11. Oil pump

AT-289

12. Torque converter

AT-278

1. Fluid level

AT-62

2. Line pressure test

AT-65

3. Control valve assembly

AT-267

4. Forward clutch

AT-312

5. Oil pump

AT-289

6. Torque converter

AT-278

1. Fluid level

AT-62

2. Throttle position sensor (Adjustment)

EC-701

EC-1273

3. Line pressure test

AT-65

4. Accumulator servo release

AT-267

5. Control valve assembly

AT-267

6. Brake band

AT-341

AT-90

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only 1. Fluid level

Almost no ON vehicle shock or slipping in change from D2 to D3 .

VG33ER only AT-62

2. Throttle position sensor (Adjustment)

EC-701

EC-1273

3. Line pressure test

AT-65

4. Control valve assembly

AT-267

5. High clutch

AT-310

6. Forward clutch

AT-312

1. Fluid level

AT-62

2. Throttle position sensor (Adjustment)

EC-701

LC EC-1273

3. Line pressure test

AT-65

4. Control valve assembly

AT-267

5. High clutch

AT-310

6. Brake band

AT-341

1. Fluid level

AT-62

Races extremely fast or slips in changing from D4 to D2 when depressing pedal.

2. Throttle position sensor (Adjustment) ON vehicle

EC-701

CL MT EC-1273

3. Line pressure test

AT-65

4. Line pressure solenoid valve

AT-164

5. Control valve assembly

AT-267

6. High clutch

AT-310

7. Forward clutch

AT-312

1. Fluid level

AT-62

TF

OFF vehicle

2. Throttle position sensor (Adjustment)

EC-701

PD EC-1273

3. Line pressure test

AT-65

4. Line pressure solenoid valve

AT-164

5. Shift solenoid valve A

AT-169

6. Control valve assembly

AT-267

7. Brake band

AT-341

8. Forward clutch

AT-312

1. Fluid level

AT-62

ON vehicle

Races extremely fast or slips in changing from D3 to D2 when depressing pedal.

EC-701

BR

OFF vehicle

3. Line pressure test

AT-65

4. Line pressure solenoid valve

AT-164

5. Control valve assembly

AT-267

6. A/T fluid temperature sensor

AT-110

7. Brake band

AT-341

8. Forward clutch

AT-312

9. High clutch

AT-310

AT-91

ST EC-1273

ON vehicle

AX SU

OFF vehicle

2. Throttle position sensor (Adjustment)

EC FE

OFF vehicle

Races extremely fast or slips in changing from D4 to D3 when depressing Slips/Will Not pedal. Engage

MA EM

OFF vehicle

Almost no ON vehicle shock or slipping in change from D3 to D4 .

GI

RS BT HA SC EL IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only 1. Fluid level

Races extremely fast or slips in changing from D4 or D3 to D1 when depressing pedal.

AT-62

2. Throttle position sensor (Adjustment) ON vehicle

OFF vehicle

Slips/Will Not Engage

VG33ER only

EC-701

EC-1273

3. Line pressure test

AT-65

4. Line pressure solenoid valve

AT-164

5. Control valve assembly

AT-267

6. Forward clutch

AT-312

7. Forward one-way clutch

AT-322

8. Low one-way clutch

AT-320

1. Fluid level

AT-62

2. Manual control linkage adjustment

AT-270

3. Line pressure test

AT-65

4. Line pressure solenoid valve

AT-164

5. Oil pump

AT-289

6. High clutch

AT-310

7. Brake band

AT-341

8. Low & reverse brake

AT-316

9. Torque converter

AT-278

10. Parking pawl components

AT-329

ON vehicle

Vehicle will not run in any position. OFF vehicle

AT-92

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only

Engine cannot be started in P and N positions. AT-217

1. Ignition switch and starter ON vehicle

Engine starts in positions other than P ON vehicle and N. AT-217

NOT USED

Transmission ON vehicle noise in P and N positions.

VG33ER only

EL-12, and SC-12

2. Manual control linkage adjustment

AT-270

3. Park/neutral position (PNP) switch adjustment

AT-270

1. Manual control linkage adjustment

AT-270

2. Park/neutral position (PNP) switch adjustment

AT-270

1. Fluid level

AT-62

2. Line pressure test

AT-65

3. Throttle position sensor (Adjustment) 4. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR

GI MA EM LC EC

EC-701

FE EC-1273

AT-116, 199

5. Engine speed signal

AT-121

6. Oil pump

AT-289

7. Torque converter

AT-278

1. Manual control linkage adjustment

AT-270

CL MT

OFF vehicle Vehicle moves when changing into ON vehicle P position or parking gear does not disengage when shifted out of OFF vehicle P position. AT-217

TF PD

2. Parking pawl components

AT-329

AX SU BR ST RS BT HA SC EL

AT-93

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only

Vehicle runs ON vehicle in N position. AT-219 OFF vehicle

ON vehicle Vehicle braked when shifting into R position.

VG33ER only

1. Manual control linkage adjustment

AT-270

2. Forward clutch

AT-312

3. Reverse clutch

AT-306

4. Overrun clutch

AT-312

1. Fluid level

AT-62

2. Manual control linkage adjustment

AT-270

3. Line pressure test

AT-65

4. Line pressure solenoid valve

AT-164

5. Control valve assembly

AT-267

6. High clutch

AT-310

7. Brake band

AT-325

8. Forward clutch

AT-312

9. Overrun clutch

AT-312

OFF vehicle

Excessive creep. NOT USED

ON vehicle

Engine stops when shifting ON vehicle lever into R, D, 2 and 1. OFF vehicle

Vehicle braked by gear change from D2 to D3. Vehicle braked by gear change from D3 to D4.

EC-648

EC-1220

1. Engine idling rpm

EC-648

EC-1220

2. Torque converter clutch solenoid valve

AT-152

3. Control valve assembly

AT-267

4. Torque converter

AT-278

1. Fluid level

AT-62

2. Reverse clutch

AT-306

3. Low & reverse brake

AT-316

4. High clutch

AT-310

5. Low one-way clutch

AT-320

ON vehicle

1. Fluid level

AT-62

OFF vehicle

2. Brake band

AT-325

ON vehicle

1. Fluid level

AT-62

2. Overrun clutch

AT-312

3. Forward one-way clutch

AT-322

4. Reverse clutch

AT-306

ON vehicle Vehicle braked by gear change from D1 to D2.

1. Engine idling rpm

OFF vehicle

OFF vehicle

AT-94

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only

ON vehicle

Maximum speed not attained. Acceleration poor.

VG33ER only

1. Fluid level

AT-62

2. Park/neutral position (PNP) switch adjustment

AT-270

3. Shift solenoid valve A

AT-169

4. Shift solenoid valve B

AT-174

5. Control valve assembly

AT-267

6. Reverse clutch

AT-306

7. High clutch

AT-310

8. Brake band

AT-341

9. Low & reverse brake

AT-316

10. Oil pump

AT-289

11. Torque converter

AT-278

1. Fluid level

AT-62

2. Torque converter

AT-278

1. Park/neutral position (PNP) switch adjustment

AT-270

2. Manual control linkage adjustment

AT-270

MA EM LC EC

OFF vehicle

NOT USED NOT USED

Transmission ON vehicle noise in D, 2, 1 and R ON vehicle positions.

3. Throttle position sensor (Adjustment) Engine brake ON vehicle does not operate in “1” position. AT-248

4. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR

EC-701

GI

FE CL MT

TF EC-1273

AT-116, 199

5. Shift solenoid valve A

AT-169

6. Control valve assembly

AT-267

7. Overrun clutch solenoid valve

AT-188

8. Overrun clutch

AT-312

9. Low & reverse brake

AT-316

PD AX SU

OFF vehicle

BR ST RS BT HA SC EL

AT-95

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Reference Page Items

Symptom

Condition

Diagnostic Item VG33E only 1. Fluid level

VG33ER only AT-62

2. Engine idling rpm

EC-648

EC-1220

3. Throttle position sensor (Adjustment)

EC-701

EC-1273

ON vehicle

Transmission overheats.

4. Line pressure test

AT-65

5. Line pressure solenoid valve

AT-164

6. Control valve assembly

AT-267

7. Oil pump

AT-289

8. Reverse clutch

AT-306

9. High clutch

AT-310

10. Brake band

AT-341

11. Forward clutch

AT-312

12. Overrun clutch

AT-312

13. Low & reverse brake

AT-316

14. Torque converter

AT-278

1. Fluid level

AT-62

2. Reverse clutch

AT-306

3. High clutch

AT-310

4. Brake band

AT-341

5. Forward clutch

AT-312

6. Overrun clutch

AT-312

7. Low & reverse brake

AT-316

1. Fluid level

AT-62

2. Torque converter

AT-278

3. Oil pump

AT-289

4. Reverse clutch

AT-306

5. High clutch

AT-310

6. Brake band

AT-341

7. Forward clutch

AT-312

8. Overrun clutch

AT-312

9. Low & reverse brake

AT-316

1. Fluid level

AT-62

2. Torque converter clutch solenoid valve

AT-152

3. Shift solenoid valve B

AT-174

4. Shift solenoid valve A

AT-169

5. Control valve assembly

AT-267

OFF vehicle

ON vehicle

NOT USED NOT USED

ATF shoots out during operation. White smoke emitted from OFF vehicle exhaust pipe during operation.

ON vehicle

Offensive smell at fluid charging pipe.

OFF vehicle

Engine is stopped at R, ON vehicle D, 2 and 1 positions.

AT-96

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value

TCM Terminals and Reference Value

=NGAT0027

PREPARATION 쐌

NGAT0027S01

Measure voltage between each terminal and terminal 25 or 48 by following “TCM INSPECTION TABLE”.

GI MA EM LC

AAT475A

TCM HARNESS CONNECTOR TERMINAL LAYOUTNGAT0027S02

EC FE CL MT AAT494A

TCM INSPECTION TABLE

NGAT0027S03

(Data are reference values.) Terminal No.

1

2

3

Wire color

GY/R

BR/Y

G/OR

Item

PD

1.5 - 2.5V

When depressing accelerator pedal fully after warming up engine.

0V

Line pressure solenoid valve (with dropping resistor

When releasing accelerator pedal after warming up engine.

5 - 14V

SU

When depressing accelerator pedal fully after warming up engine.

0V

BR

Torque converter clutch solenoid valve

When A/T performs lock-up

Battery voltage

When A/T does not performs lock-up

0V

Line pressure solenoid valve

PU/W

DT1

6*1

P/B

DT2

7*1

G/R

DT3

W/R

TF

When releasing accelerator pedal after warming up engine.

5*1

10

Judgement standard (Approx.)

Condition

Power source

—

AX

ST

—

—

—

—

—

—

RS BT

When turning ignition ON.

Battery voltage

HA

When turning ignition OFF.

0V

SC

or

EL

AT-97

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No.

11

12

13

15*1

16

17

18

19

20

22

Wire color

L/W

L/Y

Y

Y/G

BR/W

OR/B

B/Y

W/R

L/B

R

Item

Shift solenoid valve A

Shift solenoid valve B

O/D OFF indicator lamp

OBD-II

—

When shift solenoid valve A operates. (When driving in D1 or D4.)

Battery voltage

When shift solenoid valve A does not operates. (When driving in D2 or D3.)

0V

When shift solenoid valve B operates. (When driving in D1 or D2.)

Battery voltage

When shift solenoid valve B does not operates. (When driving in D3 or D4.)

0V

When setting overdrive control switch in OFF position.

0V

When setting overdrive control switch in ON position.

Battery voltage

—

Closed throttle position switch (in throttle position switch)

Wide open throttle position switch (in throttle position switch)

ASCD cruise signal

Power source (same as No. 10)

Judgement standard (Approx.)

Condition

—

When releasing accelerator pedal after warming up engine.

Battery voltage

When depressing accelerator pedal after warming up engine.

0V

When depressing accelerator pedal more than half-way after warming up engine.

Battery voltage

When releasing accelerator pedal after warming up engine.

0V

When ASCD cruise is being performed. (“CRUISE ” light comes on.)

Battery voltage

When ASCD cruise is not being performed. (“CRUISE ” light does not comes on.)

0V

When turning ignition ON.

Battery voltage

When turning ignition OFF.

0V

or

When overrun clutch solenoid valve Battery voltage operates.

Overrun clutch solenoid valve

Overdrive control switch

AT-98

When overrun clutch shift solenoid valve does not operates.

0V

When setting overdrive control switch in OFF position

0V

When setting overdrive control switch in ON position

Battery voltage

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No.

24

25

Wire color

GY

B/Y

Item

Judgement standard (Approx.)

Condition

ASCD O/D cut signal

When ASCD permits O/D.

5 - 8V

When ASCD requires O/D to be OFF.

0V

—

Ground

GI MA EM

0V

LC 26

27

28

G/B

G/W

R/Y

When setting selector lever to 1 position.

PNP switch 1 position

EC

When setting selector lever to other 0V position. When setting selector lever to 2 position.

PNP switch 2 position

Power source (Memory backup)

Battery voltage

Battery voltage

FE

When setting selector lever to other 0V position.

CL

When turning ignition switch to ON.

MT

Battery voltage

or When turning ignition switch to OFF. Battery voltage

29

B/R

When vehicle cruises at 30 km/h (19 MPH).

Revolution sensor (Measure in AC range)

When vehicle parks.

1V or more Voltage rises gradually in response to vehicle speed.

TF PD

0V

AX

30*2

Y/R

DATA LINK CONNECTOR data in

—

—

—

31*2

GY/L

DATA LINK CONNECTOR data out

—

—

—

SU BR Ignition switch ON.

32

B/W

Throttle position sensor (Power source)

4.5 - 5.5V

ST

or Ignition switch OFF.

0V

RS BT HA SC EL

AT-99

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No.

34

35

36

Wire color

L

Y/R

P

Battery voltage

When setting selector lever to other 0V position. When setting selector lever to R position.

PNP switch R position

Battery voltage

When setting selector lever to other 0V position. When setting selector lever to P or N position.

PNP switch P or N position

Battery voltage

When setting selector lever to other 0V position. 1.2 V

P/L

Engine speed signal

When engine runs at idle speed.

0.5 - 2.5V

G/B

Vehicle speed sensor

Voltage varies When moving vehicle at 2 to 3 km/h between less (1 to 2 MPH) for 1m (3 ft) or more. than 1V and more than 4.5V Fully-closed When depressing accelerator pedal throttle: 0.5V slowly after warming up engine. (Voltage rises gradually in response Fully-open to throttle position.) throttle: 4V

39

41

OR/L

Throttle position sensor

42

BR

Throttle position sensor (Ground)

45*3

BR/R

48

When setting selector lever to D position.

PNP switch D position

When engine runs at approximately 1,000 rpm.

Y

47

Judgement standard (Approx.)

Condition

Turbine revolution sensor (measured in AC range)

38*3

40

Item

R/B

B/Y

—

0V

When brake pedal is depressed.

Battery voltage

When brake pedal is released.

0V

When ATF temperature is 20°C (68°F).

1.5V

When ATF temperature is 80°C (176°F).

0.5V

Stoplamp switch

A/T fluid temperature sensor

Ground (same as No. 25)

—

*1: These terminals are connected to the ECM. *2: These terminals are connected to the Data Link Connector. *3: VG33ER only.

AT-100

0V

TROUBLE DIAGNOSIS FOR POWER SUPPLY Wiring Diagram — AT — MAIN

Wiring Diagram — AT — MAIN

NGAT0185

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC WAT518

AT-101

EL IDX

TROUBLE DIAGNOSIS FOR POWER SUPPLY Wiring Diagram — AT — MAIN (Cont’d)

TCM TERMINALS AND REFERENCE VALUE

NGAT0185S01

Remarks: Specification data are reference values. Terminal No.

Wire color

10

W/R

Item

Judgement standard (Approx.)

Condition

When turning ignition switch to ON

Battery voltage

Power source When turning ignition switch to OFF

19

W/R

Power source

25

B/Y

Ground

28

R/Y

Power source (Memory backup)

0V

Same as No. 10 —

—

0V

When turning ignition switch to OFF

Battery voltage

When turning ignition switch to ON

Battery voltage

or 48

B/Y

Ground (same as No. 25)

When turning ignition switch to OFF

0V

When turning ignition switch to ON

0V

Diagnostic Procedure 1

NGAT0209

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.

AAT476A

Voltage: Battery voltage 3. Turn ignition switch to OFF position. 4. Check voltage between TCM terminal 28 and ground. Voltage: Battery voltage OK or NG OK

䊳

GO TO 2.

NG

䊳

Check the following items: 쐌 Harness for short or open between ignition switch and TCM terminals 10, 19 and 28 (Main harness) 쐌 Ignition switch and fuse Refer to “POWER SUPPLY ROUTING”, EL-10.

AT-102

TROUBLE DIAGNOSIS FOR POWER SUPPLY Diagnostic Procedure (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. Refer to wiring diagrams. Continuity should exist. If OK, check harness for short to ground and short to power. OK or NG OK

䊳

INSPECTION END

NG

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-103

IDX

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Description

Description 쐌 쐌

NGAT0028

The PNP switch assembly includes a transmission range switch. The transmission range switch detects the selector position and sends a signal to the TCM.

AAT478A

TCM TERMINALS AND REFERENCE VALUE

NGAT0028S02

Remarks: Specification data are reference values. Terminal No.

Wire color

26

G/B

27

G/W

34

L

35

Y

36

P

Item

Judgement standard (Approx.)

Condition

When setting selector lever to 1 posiBattery voltage tion.

PNP switch 1 position

When setting selector lever to other positions.

When setting selector lever to 2 posiBattery voltage tion.

PNP switch 2 position

PNP switch D position

PNP switch R position

When setting selector lever to other positions.

0V

When setting selector lever to D position.

Battery voltage

When setting selector lever to other positions.

0V

When setting selector lever to R position.

Battery voltage

When setting selector lever to other positions.

0V

When setting selector lever to P or N Battery voltage position.

PNP switch P or N position

When setting selector lever to other positions.

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : PNP SW/CIRC : P0705

0V

Malfunction is detected when ... TCM does not receive the correct voltage signal from the switch based on the gear position.

AT-104

0V

NGAT0028S03

Check item (Possible cause) 쐌 Harness or connectors (The PNP switch circuit is open or shorted.) 쐌 PNP switch

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0028S01

SAT014K

SEF949Y

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) Turn ignition switch ON. 2) Select “DATA MONITOR” mode for “ENGINE” with CONSULTII. 3) 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 (O/D ON or OFF) With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-105

IDX

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Wiring Diagram — AT — PNP/SW

Wiring Diagram — AT — PNP/SW

NGAT0186

WAT510

AT-106

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Diagnostic Procedure

Diagnostic Procedure 1

NGAT0029

CHECK PNP SWITCH CIRCUIT (With CONSULT-II)

GI

With CONSULT 1. Turn ignition switch to ON position. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out P, R, N, D, 2 and 1 position switches moving selector lever to each position. Check the signal of the selector lever position is indicated properly.

MA EM LC EC FE

SAT643J

CL

OK or NG OK

䊳

GO TO 3.

MT

NG

䊳

Check the following items: 쐌 PNP switch Refer to “Component Inspection”, AT-109. 쐌 Harness for short or open between ignition switch and PNP switch (Main harness) 쐌 Harness for short or open between PNP switch and TCM (Main harness) 쐌 Diode (P, N positions)

TF PD AX SU BR ST RS BT HA SC EL

AT-107

IDX

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Diagnostic Procedure (Cont’d)

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 connector M78 terminals (26, 27, 34, 35, 36) and ground, while moving selector lever through each position.

AAT480A

AAT479A

Does battery voltage exist (B) or non-existent (0)? Yes

䊳

GO TO 3.

No

䊳

Check the following items: 쐌 PNP switch Refer to “Component Inspection”, AT-109. 쐌 Harness for short or open between ignition switch and PNP switch (Main harness) 쐌 Harness for short or open between PNP switch and TCM (Main harness) 쐌 Diode (P, N positions)

3

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-105. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-108

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Component Inspection

Component Inspection

NGAT0030

PNP SWITCH 1.

NGAT0030S02

Check continuity between terminals 1 and 2 and between terminals 3 and (4, 5, 6, 7, 8, 9) while moving manual shaft through each position.

Lever position

P

R

1-2 Terminal No.

N

2

1

3-7

3-8

3-9

1-2 3-5

3-4

D

GI MA EM

3-6

LC

SAT517GB

EC FE CL MT

AAT482A

2. 3.

If NG, check again with manual control linkage disconnected from manual shaft of A/T assembly. Refer to step 1. If OK on step 2, adjust manual control linkage. Refer to AT-270.

TF PD AX AAT551A

4. 5. 6.

If NG on step 2, remove PNP switch from A/T and check continuity of PNP switch terminals. Refer to step 1. If OK on step 4, adjust PNP switch. Refer to AT-270. If NG on step 4, replace PNP switch.

SU BR ST RS

AAT481A

BT HA SC EL

AT-109

IDX

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Description

Description

NGAT0031

The A/T fluid temperature sensor detects the A/T fluid temperature and sends a signal to the TCM.

SAT342HA

SAT021J

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NGAT0031S04 Remarks: Specification data are reference values. Monitor item

Condition

Specification (Approx.)

Cold [20°C (68°F)] " Hot [80°C (176°F)]

A/T fluid temperature sensor

1.5V " 0.5V

2.5 kΩ " 0.3 kΩ

TCM TERMINALS AND REFERENCE VALUE

NGAT0031S02

Remarks: Specification data are reference values. Terminal No.

Wire color

Item

42

BR

Throttle position sensor (Ground)

R/B

A/T fluid temperature sensor

47

Judgement standard (Approx.)

Condition

—

—

When ATF temperature is 20°C (68°F).

1.5V

When ATF temperature is 80°C (176°F).

0.5V

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : ATF TEMP SEN/CIRC : P0710

Malfunction is detected when ... TCM receives an excessively low or high voltage from the sensor.

AT-110

NGAT0031S03

Check item (Possible cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 A/T fluid temperature sensor

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0031S01

SAT014K

SEF949Y

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) 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.) CMPS·RPM (REF): 450 rpm or more VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.2V Selector lever: D position (O/D ON) With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-111

IDX

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Wiring Diagram — AT — FTS

Wiring Diagram — AT — FTS

NGAT0187

WAT542

AT-112

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Diagnostic Procedure

Diagnostic Procedure 1

NGAT0032

CHECK A/T FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY

GI

1. Turn ignition switch to OFF position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal cord assembly connector E72 terminals 6 and 7, when A/T is cold [20°C (68°F)].

MA EM LC EC

AAT483A

Is resistance approx. 2.5 kΩ?

FE CL

Yes

䊳

GO TO 2.

No

䊳

1. Remove oil pan. 2. Check the following items: 쐌 A/T fluid temperature sensor Refer to “Component Inspection”, AT-115. 쐌 Harness of terminal cord assembly for short or open

MT

TF PD AX SU BR ST RS BT HA SC EL

AT-113

IDX

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Diagnostic Procedure (Cont’d)

2

CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR

With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “FLUID TEMP SE”. Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V

SAT614J

Without CONSULT-II 1. Start engine. 2. Check voltage between TCM connector M78 terminal 47 and ground while warming up A/T.

AAT484A

Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following item: 쐌 Harness for short or open between TCM and terminal cord assembly (Main harness)

3

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-111. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-114

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Component Inspection

Component Inspection

NGAT0033

A/T FLUID TEMPERATURE SENSOR 쐌 쐌

NGAT0033S01

For removal, refer to “REMOVAL”, AT-267. Check resistance between terminals 6 and 7 while changing temperature as shown at left. Temperature °C (°F)

Resistance

20 (68)

Approximately 2.5 kΩ

80 (176)

Approximately 0.3 kΩ

GI MA EM LC

AAT485A

EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-115

IDX

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Description

Description

NGAT0034

The revolution sensor detects the revolution of the output shaft parking pawl lock gear and emits a pulse signal. The pulse signal is sent to the TCM which converts it into vehicle speed.

AAT478A

TCM TERMINALS AND REFERENCE VALUE

NGAT0034S02

Remarks: Specification data are reference values. Terminal No.

Wire color

29

B/R

42

BR

Item

Judgement standard (Approx.)

Condition

Revolution sensor (Measure in AC range)

When vehicle cruises at 30 km/h (19 MPH).

1V or more Voltage rises gradually in response to vehicle speed.

When vehicle parks.

0V

—

0V

Throttle position sensor (Ground)

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : VEH SPD SEN/CIR AT : P0720

NGAT0034S03

Malfunction is detected when ...

Check item (Possible cause)

TCM does not receive the proper voltage signal from the sensor.

쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Revolution sensor

AT-116

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0034S01

SAT014K

SAT971J

SAT014K

CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 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) Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Drive vehicle and check for an increase of “VHCL/S SE·MTR” value. If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-202. If the check result is OK, go to following step. 3) Select “DATA MONITOR” mode for “ENGINE” with CONSULTII. 4) Start engine and maintain the following conditions for at least 5 consecutive seconds. VHCL SPEED SE: 30 km/h (19 MPH) or more THRTL POS SEN: More than 1.2V Selector lever: D position (O/D ON) Driving condition: 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-119. If the check result is OK, go to following step. 5) Maintain the following conditions for at least 5 consecutive seconds. CMPS·RPM (REF): 3,500 rpm or more THRTL POS SEN: More than 1.2V Selector lever: D position (O/D ON) Driving condition: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS

SEF949Y

BT HA SC EL

AT-117

IDX

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Wiring Diagram — AT — VSSA/T

Wiring Diagram — AT — VSSA/T

NGAT0188

WAT543

AT-118

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Diagnostic Procedure

Diagnostic Procedure 1

NGAT0035

CHECK REVOLUTION SENSOR

GI

Refer to “Component Inspection”, AT-120. OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair or replace revolution sensor.

2

MA EM

CHECK INPUT SIGNAL

LC

With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “VHCL/S SE·A/T” while driving. Check the value changes according to driving speed.

EC FE CL MT

SAT614J

TF

Without CONSULT-II 1. Start engine. 2. Check voltage between TCM connector M78 terminal 29 and ground while driving. (Measure with AC range.)

PD AX SU BR AAT486A

Voltage: At 0 km/h (0 MPH): 0V At 30 km/h (19 MPH): 1V or more (Voltage rises gradually in response to vehicle speed.) OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following items: 쐌 Harness for short or open between TCM and revolution sensor (Main harness) 쐌 Harness for short or open between revolution sensor and ECM (Main harness) 쐌 Ground circuit for ECM Refer to EC-740, “TROUBLE DIAGNOSIS FOR POWER SUPPLY”.

ST RS BT HA SC EL

AT-119

IDX

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Diagnostic Procedure (Cont’d)

3

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-117. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

Component Inspection

NGAT0036

REVOLUTION SENSOR 쐌 쐌

NGAT0036S01

For removal, refer to “Revolution Sensor Replacement”, AT-268. Check resistance between terminals 1 and 2. Terminal No. 1

AAT487A

AT-120

Resistance 2

500 - 650Ω

DTC P0725 ENGINE SPEED SIGNAL Description

Description

NGAT0037

The engine speed signal is sent from the ECM to the TCM.

TCM TERMINALS AND REFERENCE VALUE

GI

NGAT0037S02

Remarks: Specification data are reference values. Terminal No.

Wire color

39

P/L

Item

Judgement standard (Approx.)

Condition

Engine speed signal

When engine runs at idle speed.

0.5 - 2.5V

MA EM LC EC

ON BOARD DIAGNOSIS LOGIC Malfunction is detected when ...

Check item (Possible cause)

FE

TCM does not receive the proper voltage signal from ECM.

쐌 Harness or connectors (The sensor circuit is open or shorted.)

CL

Diagnostic trouble code : ENGINE SPEED SIG : P0725

NGAT0037S03

MT DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0037S01

SAT014K

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) 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 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.2V Selector lever: D position (O/D ON) With GST Follow the procedure “With CONSULT-II”.

TF PD AX SU BR ST RS

SEF949Y

BT HA SC EL

AT-121

IDX

DTC P0725 ENGINE SPEED SIGNAL Wiring Diagram — AT — ENGSS

Wiring Diagram — AT — ENGSS

NGAT0189

AAT585A

AT-122

DTC P0725 ENGINE SPEED SIGNAL Diagnostic Procedure

Diagnostic Procedure 1

NGAT0038

CHECK DTC WITH ECM

GI

Perform diagnostic test mode II (self-diagnostic results) for engine control. Check ignition signal circuit condition. OK or NG

MA

OK

䊳

GO TO 2.

NG

䊳

Check ignition signal circuit for engine control. Refer to EC-1138 (VG33E only) or EC-1718 (VG33ER only), “IGNITION SIGNAL”.

2

EM LC

CHECK INPUT SIGNAL

With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “ENGINE SPEED”. Check engine speed changes according to throttle position.

EC FE CL MT

SAT645J

Without CONSULT-II 1. Start engine. 2. Check voltage between TCM harness connector M78 terminal 39 and ground.

TF PD AX SU BR

AAT488A

Does battery voltage (idle speed) 0.5 - 2.5V? Yes

䊳

GO TO 3.

No

䊳

Check the following items: 쐌 Harness for short or open between TCM and ECM 쐌 Resistor 쐌 Ignition coil Refer to EC-1138 (VG33E only) or EC-1718 (VG33ER only), “IGNITION SIGNAL”.

ST RS BT HA SC EL

AT-123

IDX

DTC P0725 ENGINE SPEED SIGNAL Diagnostic Procedure (Cont’d)

3

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-121. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-124

DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Description

Description 쐌 쐌 쐌

NGAT0039

This is an OBD-II self-diagnostic item and not available in TCM self-diagnosis. This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into first gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, etc.

MA EM LC

Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

TCM TERMINALS AND REFERENCE VALUE

GI

NGAT0039S02

EC FE

Remarks: Specification data are reference values. Terminal No.

11

12

Wire color

L/W

L/Y

Item

Judgement standard (Approx.)

Condition When shift solenoid valve A operates. (When driving in D1 or D4.)

Shift solenoid valve A

Battery voltage

When shift solenoid valve A does not 0V operate. (When driving in D2 or D3.) When shift solenoid valve B operates. (When driving in D1 or D2.)

Shift solenoid valve B

MT

TF

Battery voltage

PD

When shift solenoid valve B does not operate. 0V (When driving in D3 or D4.)

ON BOARD DIAGNOSIS LOGIC

CL

AX NGAT0039S03

This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (1st) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when either shift solenoid valve A is stuck open or shift solenoid valve B is stuck open. Gear position supposed by TCM

1

2

3

4

In case of gear position with no malfunctions

1

2

3

4

In case of gear position with shift solenoid valve A stuck open

2*

2

3

3

In case of gear position with shift solenoid valve B stuck open

4*

3

3

4

SU BR ST RS BT HA SC

*: P0731 is detected.

EL

AT-125

IDX

DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Description (Cont’d) Diagnostic trouble code : A/T 1ST GR FNCTN : P0731

Malfunction is detected when ... 쐌 A/T cannot be shifted to the 1st gear posi- 쐌 tion even if electrical circuit is good. 쐌 쐌

Check item (Possible cause) Shift solenoid valve A Shift solenoid valve B Each clutch Hydraulic control circuit

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0039S01

SAT014K

SAT971J

SAT021J

CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 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. TESTING CONDITIONS: Always drive vehicle on a level road to improve the accuracy of test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SEN: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). 3) Select “1ST GR FNCTN P0731” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. 4) Accelerate vehicle to 17 to 23 km/h (11 to 14 MPH) under the following condition and release the accelerator pedal completely. THROTTLE POSI: Less than 1/8 (at all times during step 4) Selector lever: D position (O/D ON) 쐌 Check that “GEAR” shows 2 after releasing pedal. 5) Depress accelerator pedal to WOT (more than 7/8 of “THROTTLE POSI”) quickly from a speed of 17 to 23 km/h (11 to 14 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to “DIAGNOSTIC PROCEDURE”, AT-129. If “STOP VEHICLE” appears on CONSULT-II screen, go to the following step. 쐌 Check that “GEAR” shows 1 when depressing accelerator pedal to WOT. 쐌 If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “ENGINE”. In case

AT-126

DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Description (Cont’d)

6) 7)

a 1st trip DTC other than P0731 is shown, refer to applicable “TROUBLE DIAGNOSIS FOR DTC”. Stop vehicle. Follow the instruction displayed. (Check for normal shifting referring to the table below.)

Vehicle condition No malfunction exists

GI MA

Gear on actual transmission shift pattern when screen is changed to 1 , 2 , 3 , 4 1,2,3,4

EM

2,2,3,3 Malfunction for P0731 exists. 4,3,3,4

8)

Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.) Refer to “DIAGNOSTIC PROCEDURE”, AT-129. Refer to “Shift Schedule”, AT-348. With GST Follow the procedure “With CONSULT-II”.

LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-127

IDX

DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Wiring Diagram — AT — 1ST

Wiring Diagram — AT — 1ST

NGAT0190

WAT473

AT-128

DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Diagnostic Procedure

Diagnostic Procedure 1

NGAT0040

CHECK SHIFT SOLENOID VALVE

GI

1. Remove control valve assembly. Refer to “REMOVAL”, AT-267. 2. Check shift solenoid valve operation. 쐌 Shift solenoid valve A 쐌 Shift solenoid valve B Refer to “Component Inspection”, AT-130.

MA EM

OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair or replace shift solenoid valve assembly.

2

LC EC

CHECK CONTROL VALVE

1. Disassemble control valve assembly. Refer to “Control Valve Assembly”, AT-293. 2. Check to ensure that: 쐌 Valve, sleeve and plug slide along valve bore under their own weight. 쐌 Valve, sleeve and plug are free from burrs, dents and scratches. 쐌 Control valve springs are free from damage, deformation and fatigue. 쐌 Hydraulic line is free from obstacles.

FE CL MT

TF PD SAT367H

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair control valve assembly.

3

CHECK DTC

AX SU BR

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-126. OK or NG OK

䊳

INSPECTION END

NG

䊳

Check control valve again. Repair or replace control valve assembly.

ST RS BT HA SC EL

AT-129

IDX

DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Component Inspection

Component Inspection

=NGAT0041

SHIFT SOLENOID VALVE A AND B 쐌

Resistance Check 쐌

NGAT0041S01

For removal, refer to “REMOVAL”, AT-267. NGAT0041S0101

Check resistance between terminals (3 or 2) and ground. Solenoid valve

Terminal No.

Shift solenoid valve A

3

Shift solenoid valve B

2

Ground

Resistance (Approx.) 20 - 40Ω

SAT649I

Operation Check 쐌

NGAT0041S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals (3 or 2) and ground.

SAT648I

AT-130

DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Description

Description 쐌 쐌 쐌

NGAT0042

This is an OBD-II self-diagnostic item and not available in TCM self-diagnosis. This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into second gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, etc.

GI MA EM LC

Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

TCM TERMINALS AND REFERENCE VALUE

EC NGAT0042S02

FE

Remarks: Specification data are reference values. Terminal No.

Wire color

12

L/Y

Item

Judgement standard (Approx.)

Condition When shift solenoid valve B operates. (When driving in “D1” or “D2”.)

Shift solenoid valve B

Battery voltage

When shift solenoid valve B does not 0V operate. (When driving in “D3” or “D4”.)

NGAT0042S03

This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (2nd) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve B is stuck open. Gear position supposed by TCM

1

2

3

4

In case of gear position with no malfunctions

1

2

3

4

In case of gear position with shift solenoid valve B stuck open

4

3*

3

4

: P0732

PD AX SU BR ST RS BT

*: P0732 is detected.

: A/T 2ND SIGNAL

MT

TF

ON BOARD DIAGNOSIS LOGIC

Diagnostic trouble code

CL

Malfunction is detected when ... A/T cannot be shifted to the 2nd gear position even if electrical circuit is good.

Check item (Possible cause) A/T cannot be shifted to the 2nd gear position even if electrical circuit is good.

HA SC EL

AT-131

IDX

DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0042S01

SAT014K

SAT971J

SAT021J

CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 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. TESTING CONDITIONS: Always drive vehicle on a level road to improve the accuracy of test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT 1) Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT. 2) Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SEN: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). 3) Select “2ND GR FNCTN P0732” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. 4) Accelerate vehicle to 50 to 55 km/h (31 to 34 MPH) under the following condition and release the accelerator pedal completely. THROTTLE POSI: Less than 1/8 (at all times during step 4) Selector lever: D position (O/D ON) 쐌 Check that “GEAR” shows 3 or 4 after releasing pedal. 5) Depress accelerator pedal to WOT (more than 7/8 of “THROTTLE POSI”) quickly from a speed of 50 to 55 km/h (31 to 34 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to “Diagnostic Procedure”, AT-135. If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. 쐌 Check that “GEAR” shows 2 when depressing accelerator pedal to WOT. 쐌 If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “ENGINE”. In case a 1st trip DTC other than P0732 is shown, refer to applicable “TROUBLE DIAGNOSIS FOR DTC”. 6) Stop vehicle. 7) Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition

Gear on actual transmission shift pattern when screen is changed to 1 , 2 , 3 , 4

No malfunction exists

1,2,3,4

Malfunction for P0732 exists.

4,3,3,4

8)

Make sure that “OK” is displayed. (If “NG” is displayed, refer

AT-132

DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Description (Cont’d)

to “DIAGNOSTIC PROCEDURE”.) Refer to “Diagnostic Procedure”, AT-135. Refer to shift schedule, AT-348. With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-133

IDX

DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Wiring Diagram — AT — 2ND

Wiring Diagram — AT — 2ND

NGAT0191

LAT503

AT-134

DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Diagnostic Procedure

Diagnostic Procedure 1

NGAT0043

CHECK SHIFT SOLENOID VALVE

GI

1. Remove control valve assembly. Refer to “REMOVAL”, AT-267. 2. Check shift solenoid valve operation. 쐌 Shift solenoid valve B Refer to “Component Inspection”, AT-135.

MA

OK or NG

EM

OK

䊳

GO TO 2.

NG

䊳

Repair or replace shift solenoid valve assembly.

2

LC

CHECK CONTROL VALVE

EC

1. Disassemble control valve assembly. Refer to “Control Valve Assembly”, AT-293. 2. Check to ensure that: 쐌 Valve, sleeve and plug slide along valve bore under their own weight. 쐌 Valve, sleeve and plug are free from burrs, dents and scratches. 쐌 Control valve springs are free from damage, deformation and fatigue. 쐌 Hydraulic line is free from obstacles.

FE CL MT

TF PD SAT367H

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair control valve assembly.

3

AX SU

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-132. OK or NG

ST

OK

䊳

INSPECTION END

NG

䊳

Check control valve again. Repair or replace control valve assembly.

RS

Component Inspection

NGAT0044

SHIFT SOLENOID VALVE B 쐌

HA NGAT0044S0101

Check resistance between terminal 2 and ground. Solenoid valve

Shift solenoid valve B

BT

NGAT0044S01

For removal, refer to “REMOVAL”, AT-267.

Resistance Check 쐌

BR

Terminal No. 2

Ground

SC

Resistance (Approx.) 20 - 40Ω

EL

SAT651I

AT-135

IDX

DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Component Inspection (Cont’d)

Operation Check 쐌

NGAT0044S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 2 and ground.

SAT650I

AT-136

DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Description

Description 쐌 쐌 쐌

NGAT0045

This is an OBD-II self-diagnostic item and not available in TCM self-diagnosis. This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into third gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, malfunctioning servo piston or brake band, etc.

Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

GI MA EM LC EC FE

TCM TERMINALS AND REFERENCE VALUE

NGAT0045S02

Remarks: Specification data are reference values. Terminal No.

Wire color

11

L/W

Item

Judgement standard (Approx.)

Condition When shift solenoid valve A operates. (When driving in D1 or D4.)

Shift solenoid valve A

CL MT

Battery voltage

When shift solenoid valve A does not operate. 0V (When driving in D2 or D3.)

TF

ON BOARD DIAGNOSIS LOGIC

NGAT0045S03

This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (3rd) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve A is stuck closed. Gear position supposed by TCM

1

2

3

4

In case of gear position with no malfunctions

1

2

3

4

In case of gear position with shift solenoid valve A stuck closed

1

1

4*

4

PD AX SU BR ST RS BT

*: P0733 is detected.

Diagnostic trouble code : A/T 3RD GR FNCTN : P0733

Malfunction is detected when ... A/T cannot be shifted to the 3rd gear position even if electrical circuit is good.

Check item (Possible cause) 쐌 Shift solenoid valve A 쐌 Each clutch 쐌 Hydraulic control circuit

HA SC EL

AT-137

IDX

DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0045S01

SAT014K

SAT971J

SAT021J

CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 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. TESTING CONDITIONS: Always drive vehicle on a level road to improve the accuracy of test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SEN: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). 3) Select “3RD GR FNCTN P0733” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. 4) Accelerate vehicle to 70 to 85 km/h (43 to 53 MPH) under the following condition and release the accelerator pedal completely. THROTTLE POSI: Less than 1/8 (at all times during step 4) Selector lever: D position (O/D ON) 쐌 Check that “GEAR” shows 4 after releasing pedal. 5) Depress accelerator pedal steadily with 3.5/8 - 4.5/8 of “THROTTLE POSI” from a speed of 70 to 85 km/h (43 to 53 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to “Diagnostic Procedure”, AT-141. If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. 쐌 Check that “GEAR” shows 3 when depressing accelerator pedal with 3.5/8 - 4.5/8 of “THROTTLE POSI”. 쐌 If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “ENGINE”. In case a 1st trip DTC other than P0733 is shown, refer to applicable “TROUBLE DIAGNOSIS FOR DTC”. 6) Stop vehicle. 7) Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition

Gear on actual transmission shift pattern when screen is changed to 1 , 2 , 3 , 4

No malfunction exists.

1,2,3,4

Malfunction for P0733 exists.

1,1,4,4

8)

Make sure that “OK” is displayed. (If “NG” is displayed, refer

AT-138

DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Description (Cont’d)

to “Diagnostic Procedure”.) Refer to “Diagnostic Procedure”, AT-141. Refer to “Shift Schedule”, AT-348. With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-139

IDX

DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Wiring Diagram — AT — 3RD

Wiring Diagram — AT — 3RD

NGAT0192

WAT474

AT-140

DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Diagnostic Procedure

Diagnostic Procedure 1

NGAT0046

CHECK SHIFT SOLENOID VALVE

GI

1. Remove control valve assembly. Refer to “REMOVAL”, AT-267. 2. Check shift solenoid valve operation. 쐌 Shift solenoid valve A Refer to “Component Inspection”, AT-142.

MA

OK or NG

EM

OK

䊳

GO TO 2.

NG

䊳

Repair or replace shift solenoid valve assembly.

2

LC

CHECK CONTROL VALVE

EC

1. Disassemble control valve assembly. Refer to “Control Valve Assembly”, AT-293. 2. Check to ensure that: 쐌 Valve, sleeve and plug slide along valve bore under their own weight. 쐌 Valve, sleeve and plug are free from burrs, dents and scratches. 쐌 Control valve springs are free from damage, deformation and fatigue. 쐌 Hydraulic line is free from obstacles.

FE CL MT

TF PD SAT367H

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair control valve assembly.

3

AX SU

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-138. OK or NG OK

䊳

INSPECTION END

NG

䊳

Check control valve again. Repair or replace control valve assembly.

BR ST RS BT HA SC EL

AT-141

IDX

DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Component Inspection

Component Inspection

=NGAT0047

SHIFT SOLENOID VALVE A 쐌

NGAT0047S01

For removal, refer to “REMOVAL”, AT-267.

Resistance Check 쐌

NGAT0047S0101

Check resistance between terminal 3 and ground. Solenoid valve

Shift solenoid valve A

Terminal No. 3

Ground

Resistance (Approx.) 20 - 40Ω

SAT654I

Operation Check 쐌

NGAT0047S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 3 and ground.

SAT653I

AT-142

DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Description

Description 쐌 쐌 쐌

NGAT0048

This is an OBD-II self-diagnostic item and not available in TCM self-diagnosis. This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter clutch does not lock up as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, malfunctioning oil pump or torque converter clutch, etc.

GI MA EM LC

CONSULT-II REFERENCE VALUE IN DATA MONITOR EC MODE NGAT0048S04 Remarks: Specification data are reference values. Monitor item

Condition

Specification (Approx.)

FE

Torque converter clutch solenoid valve duty

Lock-up OFF " Lock-up ON

4% " 94%

CL

Line pressure solenoid valve duty

Small throttle opening (Low line pressure) " Large throttle opening (High line pressure)

24% " 95%

MT

Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

TCM TERMINALS AND REFERENCE VALUE

TF PD NGAT0048S02

Remarks: Specification data are reference values. Terminal No.

1

2

Wire color

GY/R

BR/Y

Item

Judgement standard (Approx.)

Condition

Line pressure solenoid valve

Line pressure solenoid valve (with dropping resistor)

When releasing accelerator pedal after warming up engine.

1.5 - 2.5V

When depressing accelerator pedal fully after warming up engine.

0V

When releasing accelerator pedal after warming up engine.

5 - 14V

When depressing accelerator pedal fully after warming up engine.

0V

AX SU BR ST RS BT HA SC EL

AT-143

IDX

DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Description (Cont’d) Terminal No.

Wire color

11

L/W

12

L/Y

Item

Judgement standard (Approx.)

Condition When shift solenoid valve A operates. (When driving in D1 or D4.)

Shift solenoid valve A

Battery voltage

When shift solenoid valve A does not 0V operate. (When driving in D2 or D3.) When shift solenoid valve B operates. (When driving in D1 or D2.)

Shift solenoid valve B

Battery voltage

When shift solenoid valve B does not 0V operate. (When driving in D3 or D4.)

ON BOARD DIAGNOSIS LOGIC

NGAT0048S03

This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve B is stuck closed. Gear position supposed by TCM

1

2

3

4

In case of gear position with no malfunctions

1

2

3

4

In case of gear position with shift solenoid valve B stuck closed

1

2

2

1*

*: P0734 is detected.

Diagnostic trouble code

Check item (Possible cause)

Malfunction is detected when ...

: A/T 4TH GR FNCTN A/T cannot be shifted to the 4th gear position even if electrical circuit is good. : P0734

AT-144

쐌 쐌 쐌 쐌 쐌

Shift solenoid valve A Shift solenoid valve B Line pressure solenoid valve Each clutch Hydraulic control circuit

DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0048S01

SAT014K

SAT971J

SAT021J

CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 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. TESTING CONDITIONS: Always drive vehicle on a level road to improve the accuracy of test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SEN: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). 3) Select “4TH GR FNCTN P0734” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. 4) Accelerate vehicle to 50 to 60 km/h (31 to 37 MPH) under the following condition and release the accelerator pedal completely. THROTTLE POSI: Less than 5.5/8 (at all times during step 4) Selector lever: D position (O/D ON) 쐌 Check that “GEAR” shows 3 after releasing pedal. 5) Depress accelerator pedal steadily with 1/8 - 2/8 of “THROTTLE POSI” from a speed of 50 to 60 km/h (31 to 37 MPH) until “TESTING” has turned to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to “Diagnostic Procedure”, AT-148. If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. 쐌 Check that “GEAR” shows 4 when depressing accelerator pedal with 1/8 - 2/8 of “THROTTLE POSI”. 쐌 If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “ENGINE”. In case a 1st trip DTC other than P0734 is shown, refer to applicable “TROUBLE DIAGNOSIS FOR DTC”. 6) Stop vehicle. 7) Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition

Gear on actual transmission shift pattern when screen is changed to 1 , 2 , 3 , 4

No malfunction exists

1,2,3,4

Malfunction for P0734 exists.

1,2,2,1

AT-145

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL IDX

DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Description (Cont’d)

8)

Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, AT-148. Refer to “Shift Schedule”, AT-348. With GST Follow the procedure “With CONSULT-II”.

AT-146

DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Wiring Diagram — AT — 4TH

Wiring Diagram — AT — 4TH

NGAT0193

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC WAT475

AT-147

EL IDX

DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Diagnostic Procedure

Diagnostic Procedure 1

NGAT0049

CHECK SHIFT UP (D3 TO D4)

Perform “Cruise test − Part 1”, AT-74. Does A/T shift from D3 to D4 at the specified speed?

SAT988H

Yes or No Yes

䊳

GO TO 9.

No

䊳

GO TO 2.

2

CHECK LINE PRESSURE

Perform line pressure test. Refer to AT-65. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 7.

3

CHECK SOLENOID VALVES

1. Remove control valve assembly. Refer to “REMOVAL”, AT-267. 2. Refer to “Component Inspection”, AT-151. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace solenoid valve assembly.

AT-148

DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Diagnostic Procedure (Cont’d)

4

CHECK CONTROL VALVE

1. Disassemble control valve assembly. Refer to AT-293. 2. Check to ensure that: 쐌 Valve, sleeve and plug slide along valve bore under their own weight. 쐌 Valve, sleeve and plug are free from burrs, dents and scratches. 쐌 Control valve springs are free from damage, deformation and fatigue. 쐌 Hydraulic line is free from obstacles.

GI MA EM LC EC FE SAT367H

OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair control valve.

5

CL MT

CHECK SHIFT UP (D3 TO D4)

Does A/T shift from D3 to D4 at the specified speed? Yes or No Yes

䊳

GO TO 9.

No

䊳

Check control valve again. Repair or replace control valve assembly.

6

CHECK LINE PRESSURE SOLENOID VALVE

TF PD AX

1. Remove control valve assembly. Refer to AT-267. 2. Refer to “Component Inspection”, AT-151. OK or NG

SU BR

OK

䊳

GO TO 7.

NG

䊳

Replace solenoid valve assembly.

ST RS BT HA SC EL

AT-149

IDX

DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Diagnostic Procedure (Cont’d)

7

CHECK CONTROL VALVE

1. Disassemble control valve assembly. Refer to AT-293. 2. Check line pressure circuit valves for sticking. 쐌 Pressure regulator valve 쐌 Pilot valve 쐌 Pressure modifier valve

SAT367H

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair control valve.

8

CHECK SHIFT UP (D3 TO D4)

Does A/T shift from D3 to D4 at the specified speed? OK or NG OK

䊳

GO TO 9.

NG

䊳

Check control valve again. Repair or replace control valve assembly.

9

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-145. OK or NG OK

䊳

INSPECTION END

NG

䊳

Perform “Cruise test — Part 1” again and return to the start point of this flow chart.

AT-150

DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Component Inspection

Component Inspection

NGAT0050

SOLENOID VALVES 쐌

NGAT0050S01

For removal, refer to AT-267.

Resistance Check 쐌

NGAT0050S0101

Check resistance between terminals (3, 2 or 6) and ground. Solenoid valve

Shift solenoid valve A

Terminal No.

GI MA

Resistance (Approx.)

EM

3 20 - 40Ω

Shift solenoid valve B

2

Line pressure solenoid valve

6

Ground 2.5 - 5Ω

LC EC FE CL MT

AAT613A

Operation Check 쐌

NGAT0050S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals (3, 2, 4, 6 or 7) and ground.

TF PD AX SU BR ST RS

SAT158J

BT HA SC EL

AT-151

IDX

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Description

Description

NGAT0051

The torque converter clutch solenoid valve is activated, with the gear in “D4”, 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 A/T 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. SAT342HA

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NGAT0051S02 Remarks: Specification data are reference values. Monitor item

Condition

Specification (Approx.)

Torque converter clutch solenoid valve duty

Lock-up OFF " Lock-up ON

4% " 94%

TCM TERMINALS AND REFERENCE VALUE

NGAT0051S03

Remarks: Specification data are reference values. Terminal No.

Wire color

Item

3

G/OR

Torque converter clutch solenoid valve

Judgement standard (Approx.)

Condition

When A/T performs lock-up.

8 - 15V

When A/T does not perform lock-up.

0V

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : TCC SOLENOID/CIRC : P0740

Malfunction is detected when ... TCM detects an improper voltage drop when it tires to operate the solenoid valve.

AT-152

NGAT0051S04

Check item (Possible cause) 쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 T/C clutch solenoid valve

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0051S01

SAT014K

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. 2) Select “DATA MONITOR” mode for “ENGINE” with CONSULT-II and wait at least 1 second. With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC EC FE CL MT

SEF949Y

TF PD AX SU BR ST RS BT HA SC EL

AT-153

IDX

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Wiring Diagram — AT — TCV

Wiring Diagram — AT — TCV

NGAT0194

LAT504

AT-154

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Diagnostic Procedure

Diagnostic Procedure 1

NGAT0052

CHECK GROUND CIRCUIT

GI

1. Turn ignition switch to OFF position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal cord assembly connector E72 terminal 5 and ground. Refer to wiring diagram.

MA

Is resistance approx. 10 - 20 Ω?

EM

Yes

䊳

GO TO 2.

No

䊳

1. Remove oil pan. Refer to AT-267. 2. Check the following items: 쐌 Torque converter clutch solenoid valve Refer to “Component Inspection”, AT-156. 쐌 Harness of terminal cord assembly for short or open

2

CHECK RESISTANCE

1. Turn ignition switch to OFF position. 2. Disconnect TCM harness connector. 3. Check resistance between terminal cord assembly connector E72 terminal 5 and TCM harness connector M77 terminal 3. Refer to wiring diagram. If OK, check harness for short to ground and short to power. Is resistance approx. 0Ω? Yes

䊳

GO TO 3.

No

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

3

CHECK DTC

LC EC FE CL MT

TF

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-153. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

PD AX SU BR ST RS BT HA SC EL

AT-155

IDX

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Component Inspection

Component Inspection

=NGAT0053

TORQUE CONVERTER CLUTCH SOLENOID VALVENGAT0053S01 쐌

For removal, refer to AT-267.

Resistance Check 쐌

NGAT0053S0101

Check resistance between terminal 7 and ground. Solenoid valve

Torque converter clutch solenoid valve

Terminal No. 7

Ground

Resistance (Approx.) 10 - 20Ω

SAT160J

Operation Check 쐌

NGAT0053S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 7 and ground.

SAT161J

AT-156

DTC P0744 IMPROPER LOCK-UP OPERATION Description

Description 쐌 쐌 쐌

NGAT0054

This is an OBD-II self-diagnostic item and not available in TCM self-diagnosis. This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter clutch does not lock up as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, malfunctioning oil pump or torque converter clutch, etc.

GI MA EM LC

CONSULT-II REFERENCE VALUE IN DATA MONITOR EC MODE NGAT0054S02 Remarks: Specification data are reference values. Monitor item

Condition

Specification (Approx.)

FE

Torque converter clutch solenoid valve duty

Lock-up OFF " Lock-up ON

4% " 94%

CL

TCM TERMINALS AND REFERENCE VALUE

NGAT0054S03

MT

Remarks: Specification data are reference values. Terminal No.

1

2

3

Wire color

GY/R

BR/Y

G/OR

Item

Judgement standard (Approx.)

Condition

Line pressure solenoid valve

Line pressure solenoid valve (with dropping resistor)

Torque converter clutch solenoid valve

When releasing accelerator pedal after warming up engine.

1.5 - 2.5V

TF

When depressing accelerator pedal fully after warming up engine.

0V

PD

When releasing accelerator pedal after warming up engine.

5 - 14V

AX

When depressing accelerator pedal fully after warming up engine.

0V

When A/T performs lock-up.

8 - 15V

SU BR

When A/T does not perform lock- up. 0V

ST

ON BOARD DIAGNOSIS LOGIC

NGAT0054S04

This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve B is stuck closed. Gear position supposed by TCM

1

2

3

4

In case of gear position with no malfunctions

1

2

3

4

AT-157

RS BT HA SC EL IDX

DTC P0744 IMPROPER LOCK-UP OPERATION Description (Cont’d) In case of gear position with shift solenoid valve B stuck closed

1

2

2

1*

*: P0744 is detected. Diagnostic trouble code : A/T TCC S/V FNCTN : P0744

Malfunction is detected when ... 쐌 A/T cannot perform lock-up even if electri- 쐌 cal circuit is good. 쐌 쐌

Check item (Possible cause) Line pressure solenoid valve Torque converter clutch solenoid valve Each clutch Hydraulic control circuit

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0054S01

SAT014K

SAT971J

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) Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SEN: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). 3) Select “TCC S/V FNCTN P0744” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. 4)

SAT021J

Accelerate vehicle to more than 70 km/h (43 MPH) and maintain the following condition continuously until “TESTING” has turned to “COMPLETED”. (It will take approximately 30 seconds after “TESTING” shows.) THROTTLE POSI: 1/8 - 2/8 (at all times during step 4) Selector lever: D position (O/D ON) TCC S/V DUTY: More than 94% VHCL/S SE·A/T: Constant speed of more than 70 km/h (43 MPH) 쐌 Check that “GEAR” shows 4. 쐌 For shift schedule, refer to “SERVICE DATA AND SPECIFICATIONS (SDS)”, AT-348. 쐌 If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS”. In case a 1st trip DTC other than P0744 is shown, refer to applicable “TROUBLE DIAGNOSIS FOR DTC”. 5) Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.) Refer to “DIAGNOSTIC PROCEDURE”, AT-160. Refer to “Shift Schedule”, AT-348. With GST Follow the procedure “With CONSULT-II”.

AT-158

DTC P0744 IMPROPER LOCK-UP OPERATION Wiring Diagram — AT — TCCSIG

Wiring Diagram — AT — TCCSIG

NGAT0195

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC LAT505

AT-159

EL IDX

DTC P0744 IMPROPER LOCK-UP OPERATION Diagnostic Procedure

Diagnostic Procedure 1

=NGAT0055

CHECK SHIFT UP (D3 TO D4)

During “Cruise test − Part 1”, AT-74. Does A/T shift from D3 to D4 at the specified speed?

SAT988H

Yes or No Yes

䊳

Check for proper lock-up. GO TO 10.

No

䊳

GO TO 2.

2

CHECK LINE PRESSURE

Perform line pressure test. Refer to AT-65. OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 6.

3

CHECK CONTROL VALVE

1. Disassemble control valve assembly. Refer to “Control Valve Assembly”, AT-293. 2. Check to ensure that: 쐌 Valve, sleeve and plug slide along valve bore under their own weight. 쐌 Valve, sleeve and plug are free from burrs, dents and scratches. 쐌 Control valve springs are free from damage, deformation and fatigue. 쐌 Hydraulic line is free from obstacles.

SAT367H

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair control valve.

AT-160

DTC P0744 IMPROPER LOCK-UP OPERATION Diagnostic Procedure (Cont’d)

4

CHECK SHIFT UP (D3 TO D4)

Does A/T shift from D3 to D4 at the specified speed?

GI Yes or No

Yes

䊳

GO TO 5.

No

䊳

Check control valve again. Repair or replace control valve assembly.

5

MA EM

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-158.

LC

OK or NG

EC

OK

䊳

INSPECTION END

NG

䊳

Check for proper lock-up. GO TO 10.

FE 6

CHECK LINE PRESSURE SOLENOID VALVE

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check line pressure solenoid valve operation. Refer to “SOLENOID VALVES”, AT-163.

CL

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace solenoid valve assembly.

7

MT

CHECK CONTROL VALVE

TF

1. Disassemble control valve assembly. Refer to “Control Valve Assembly”, AT-293. 2. Check line pressure circuit valves for sticking. 쐌 Pressure regulator valve 쐌 Pilot valve 쐌 Pressure modifier valve

PD AX SU BR ST SAT367H

OK or NG OK

䊳

GO TO 8.

NG

䊳

Repair control valve.

8

RS BT

CHECK SHIFT UP (D3 TO D4)

HA

Does A/T shift from D3 to D4 at the specified speed? Yes or No Yes

䊳

GO TO 9.

No

䊳

Check control valve again. Repair or replace control valve assembly.

AT-161

SC EL IDX

DTC P0744 IMPROPER LOCK-UP OPERATION Diagnostic Procedure (Cont’d)

9

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-158. OK or NG OK

䊳

INSPECTION END

NG

䊳

Check for proper lock-up. GO TO 10.

10

CHECK LOCK-UP CONDITION

During “Cruise test − Part 1”, AT-74, Does A/T perform lock-up at the specified speed? Yes or No Yes

䊳

Perform “Cruise test − Part 1” again and return to the start point of this flow chart.

No

䊳

GO TO 11.

11

CHECK TORQUE CONVERTER CLUTCH SOLENOID VALVE

1. Remove control valve assembly. Refer to AT-267. 2. Check torque converter clutch solenoid valve operation. Refer to AT-163. OK or NG OK

䊳

GO TO 12.

NG

䊳

Replace solenoid valve assembly.

12

CHECK CONTROL VALVE

1. Disassemble control valve assembly. Refer to “Control Valve Assembly”, AT-293. 2. Check control valves for sticking. 쐌 Torque converter clutch control valve 쐌 Torque converter clutch relief valve

SAT367H

OK or NG OK

䊳

GO TO 13.

NG

䊳

Repair control valve

13

CHECK LOCK-UP CONDITION

Does A/T perform lock-up at the specified speed? Yes or No Yes

䊳

GO TO 14.

No

䊳

Check control valve again. Repair or replace control valve assembly.

AT-162

DTC P0744 IMPROPER LOCK-UP OPERATION Diagnostic Procedure (Cont’d)

14

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-158. OK or NG

GI MA

OK

䊳

INSPECTION END

NG

䊳

Perform “Cruise test — Part 1” again and return to the start point of this flow chart.

EM LC

Component Inspection

NGAT0056

SOLENOID VALVES 쐌

NGAT0056S01

For removal, refer to Accumulators”, AT-267.

“Control

Valve Assembly

FE

Resistance Check 쐌

EC

and

NGAT0056S0101

Check resistance between terminals (6 or 7) and ground. Solenoid valve

Terminal No.

Line pressure solenoid valve

6

Torque converter clutch solenoid valve

7

Resistance (Approx.) 2.5 - 5Ω

CL MT

Ground 10 - 20Ω

TF PD AX AAT614A

Operation Check 쐌

NGAT0056S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals (2, 3, 4, 6 or 7) and ground.

SU BR ST RS BT HA SC EL

SAT158J

AT-163

IDX

DTC P0745 LINE PRESSURE SOLENOID VALVE Description

Description

NGAT0057

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.

SAT341H

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NGAT0057S02 Remarks: Specification data are reference values. Monitor item

Line pressure solenoid valve duty

Condition

Specification (Approx.)

Small throttle opening (Low line pressure) " Large throttle opening (High line pressure)

24% " 95%

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

NGAT0057S03

Remarks: Specification data are reference values. Terminal No.

1

2

Wire color

Item

GY/R

Line pressure solenoid valve

BR/Y

Judgement standard (Approx.)

Condition

Line pressure solenoid valve (with dropping resistor)

When releasing accelerator pedal after warming up engine.

1.5 - 2.5V

When depressing accelerator pedal fully after warming up engine.

0V

When releasing accelerator pedal after warming up engine.

5 - 14V

When depressing accelerator pedal fully after warming up engine.

0V

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : L/PRESS SOL/CIRC : P0745

Malfunction is detected when ... TCM detects an improper voltage drop when it tries to operate the solenoid valve.

AT-164

NGAT0057S04

Check item (Possible cause) 쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 Line pressure solenoid valve

DTC P0745 LINE PRESSURE SOLENOID VALVE Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0057S01

SAT014K

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 “ENGINE” with CONSULT-II. 2) Depress accelerator pedal completely and wait at least 1 second. With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC EC FE CL MT

SEF949Y

TF PD AX SU BR ST RS BT HA SC EL

AT-165

IDX

DTC P0745 LINE PRESSURE SOLENOID VALVE Wiring Diagram — AT — LPSV

Wiring Diagram — AT — LPSV

NGAT0196

LAT506

AT-166

DTC P0745 LINE PRESSURE SOLENOID VALVE Diagnostic Procedure

Diagnostic Procedure 1

NGAT0058

CHECK GROUND CIRCUIT

GI

1. Turn ignition switch to OFF position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal cord assembly connector E72 terminal 4 and ground. Refer to “Wiring Diagram — AT — LPSV”, AT-166.

MA

Is resistance approx. 2.5 - 5Ω?

EM LC

Yes

䊳

GO TO 2.

No

䊳

1. Remove control valve assembly. Refer to AT-267. 2. Check the following items: 쐌 Line pressure solenoid valve Refer to “Component Inspection”, AT-168. 쐌 Harness of terminal cord assembly for short or open

EC FE

2

CHECK POWER SOURCE CIRCUIT

1. Turn ignition switch to OFF position. 2. Disconnect TCM harness connector. 3. Check resistance between terminal cord assembly connector E72 terminal 4 and TCM harness connector M77 terminal 2. Refer to “Wiring Diagram — AT — LPSV”, AT-166.

CL MT

Is resistance approx. 12Ω? Yes

䊳

GO TO 3.

No

䊳

Check the following items: 쐌 Dropping resistor Refer to “Component Inspection”, AT-168. 쐌 Harness for short or open between TCM connector M77 terminal 2 and terminal cord assembly.

TF PD

3

CHECK POWER SOURCE CIRCUIT

1. Turn ignition switch to OFF position. 2. Check resistance between terminal cord assembly connector E72 terminal 4 and TCM connector M77 terminal 1. Refer to “Wiring Diagram — AT — LPSV”, AT-166. Is resistance approx. 0Ω? Yes

䊳

GO TO 4.

No

䊳

Repair or replace harness between TCM connector and terminal cord assembly connector.

AX SU BR ST

4

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-165.

RS

OK or NG OK

䊳

INSPECTION END

BT

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

HA SC EL

AT-167

IDX

DTC P0745 LINE PRESSURE SOLENOID VALVE Component Inspection

Component Inspection

=NGAT0059

LINE PRESSURE SOLENOID VALVE 쐌

For removal, refer to Accumulators”, AT-267.

“Control

NGAT0059S01

Valve Assembly

Resistance Check 쐌

and

NGAT0059S0101

Check resistance between terminal 6 and ground. Solenoid valve

Line pressure solenoid valve

Terminal No. 6

Resistance (Approx.)

Ground

2.5 - 5Ω

SAT657I

Operation Check 쐌

NGAT0059S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 6 and ground.

SAT658I

DROPPING RESISTOR 쐌

Check resistance between terminals 1 and 2. Resistance: Approx. 12Ω

AAT492A

AT-168

NGAT0059S02

DTC P0750 SHIFT SOLENOID VALVE A Description

Description

NGAT0060

Shift solenoid valves A and B are turned ON or OFF by the TCM in response to signals sent from the PNP switch, vehicle speed and throttle position sensors. Gears will then be shifted to the optimum position.

GI MA EM LC

SAT341H

Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

TCM TERMINALS AND REFERENCE VALUE

EC FE NGAT0060S02

Remarks: Specification data are reference values. Terminal No.

Wire color

11

L/W

CL

Item

Judgement standard (Approx.)

Condition When shift solenoid valve A operates. (When driving in D1 or D4.)

Shift solenoid valve A

Battery voltage

When shift solenoid valve A does not operate. 0V (When driving in D2 or D3.)

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : SFT SOL A/CIRC : P0750

Malfunction is detected when ... TCM detects an improper voltage drop when it tires to operate the solenoid valve.

MT

TF NGAT0060S03

Check item (Possible cause) 쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 Shift solenoid valve A

PD AX SU BR ST RS BT HA SC EL

AT-169

IDX

DTC P0750 SHIFT SOLENOID VALVE A Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0060S01

SAT014K

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) Turn ignition switch ON and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. 2) Start engine. 3) Drive vehicle in D position and allow the transmission to shift 1 , 2 (“GEAR”). With GST Follow the procedure “With CONSULT-II”.

SEF949Y

AT-170

DTC P0750 SHIFT SOLENOID VALVE A Wiring Diagram — AT — SSV/A

Wiring Diagram — AT — SSV/A

NGAT0197

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC WAT476

AT-171

EL IDX

DTC P0750 SHIFT SOLENOID VALVE A Diagnostic Procedure

Diagnostic Procedure 1

NGAT0061

CHECK GROUND CIRCUIT

1. Turn ignition switch to OFF position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal cord assembly connector E72 terminal 2 and ground.

AAT506A

Is resistance approx. 20 - 40Ω? Yes

䊳

GO TO 2.

No

䊳

1. Remove control valve assembly. Refer to AT-267. 2. Check the following items: 쐌 Shift solenoid valve A Refer to “Component Inspection”, AT-173. 쐌 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 cord assembly connector terminal 2 and TCM harness connector M77 terminal 11. Refer to wiring diagram. If OK, check harness for short to ground and short to power. Is resistance approx. 0Ω? Yes

䊳

GO TO 3.

No

䊳

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. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-170. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-172

DTC P0750 SHIFT SOLENOID VALVE A Component Inspection

Component Inspection

=NGAT0062

SHIFT SOLENOID VALVE A 쐌

For removal, refer to Accumulators”, AT-267.

NGAT0062S01

“Control

Valve Assembly

GI MA

Resistance Check 쐌

and

NGAT0062S0101

Check resistance between terminal 3 and ground. Solenoid valve

Shift solenoid valve A

Terminal No. 3

Ground

Resistance (Approx.)

EM

20 - 40Ω

LC

SAT654I

Operation Check 쐌

NGAT0062S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 3 and ground.

EC FE CL MT

SAT653I

TF PD AX SU BR ST RS BT HA SC EL

AT-173

IDX

DTC P0755 SHIFT SOLENOID VALVE B Description

Description

NGAT0063

Shift solenoid valves A and B are turned ON or OFF by the TCM in response to signals sent from the PNP switch, vehicle speed and throttle position sensors. Gears will then be shifted to the optimum position.

SAT341H

Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

TCM TERMINALS AND REFERENCE VALUE

NGAT0063S02

Remarks: Specification data are reference values. Terminal No.

Wire color

12

L/Y

Item

Judgement standard (Approx.)

Condition When shift solenoid valve B operates. (When driving in D1 or D2.)

Shift solenoid valve B

Battery voltage

When shift solenoid valve B does not operate. 0V (When driving in D3 or D4.)

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : SFT SOL B/CIRC : P0755

Malfunction is detected when ... TCM detects an improper voltage drop when it tires to operate the solenoid valve.

AT-174

NGAT0063S03

Check item (Possible cause) 쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 Shift solenoid valve B

DTC P0755 SHIFT SOLENOID VALVE B Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0063S01

SAT014K

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) Turn ignition switch ON and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. 2) Drive vehicle in D position and allow the transmission to shift 1 , 2 , 3 (“GEAR”). With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC EC FE CL MT

SEF949Y

TF PD AX SU BR ST RS BT HA SC EL

AT-175

IDX

DTC P0755 SHIFT SOLENOID VALVE B Wiring Diagram — AT — SSV/B

Wiring Diagram — AT — SSV/B

NGAT0198

LAT507

AT-176

DTC P0755 SHIFT SOLENOID VALVE B Diagnostic Procedure

Diagnostic Procedure 1

NGAT0064

CHECK GROUND CIRCUIT

GI

1. Turn ignition switch to OFF position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal cord assembly connector E72 terminal 1 and ground.

MA EM LC EC AAT508A

Is resistance approx. 20 - 40Ω?

FE CL

Yes

䊳

GO TO 2.

No

䊳

1. Remove control valve assembly. Refer to AT-267. 2. Check the following items: 쐌 Shift solenoid valve B Refer to “Component Inspection”, AT-178. 쐌 Harness of terminal cord assembly for short or open

2

MT

CHECK POWER SOURCE CIRCUIT

1. Turn ignition switch to OFF position. 2. Disconnect TCM harness connector. 3. Check resistance between terminal cord assembly connector E72 terminal 1 and TCM harness connector M77 terminal 12. Refer to wiring diagram. If OK, check harness for short to ground and short to power.

TF

Is resistance approx. 0Ω?

AX

Yes

䊳

GO TO 3.

No

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

3

PD

SU

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-175. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

BR ST RS BT HA SC EL

AT-177

IDX

DTC P0755 SHIFT SOLENOID VALVE B Component Inspection

Component Inspection

=NGAT0065

SHIFT SOLENOID VALVE B 쐌

NGAT0065S01

For removal, refer to “REMOVAL”, AT-267.

Resistance Check 쐌

NGAT0065S0101

Check resistance between terminal 2 and ground. Solenoid valve

Shift solenoid valve B

Terminal No. 2

Ground

Resistance (Approx.) 20 - 40Ω

SAT651I

Operation Check 쐌

NGAT0065S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 2 and ground.

SAT650I

AT-178

DTC P1705 THROTTLE POSITION SENSOR Description

Description 쐌 쐌

AAT495A

NGAT0066

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 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 NGAT0066S02 Remarks: Specification data are reference values. Monitor item

Condition

Specification (Approx.)

Fully-closed throttle

0.5V

Fully-open throttle

4V

GI MA EM LC EC FE

Throttle position sensor

CL

TCM TERMINALS AND REFERENCE VALUE

NGAT0066S03

Remarks: Specification data are reference values. Terminal No.

16

17

Wire color

BR/W

OR/B

MT

Item

Judgement standard (Approx.)

Condition

Closed throttle position switch (in throttle position switch)

When releasing accelerator pedal after warming up engine.

Battery voltage

When depressing accelerator pedal after warming up engine.

0V

Wide open throttle position switch (in throttle position switch)

When depressing accelerator pedal more than half-way after warming up Battery voltage engine. When releasing accelerator pedal after warming up engine.

TF PD AX

0V

SU Ignition switch ON. 32

B/W

Throttle position sensor (Power source)

4.5 - 5.5V

BR

or Ignition switch OFF.

0V

ST 41

42

OR/L

Throttle position sensor

BR

Throttle position sensor (Ground)

When depressing accelerator pedal slowly after warming up engine. (Voltage rises gradually in response to throttle position.)

—

Fully-closed throttle: 0.5V Fully-open throttle: 4V 0V

RS BT HA SC EL

AT-179

IDX

DTC P1705 THROTTLE POSITION SENSOR Description (Cont’d)

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Check item (Possible cause)

Malfunction is detected when ...

: TP SEN/CIRC A/T TCM receives an excessively low or high voltage from the sensor. : P1705

NGAT0066S04

쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 Throttle position sensor 쐌 Throttle position switch

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0066S01

SAT014K

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) Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Apply vacuum to the throttle opener, then check the following. Refer to step 1 and step 2 of “Preparation”, “TCM SELF-DIAGNOSIS PROCEDURE (NO TOOLS)”, AT-47. Accelerator pedal condition

SAT971J

3) 4) SAT014K

5)

THRTL POS SEN CLOSED THL/SW

W/O THRL/P·SW

Fully released

Less than 4.7V

ON

OFF

Partially depressed

0.1 - 4.6V

OFF

OFF

Fully depressed

More than 1.9 - 4.6V

OFF

ON

If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-183. 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 3 consecutive seconds. Then release accelerator pedal completely. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: Approximately 3V or less Selector lever: D position (O/D ON) If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-183. If the check result is OK, go to following step. Maintain the following conditions for at least 3 consecutive seconds. Then release accelerator pedal completely. VHCL SPEED SE: 10 km/h (6 MPH) or more Accelerator pedal: Wide open throttle Selector lever: D position (O/D ON)

SEF949Y

AT-180

DTC P1705 THROTTLE POSITION SENSOR Description (Cont’d)

With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-181

IDX

DTC P1705 THROTTLE POSITION SENSOR Wiring Diagram — AT — TPS

Wiring Diagram — AT — TPS

NGAT0199

WAT544

AT-182

DTC P1705 THROTTLE POSITION SENSOR Diagnostic Procedure

Diagnostic Procedure 1

NGAT0067

CHECK DTC WITH ECM

GI

Check P code CONSULT-II “ENGINE”. Turn ignition switch “ON” and select “SELF-DIAG RESULTS” mode for “ENGINE” with CONSULT-II. Refer to EC-88 (VG33E only) or EC-1247 (VG33ER only), “MALFUNCTION INDICATOR LAMP (MIL)”..

MA

OK or NG

EM

OK

䊳

GO TO 2.

NG

䊳

Check throttle position sensor circuit for engine control. Refer to EC-701 (VG33E only) or EC-1273 (VG33ER only), “BASIC INSPECTION”.

LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-183

IDX

DTC P1705 THROTTLE POSITION SENSOR Diagnostic Procedure (Cont’d)

2

CHECK INPUT SIGNAL

With CONSULT-II 1. Turn ignition switch to ON position. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “THRTL POS SEN”.

SAT614J

Voltage: Fully-closed throttle: Approximately 0.5V Fully-open throttle: Approximately 4V Without CONSULT-II 1. Turn ignition switch to ON position. (Do not start engine.) 2. Check voltage between TCM connector M78 terminals 41 and 42 while accelerator pedal is depressed slowly.

AAT474A

Voltage: Fully-closed throttle valve: Approximately 0.5V Fully-open throttle valve: Approximately 4V (Voltage rises gradually in response to throttle position.) OK or NG OK (With CONSULT-II)

䊳

GO TO 3.

OK (Without CONSULTII)

䊳

GO TO 4.

NG

䊳

Check harness for short or open between ECM and TCM regarding throttle position sensor circuit. (Main harness)

AT-184

DTC P1705 THROTTLE POSITION SENSOR Diagnostic Procedure (Cont’d)

3

CHECK THROTTLE POSITION SWITCH CIRCUIT (With CONSULT-II)

With CONSULT-II 1. Turn ignition switch to ON position. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal. Check the signal of throttle position switch is indicated properly.

GI MA EM LC MTBL0011

EC FE CL MT SAT646J

OK or NG OK

䊳

GO TO 5.

NG

䊳

Check the following items: 쐌 Throttle position switch Refer to “Component Inspection”, AT-187. 쐌 Harness for short or open between ignition switch and throttle position switch (Main harness) 쐌 Harness for short or open between throttle position switch and TCM (Main harness)

TF PD AX SU BR ST RS BT HA SC EL

AT-185

IDX

DTC P1705 THROTTLE POSITION SENSOR Diagnostic Procedure (Cont’d)

4

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 connector M77 terminals [16 (BR/W), 17 (OR/B)] and ground while depressing, and releasing accelerator pedal slowly. (after warming up engine)

LAT329

OK or NG OK

䊳

GO TO 5.

NG

䊳

Check the following items: 쐌 Throttle position switch Refer to “Component Inspection”, AT-187. 쐌 Harness for short or open between ignition switch and throttle position switch (Main harness) 쐌 Harness for short or open between throttle position switch and TCM (Main harness)

5

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-180. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-186

DTC P1705 THROTTLE POSITION SENSOR Component Inspection

Component Inspection

=NGAT0205

THROTTLE POSITION SWITCH Closed Throttle Position Switch (Idle position) 쐌

AAT498A

쐌

NGAT0205S01

GI

NGAT0205S0101

Check continuity between terminals 4 and 5. Accelerator pedal condition

Continuity

Released

Yes

Depressed

No

MA EM

To adjust closed throttle position switch, refer to EC-701 (VG33E only) or EC-1273 (VG33ER only), “Basic Inspection”.

LC EC FE CL MT

Wide Open Throttle Position Switch 쐌

NGAT0205S0102

Check continuity between terminals 5 and 6. Accelerator pedal condition

Continuity

Released

No

Depressed

Yes

TF PD AX

AAT499A

SU BR ST RS BT HA SC EL

AT-187

IDX

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Description

Description

NGAT0068

The overrun clutch solenoid valve is activated by the TCM in response to signals sent from the PNP switch, overdrive control switch, vehicle speed and throttle position sensors. The overrun clutch operation will then be controlled.

SAT341H

TCM TERMINALS AND REFERENCE VALUE

NGAT0068S02

Remarks: Specification data are reference values. Terminal No.

Wire color

20

L/B

Item

Judgement standard (Approx.)

Condition

Overrun clutch solenoid valve

When overrun clutch solenoid valve operates.

Battery voltage

When overrun clutch solenoid valve does not operate.

0V

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : O/R CLTCH SOL/CIRC : P1760

Malfunction is detected when ... TCM detects an improper voltage drop when it tries to operate the solenoid valve.

AT-188

NGAT0068S03

Check item (Possible cause) 쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 Overrun clutch solenoid valve

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE =NGAT0068S01

SAT014K

SEF949Y

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. TESTING CONDITION: Always drive vehicle on a level road to improve accuracy of 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 “ENGINE” with CONSULT-II. 2) Start engine. 3) Accelerate vehicle to a speed of more than 10 km/h (6MPH) in D position (O/D ON). 4) Release accelerator pedal completely in D position (O/D OFF). With GST Follow the procedure “With CONSULT-II”.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-189

IDX

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Wiring Diagram — AT — OVRCSV

Wiring Diagram — AT — OVRCSV

NGAT0200

LAT508

AT-190

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Diagnostic Procedure

Diagnostic Procedure 1

NGAT0069

CHECK GROUND CIRCUIT

GI

1. Turn ignition switch to OFF position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal cord assembly connector E72 terminal 3 and ground.

MA EM LC EC AAT500A

Is resistance approx. 20 - 40Ω?

FE CL

Yes

䊳

GO TO 2.

No

䊳

1. Remove control valve assembly. Refer to “REMOVAL”, AT-267. 2. Check the following items: 쐌 Overrun clutch solenoid valve Refer to “Component Inspection”, AT-192. 쐌 Harness of terminal cord assembly for short or open

2

MT

CHECK POWER SOURCE CIRCUIT

1. Turn ignition switch to OFF position. 2. Disconnect TCM harness connector. 3. Check resistance between terminal cord assembly connector E72 terminal 3 and TCM harness connector M77 terminal 20. Refer to “Wiring Diagram — AT — OVRCSV —”, AT-190. If OK, check harness for short to ground and short to power.

TF

Is resistance approx 0Ω?

AX

Yes

䊳

GO TO 3.

No

䊳

Repair open circuit or short to ground or short to power in harness or connectors.

3

PD

SU

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure. Refer to “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-189. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

BR ST RS BT HA SC EL

AT-191

IDX

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Component Inspection

Component Inspection

=NGAT0070

OVERRUN CLUTCH SOLENOID VALVE 쐌

NGAT0070S01

For removal, refer to “REMOVAL”, AT-267.

Resistance Check 쐌

NGAT0070S0101

Check resistance between terminal 4 and ground. Solenoid valve

Overrun clutch solenoid valve

Terminal No. 4

Ground

Resistance (Approx.) 20 - 40Ω

SAT139K

Operation Check 쐌

NGAT0070S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 4 and ground.

SAT688I

AT-192

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Description

Description

NGAT0172

The A/T fluid temperature sensor detects the A/T fluid temperature and sends a signal to the TCM.

GI MA EM LC

SAT342HA

EC FE CL MT

SAT021J

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NGAT0172S02 Remarks: Specification data are reference values. Monitor item A/T fluid temperature sensor

Condition

Specification (Approx.)

Cold [20°C (68°F)] " Hot [80°C (176°F)]

1.5V " 0.5V

TF 2.5 kΩ " 0.3 kΩ

TCM TERMINALS AND REFERENCE VALUE

PD NGAT0172S03

Remarks: Specification data are reference values. Terminal No.

Wire color

10

W/R

19

28

42

47

W/R

R/Y

BR

R/B

Item

Judgement standard (Approx.)

Condition When turning ignition switch to ON.

Battery voltage

When turning ignition switch to OFF.

0V

Power source Power source (same as No. 10)

Power source (Memory backup)

AX SU BR ST

Same as No. 10

When turning ignition switch to OFF.

Battery voltage

When turning ignition switch to ON.

Battery voltage

or

RS BT HA

Throttle position sensor (Ground)

—

0V

SC

A/T fluid temperature sensor

AT-193

When ATF temperature is 20°C (68°F).

1.5V

When ATF temperature is 80°C (176°F).

0.5V

EL IDX

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Description (Cont’d)

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : BATT/FLUID TEMP SEN : 8th judgement flicker

Malfunction is detected when ... TCM receives an excessively low or high voltage from the sensor.

NGAT0172S04

Check item (Possible cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 A/T fluid temperature sensor

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0172S01 After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine. 2) Select “DATA MONITOR” mode for “A/T” with CONSULT-II. 3) Drive vehicle under the following conditions: Selector lever in D position, vehicle speed higher than 20 km/h (12 MPH). SAT014K

SAT971J

Without CONSULT-II Start engine. Drive vehicle under the following conditions: Selector lever in D position, vehicle speed higher than 20 km/h (12 MPH). 3) Perform self-diagnosis. Refer to “TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)”, AT-47. 1) 2)

SAT335HB

AT-194

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Wiring Diagram — AT — BA/FTS

Wiring Diagram — AT — BA/FTS

NGAT0201

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC WAT545

AT-195

EL IDX

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Diagnostic Procedure

Diagnostic Procedure 1

NGAT0173

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.

AAT476A

Voltage: Battery voltage 3. Turn ignition switch to OFF position. 4. Check voltage between TCM terminal 28 and ground. Voltage: Battery voltage OK or NG OK

䊳

GO TO 2.

NG

䊳

Check the following items: 쐌 Harness for short or open between ignition switch and TCM terminals (10, 19 and 28) (Main harness) 쐌 Ignition switch and fuse Refer to EL-10, “POWER SUPPLY ROUTING”.

2

CHECK A/T 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 terminal cord assembly connector E72 terminals 6 and 7 when A/T is cold [20°C (68°F)].

AAT502A

Is resistance approx. 2.5kΩ? Yes

䊳

GO TO 3.

No

䊳

1. Remove oil pan. 2. Check the following items: 쐌 A/T fluid temperature sensor Refer to “Component Inspection”, AT-198. 쐌 Harness of terminal cord assembly for short or open

AT-196

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR

With CONSULT 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT. 3. Read out the value of “FLUID TEMP SE”.

GI MA EM LC EC SAT614J

Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V

FE CL

Without CONSULT 1. Start engine. 2. Check voltage between TCM connector M78 terminal 47 and ground while warming up A/T.

MT

TF PD AAT503A

Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V

AX SU

OK or NG OK

䊳

GO TO 4.

NG

䊳

Check the following item: 쐌 Harness for short or open between TCM and terminal cord assembly (Main harness)

BR ST

4

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation Procedure, AT-194.

RS

OK or NG OK

䊳

INSPECTION END

BT

NG

䊳

쐌 Perform TCM input/output signal inspection. 쐌 If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

HA SC EL

AT-197

IDX

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Component Inspection

Component Inspection

NGAT0174

A/T FLUID TEMPERATURE SENSOR 쐌 쐌

NGAT0174S01

For removal, refer to “REMOVAL”, AT-267. Check resistance between terminals 6 and 7 while changing temperature as shown at left. Temperature °C (°F)

Resistance (Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

AAT485A

AT-198

DTC VEHICLE SPEED SENSOR·MTR Description

Description

NGAT0071

The vehicle speed sensor·MTR is built into the unified meter control unit. The sensor functions as an auxiliary device to the revolution sensor when it is malfunctioning. The TCM will then use a signal sent from the vehicle speed sensor·MTR.

GI MA EM LC

WAT497

TCM TERMINALS AND REFERENCE VALUE

NGAT0071S02

Remarks: Specification data are reference values. Terminal No.

40

Wire color

G/B

EC

Item

Judgement standard (Approx.)

Condition

When moving vehicle at 2 to 3 km/h (1 to 2 MPH) for 1 m (3 ft) or more.

Vehicle speed sensor

Voltage varies between less than 1V and more than 4.5V

FE CL MT

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : VHCL SPEED SEN·MTR : 2nd judgement flicker

Malfunction is detected when ... TCM does not receive the proper voltage signal from the sensor.

NGAT0071S03

Check item (Possible cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Vehicle speed sensor

TF PD AX SU BR ST RS BT HA SC EL

AT-199

IDX

DTC VEHICLE SPEED SENSOR·MTR Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE =NGAT0071S01

SAT014K

CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 If conducting this “DTC CONFIRMATION PROCEDURE” again, always turn ignition switch OFF and wait at least 5 seconds before continuing. 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 “A/T” with CONSULT-II. 2) Start engine and accelerate vehicle from 0 to 25 km/h (0 to 6 MPH).

SAT971J

Without CONSULT-II Start engine. Drive vehicle under the following conditions: Selector lever in D position and vehicle speed higher than 25 km/h (16 MPH). 3) Perform self-diagnosis. Refer to “TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)”, AT-47. 1) 2)

LAT436

AT-200

DTC VEHICLE SPEED SENSOR·MTR Wiring Diagram — AT — VSSMTR

Wiring Diagram — AT — VSSMTR

NGAT0202

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC WAT523

AT-201

EL IDX

DTC VEHICLE SPEED SENSOR·MTR Diagnostic Procedure

Diagnostic Procedure 1

NGAT0072

CHECK INPUT SIGNAL.

With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “VHCL/S SE·MTR” while driving. Check the value changes according to driving speed.

SAT614J

Without CONSULT-II 1. Start engine. 2. Check voltage between TCM connector M78 terminal 40 and ground while driving at 2 to 3 km/h (1 to 2 MPH) for 1 m (3 ft) or more.

AAT504A

Does battery voltage vary between less than 1V and more than 4.5V? Yes

䊳

GO TO 2.

No

䊳

Check the following items: 쐌 Vehicle speed sensor and ground circuit for vehicle speed sensor Refer to EL-75, “METERS AND GAUGES”. 쐌 Harness for short or open between TCM and vehicle speed sensor (Main harness)

2

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-200. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-202

DTC TURBINE REVOLUTION SENSOR (VG33ER ONLY) Description

Description

NGAT0215

The turbine revolution sensor detects input shaft rpm (revolutions per minute). It is located on the input side of the automatic transmission. The vehicle speed sensor A/T (Revolution sensor) is located on the output side of the automatic transmission. With the two sensors, input and output shaft rpms are accurately detected. The result is optimal shift timing during deceleration and improved shifting.

GI MA EM LC EC FE CL MT

SAT136K

TCM TERMINALS AND REFERENCE VALUE

NGAT0215S01

Remarks: Specification data are reference values. Terminal No.

38

Wire color

Y

Item

Judgement standard (Approx.)

Condition

Turbine revolution sensor (Measure in AC range)

When engine is running at 1,000 rpm

1.2V Voltage rises gradually in response to engine speed.

TF PD AX SU

42

BR

Throttle position sensor (Ground)

—

0V

BR ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : TURBINE REV : 10th judgement flicker

Malfunction is detected when ... TCM does not receive the proper voltage signal from the sensor.

NGAT0215S02

ST

Check item (Possible cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Turbine revolution sensor

RS BT HA SC EL

AT-203

IDX

DTC TURBINE REVOLUTION SENSOR (VG33ER ONLY) Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0215S03

SAT014K

SAT971J

CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 If conducting this “DTC CONFIRMATION PROCEDURE” again, always turn ignition switch “OFF” and wait at least 5 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine. 2) Select “DATA MONITOR” mode for “A/T” with CONSULT-II. 3) Drive vehicle under the following conditions: Selector lever in “D”, vehicle speed higher than 40 km/h (25 MPH), engine speed higher than 1,500 rpm, throttle opening greater than 1.0/8 of the full throttle position and driving for more than 5 seconds. No Tools 1) Start engine. 2) Drive vehicle under the following conditions: Selector lever in “D”, vehicle speed higher than 40 km/h (25 MPH), engine speed higher than 1,500 rpm, throttle opening greater than 1/8 of the full throttle position and driving for more than 5 seconds. 3) Perform self-diagnosis. Refer to “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”, AT-47.

SAT635I

AT-204

DTC TURBINE REVOLUTION SENSOR (VG33ER ONLY) Wiring Diagram — AT — TRSA/T

Wiring Diagram — AT — TRSA/T

NGAT0216

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC WAT546

AT-205

EL IDX

DTC TURBINE REVOLUTION SENSOR (VG33ER ONLY) Diagnostic Procedure

Diagnostic Procedure 1

NGAT0217

CHECK INPUT SIGNAL

With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “TURBINE REV”. Check the value changes according to engine speed.

SAT740J

Without CONSULT-II 1. Start engine. 2. Check voltage between TCM terminal 38 and ground. (Measure in AC range.)

SAT140K

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

DETECT MALFUNCTIONING ITEM

Check harness for short or open between TCM and turbine revolution sensor. OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace damaged parts.

3

CHECK DTC

Perform “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, AT-204. OK or NG OK

䊳

INSPECTION END

NG

䊳

GO TO 4.

AT-206

DTC TURBINE REVOLUTION SENSOR (VG33ER ONLY) Diagnostic Procedure (Cont’d)

4

CHECK TCM INSPECTION

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminal for damage or loose connection with harness connector.

GI

OK or NG OK

䊳

INSPECTION END

NG

䊳

Repair or replace damaged parts.

MA EM LC

Component Inspection

NGAT0218

TURBINE REVOLUTION SENSOR 쐌

NGAT0218S01

EC

Check resistance between terminals 1, 2 and 3. Terminal No.

Resistance (Approx.)

1

2

2.4 - 2.8 kΩ

1

3

No continuity

2

3

No continuity

FE CL MT

TF PD AX LAT449

SU BR ST RS BT HA SC EL

AT-207

IDX

NGAT0206

DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM) Description

Description

NGAT0206S01

The TCM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the A/T.

SAT574J

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : CONTROL UNIT (RAM) : CONTROL UNIT (ROM)

Malfunction is detected when ... 쐌 TCM memory (RAM) or (ROM) is malfunctioning.

NGAT0206S0101

Check Items (Possible Cause) 쐌 TCM

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0206S0102

SAT014K

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 for A/T with CONSULT-II. 2) Start engine. 3) Run engine for at least 2 seconds at idle speed.

SAT971J

AT-208

DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM) Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4.

INSPECTION START

=NGAT0206S04

GI

With CONSULT-II Turn ignition switch ON and select “SELF DIAG RESULTS” mode for A/T with CONSULT-II. Touch “ERASE”. Perform “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, refer to AT-208. Is the “CONTROL UNIT (RAM)” or “CONTROL UNIT (ROM)” displayed again? Yes or No

Yes

䊳

Replace TCM.

No

䊳

INSPECTION END

MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-209

IDX

NGAT0208

DTC CONTROL UNIT (EEP ROM) Description

Description

NGAT0208S01

The TCM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the A/T.

SAT574J

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : CONT UNIT (EEP ROM)

Malfunction is detected when ... TCM memory (EEP ROM) is malfunctioning.

NGAT0208S0101

Check item (possible cause) TCM

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NGAT0208S0102

SAT014K

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) Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Start engine. 3) Run engine for at least 2 seconds at idle speed.

SAT971J

AT-210

DTC CONTROL UNIT (EEP ROM) Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4. 5.

CHECK DTC

NGAT0208S02

GI

With CONSULT-II Turn ignition switch ON and select “SELF DIAG RESULTS” mode for A/T with CONSULT-II. Move selector lever to “R” position. Depress accelerator pedal (Full throttle position). Touch “ERASE”. Turn ignition switch OFF for 10 seconds. PERFORM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE. See previous page. Is the “CONT UNIT (EEP ROM)” displayed again?

Yes

䊳

Replace TCM

No

䊳

INSPECTION END

MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-211

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS Wiring Diagram — AT — NONDTC

Wiring Diagram — AT — NONDTC

NGAT0203

WAT517

AT-212

TROUBLE DIAGNOSES FOR SYMPTOMS Wiring Diagram — AT — NONDTC (Cont’d)

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC LAT492

EL

AT-213

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS Wiring Diagram — AT — NONDTC (Cont’d)

LAT306

AT-214

TROUBLE DIAGNOSES FOR SYMPTOMS 1. O/D OFF Indicator Lamp Does Not Come On

1. O/D OFF Indicator Lamp Does Not Come On

NGAT0073

SYMPTOM: O/D OFF indicator lamp does not come on for about 2 seconds when turning ignition switch to ON. 1

GI MA

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.

EM LC EC FE AAT476A

CL

Voltage: Battery voltage 3. Turn ignition switch to OFF position. 4. Check voltage between TCM terminal 28 and ground. Voltage: Battery voltage

MT OK or NG

OK

䊳

GO TO 2.

NG

䊳

Check the following items: 쐌 Harness for short or open between ignition switch and TCM (Main harness) 쐌 Refer to “Wiring Diagram — AT — MAIN”, AT-101. 쐌 Ignition switch and fuse Refer to EL-10, “POWER SUPPLY ROUTING”.

2

TF PD AX

CHECK TCM GROUND CIRCUIT

1. Turn ignition switch to OFF position. 2. Disconnect TCM harness connector. 3. Check resistance between TCM terminals (25, 48) and ground. Refer to “Wiring Diagram — AT — MAIN”, AT-101. If OK, check harness for short to ground and short to power. Is resistance approx. 0Ω? Yes

䊳

GO TO 3.

No

䊳

쐌 Repair open circuit or short to ground or short to power in harness or connectors. 쐌 Refer to “Wiring Diagram — AT — MAIN”, AT-101.

SU BR ST RS BT HA SC EL

AT-215

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 1. O/D OFF Indicator Lamp Does Not Come On (Cont’d)

3

CHECK LAMP CIRCUIT

1. Turn ignition switch to ON position. 2. Set overdrive control switch to ON position. 3. Check voltage between TCM connector M77 terminal 13 and ground.

AAT505A

Does battery voltage exist? Yes

䊳

GO TO 4.

No

䊳

Check the following items. 쐌 Fuse 쐌 O/D OFF indicator lamp Refer to EL-94, “WARNING LAMPS”. 쐌 Harness for short or open between ignition switch and O/D OFF indicator lamp (Main harness) 쐌 Refer to EL-10, “POWER SUPPLY ROUTING”. 쐌 Harness for short or open between O/D OFF indicator lamp and TCM

4

CHECK SYMPTOM

Check again. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-216

TROUBLE DIAGNOSES FOR SYMPTOMS 2. Engine Cannot Be Started In P and N Position

2. Engine Cannot Be Started In P and N Position

=NGAT0074

SYMPTOM: Engine cannot be started with selector lever in P or N position. Engine cannot be started with selector lever in P. Engine can be started with selector lever in D, 2, 1 or R position. 1

CHECK PNP SWITCH CIRCUIT

GI MA EM

With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit?

LC

Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit?

EC FE CL MT SAT367J

Yes or No Yes

䊳

Check PNP switch circuit. Refer to “DTC P0705”, AT-104.

No

䊳

GO TO 2.

2

TF

CHECK PNP SWITCH INSPECTION

PD

Check for short or open of PNP switch 2-pin connector. Refer to “Components Inspection”, AT-109.

AX SU BR ST AAT482A

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace PNP switch.

3

CHECK STARTING SYSTEM

Check starting system. Refer to SC-10, “System Description”. OK or NG OK

䊳

INSPECTION END

NG

䊳

Repair or replace damaged parts.

RS BT HA SC EL

AT-217

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 3. In “P” Position, Vehicle Moves Forward Or Backward When Pushed

3. In “P” Position, Vehicle Moves Forward Or Backward When Pushed

=NGAT0075

SYMPTOM: Vehicle moves when it is pushed forward or backward with selector lever in P position. 1

CHECK PARKING COMPONENTS

Check parking components. Refer to “Parking Pawl Components”, AT-329.

SAT133B

OK or NG OK

䊳

INSPECTION END

NG

䊳

Repair or replace damaged parts.

AT-218

TROUBLE DIAGNOSES FOR SYMPTOMS 4. In N Position, Vehicle Moves

4. In N Position, Vehicle Moves

=NGAT0076

SYMPTOM: Vehicle moves forward or backward when selecting N position. 1

GI MA

CHECK PNP SWITCH CIRCUIT

With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit?

EM

Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit?

LC EC FE CL SAT367J

MT

Yes or No Yes

䊳

Check PNP switch circuit. Refer to “DTC P0705”, AT-104.

No

䊳

GO TO 2.

2

TF

CHECK CONTROL LINKAGE

Check control linkage. Refer to “Manual Control Linkage Adjustment”, AT-270.

PD AX SU

SAT032G

OK or NG OK

䊳

GO TO 3.

NG

䊳

Adjust control linkage. Refer to “Manual Control Linkage Adjustment”, AT-270.

BR ST RS BT HA SC EL

AT-219

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 4. In N Position, Vehicle Moves (Cont’d)

3

CHECK A/T FLUID LEVEL

Check A/T fluid level again.

SAT638A

OK or NG OK

䊳

GO TO 4.

NG

䊳

Refill ATF.

4

CHECK A/T FLUID CONDITION

1. Remove oil pan. 2. Check A/T fluid condition.

SAT171B

OK or NG OK

䊳

GO TO 5.

NG

䊳

1. Disassemble A/T. 2. Check the following items: 쐌 Forward clutch assembly 쐌 Overrun clutch assembly 쐌 Reverse clutch assembly

5

CHECK SYMPTOM

Check again. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-220

TROUBLE DIAGNOSES FOR SYMPTOMS 5. Large Shock. N → R Position

5. Large Shock. N → R Position

=NGAT0077

SYMPTOM: There is large shock when changing from N to R position. 1

CHECK SELF-DIAGNOSTIC RESULTS

Does self-diagnosis show damage to A/T fluid temperature sensor, line pressure solenoid valve or throttle position sensor circuit?

GI MA EM LC EC FE

LAT456

Yes or No Yes

䊳

Check damaged circuit. Refer to “DTC P0710 A/T FLUID TEMPERATURE SENSOR”, “DTC P0745 LINE PRESSURE SOLENOID VALVE”or “DTC P1705 THROTTLE POSITION SENSOR”, AT-113, 167 or 183.

No

䊳

GO TO 2.

2

CL MT

CHECK THROTTLE POSITION SENSOR

Check throttle position sensor. Refer to EC-780 (VG33E only) or EC-1353 (VG33ER only), “DTC P0121, P0122, P0123 TP SENSOR”.

TF PD AX SU

AAT495A

BR

OK or NG

ST

OK

䊳

GO TO 3.

NG

䊳

Repair or replace throttle position sensor.

RS BT HA SC EL

AT-221

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 5. Large Shock. N → R Position (Cont’d)

3

CHECK LINE PRESSURE

Check line pressure at idle with selector lever in D position. Refer to “Line Pressure Test”, AT-65.

SAT494G

OK or NG OK

䊳

GO TO 4.

NG

䊳

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve

4

CHECK SYMPTOM

Check again. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-222

TROUBLE DIAGNOSES FOR SYMPTOMS 6. Vehicle Does Not Creep Backward In R Position

6. Vehicle Does Not Creep Backward In R Position

=NGAT0078

SYMPTOM: Vehicle does not creep backward when selecting R position. 1

GI MA

CHECK A/T FLUID LEVEL

Check A/T fluid level again.

EM LC EC FE SAT638A

CL

OK or NG OK

䊳

GO TO 2.

NG

䊳

Refill ATF.

2

MT

CHECK STALL TEST

Check stall revolution with selector lever in 1 and R positions. Refer to “Stall Test”, AT-62.

TF PD AX SU SAT493G

OK or NG OK

䊳

GO TO 3.

OK in “1” position, NG in R position

䊳

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Oil pump assembly 쐌 Torque converter 쐌 Reverse clutch assembly 쐌 High clutch assembly

NG in both 1 and R positions

䊳

GO TO 6.

BR ST RS BT HA SC EL

AT-223

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 6. Vehicle Does Not Creep Backward In R Position (Cont’d)

3

CHECK LINE PRESSURE

Check line pressure at idle with selector lever in R position. Refer to “Line Pressure Test”, AT-65.

SAT494G

OK or NG OK

䊳

GO TO 4.

NG

䊳

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Oil pump assembly

4

CHECK A/T FLUID CONDITION

1. Remove oil pan. 2. Check A/T fluid condition.

SAT171B

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 6.

5

CHECK SYMPTOM

Check again. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-224

TROUBLE DIAGNOSES FOR SYMPTOMS 6. Vehicle Does Not Creep Backward In R Position (Cont’d)

6

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Oil pump assembly 쐌 Torque converter 쐌 Reverse clutch assembly 쐌 High clutch assembly 쐌 Low & reverse brake assembly 쐌 Low one-way clutch 䊳

Repair or replace damaged parts.

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-225

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position

7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position

=NGAT0079

SYMPTOM: Vehicle does not creep forward when selecting D, 2 or 1 position. 1

CHECK A/T FLUID LEVEL

Check A/T fluid level again.

SAT638A

OK or NG OK

䊳

GO TO 2.

NG

䊳

Refill ATF.

2

CHECK STALL TEST

Check stall revolution with selector lever in D position. Refer to “Stall Test”, AT-62.

SAT493G

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 6.

AT-226

TROUBLE DIAGNOSES FOR SYMPTOMS 7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position (Cont’d)

3

CHECK LINE PRESSURE

Check line pressure at idle with selector lever in R position. Refer to “Line Pressure Test”, AT-65.

GI MA EM LC SAT494G

EC

OK or NG

FE

OK

䊳

GO TO 4.

NG

䊳

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Oil pump assembly

4

CL MT

TF

CHECK A/T FLUID CONDITION

1. Remove oil pan. 2. Check A/T fluid condition.

PD AX SU BR SAT171B

ST

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 6.

5

RS BT

CHECK SYMPTOM

Check again. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-227

HA SC EL IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position (Cont’d)

6

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Oil pump assembly 쐌 Forward clutch assembly 쐌 Forward one-way clutch 쐌 Low one-way clutch 쐌 Low & reverse brake assembly 쐌 Torque converter 䊳

Repair or replace damaged parts.

AT-228

TROUBLE DIAGNOSES FOR SYMPTOMS 8. Vehicle Cannot Be Started From D1

8. Vehicle Cannot Be Started From D1

=NGAT0080

SYMPTOM: Vehicle cannot be started from D1on Cruise test — Part 1. 1

CHECK SYMPTOM

GI MA

Is “6. Vehicle Does Not Creep Backward In R Position” OK? Yes or No

EM

Yes

䊳

GO TO 2.

No

䊳

Go to “6. Vehicle Does Not Creep Backward In R Position”, AT-223.

LC 2

CHECK SELF-DIAGNOSTIC RESULTS

Does self-diagnosis show damage to vehicle speed sensor·A/T (revolution sensor), shift solenoid valve A, B or vehicle speed sensor·MTR after cruise test?

EC FE CL MT

SAT934FB

Yes or No Yes

No

3

䊳

䊳

TF

Check damaged circuit. Refer to “DTC P0720 VEHICLE SPEED SENSOR-A/T (REVOLUTION SENSOR)”, AT-119 “DTC P0750 SHIFT SOLENOID VALVE A”, AT-172, “DTC P0755 SHIFT SOLENOID VALVE B”, AT-177 or “DTC VEHICLE SPEED SENSOR. MTR”, AT-202. GO TO 3.

PD AX

CHECK THROTTLE POSITION SENSOR

Check throttle position sensor. Refer to EC-780 (VG33E only) or EC-1353 (VG33ER only), “DTC P0121, P0122, P0123 TP SENSOR”.

SU BR ST RS BT

AAT495A

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace throttle position sensor.

HA SC EL

AT-229

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 8. Vehicle Cannot Be Started From D1 (Cont’d)

4

CHECK LINE PRESSURE

Check line pressure at stall point with selector lever in D position. Refer to “Line Pressure Test”, AT-65.

SAT494G

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 8.

5

CHECK A/T FLUID CONDITION

1. Remove oil pan. 2. Check A/T fluid condition.

SAT171B

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 8.

6

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Shift valve A 쐌 Shift valve B 쐌 Shift solenoid valve A 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair or replace damaged parts.

AT-230

TROUBLE DIAGNOSES FOR SYMPTOMS 8. Vehicle Cannot Be Started From D1 (Cont’d)

7

CHECK SYMPTOM

Check again.

GI OK or NG

OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

8

MA

DETECT MALFUNCTIONING ITEM

EM LC

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Shift valve A 쐌 Shift valve B 쐌 Shift solenoid valve A 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter 3. Disassemble A/T. 4. Check the following items: 쐌 Forward clutch assembly 쐌 Forward one-way clutch 쐌 Low one-way clutch 쐌 High clutch assembly 쐌 Torque converter 쐌 Oil pump assembly

EC FE CL MT

OK or NG

TF PD

OK

䊳

GO TO 7.

NG

䊳

Repair or replace damaged parts.

AX SU BR ST RS BT HA SC EL

AT-231

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 9. A/T Does Not Shift: D1 → D2 Or Does Not Kickdown: D4 → D2

9. A/T Does Not Shift: D1 → D2 Or Does Not Kickdown: D4 → D2

=NGAT0081

SYMPTOM: A/T does not shift from D1 to D2 at the specified speed. A/T does not shift from D4 to D2 when depressing accelerator pedal fully at the specified speed. 1

CHECK SYMPTOM

Are “7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position” and “8. Vehicle Cannot Be Started From D1” OK? Yes or No Yes

䊳

GO TO 2.

No

䊳

Go to “7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position” and “8. Vehicle Cannot Be Started From D1”, AT-226, 229.

2

CHECK PNP SWITCH CIRCUIT

With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit? Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit?

SAT367J

Yes or No Yes

䊳

Check PNP switch circuit. Refer to “Diagnostic Procedure”, AT-107.

No

䊳

GO TO 3.

3

CHECK VEHICLE SPEED SENSOR·A/T AND VEHICLE SPEED SENSOR·MTR CIRCUIT

Check vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuit. Refer to “DTC P0720 VEHICLE SPEED SENSOR (REVOLUTION SENSOR)”, AT-119 and “VEHICLE SPEED SENSOR·MTR”, AT-202. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuits.

AT-232

TROUBLE DIAGNOSES FOR SYMPTOMS 9. A/T Does Not Shift: D1 → D2 Or Does Not Kickdown: D4 → D2 (Cont’d)

4

CHECK THROTTLE POSITION SENSOR

Check throttle position sensor. Refer to EC-780 (VG33E only) or EC-1353(VG33ER only), “DTC P0121, P0122, P0123 TP SENSOR”.

GI MA EM LC EC

AAT495A

OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair or replace throttle position sensor.

5

FE CL

CHECK A/T FLUID CONDITION

MT

1. Remove oil pan. 2. Check A/T fluid condition.

TF PD AX SAT171B

OK or NG OK

䊳

GO TO 6.

NG

䊳

GO TO 8.

6

SU BR

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Shift valve A 쐌 Shift solenoid valve A 쐌 Pilot valve 쐌 Pilot filter

ST RS BT

OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair or replace damaged parts.

HA SC EL

AT-233

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 9. A/T Does Not Shift: D1 → D2 Or Does Not Kickdown: D4 → D2 (Cont’d)

7

CHECK SYMPTOM

Check again. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

8

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Shift valve A 쐌 Shift solenoid valve A 쐌 Pilot valve 쐌 Pilot filter 3. Disassemble A/T. 4. Check the following items: 쐌 Servo piston assembly 쐌 Brake band 쐌 Oil pump assembly OK or NG OK

䊳

GO TO 7.

NG

䊳

Repair or replace damaged parts.

AT-234

TROUBLE DIAGNOSES FOR SYMPTOMS 10. A/T Does Not Shift: D2 → D3

10. A/T Does Not Shift: D2 → D3

=NGAT0082

SYMPTOM: A/T does not shift from D2 to D3 at the specified speed. 1

CHECK SYMPTOM

GI MA

Are “7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position” and “8. Vehicle Cannot Be Started From D1” OK? Yes or No Yes

䊳

GO TO 2.

EM

No

䊳

Go to “7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position” and “8. Vehicle Cannot Be Started From D1”, AT-226, 229.

LC

2

CHECK PNP SWITCH CIRCUIT

EC

With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit?

FE

Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit?

CL MT

TF SAT367J

PD

Yes or No Yes

䊳

Check PNP switch circuit. Refer to “Diagnostic Procedure”, AT-107.

No

䊳

GO TO 3.

3

AX

CHECK THROTTLE POSITION SENSOR

SU

Check throttle position sensor. Refer to EC-780 (VG33E only) or EC-1353 (VG33ER only), “DTC P0121, P0122, P0123 TP SENSOR”.

BR ST RS BT AAT495A

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace throttle position sensor.

HA SC EL

AT-235

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 10. A/T Does Not Shift: D2 → D3 (Cont’d)

4

CHECK A/T FLUID CONDITION

1. Remove oil pan. 2. Check A/T fluid condition.

SAT171B

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 7.

5

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Shift valve B 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair or replace damaged parts.

6

CHECK SYMPTOM

Check again. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-236

TROUBLE DIAGNOSES FOR SYMPTOMS 10. A/T Does Not Shift: D2 → D3 (Cont’d)

7

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Shift valve B 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter 3. Disassemble A/T. 4. Check the following items: 쐌 Servo piston assembly 쐌 High clutch assembly 쐌 Oil pump assembly

GI MA EM LC

OK or NG

EC

OK

䊳

GO TO 6.

NG

䊳

Repair or replace damaged parts.

FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-237

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 11. A/T Does Not Shift: D3 → D4

11. A/T Does Not Shift: D3 → D4

=NGAT0083

SYMPTOM: 쐌 A/T does not shift from D3 to D4 at the specified speed. 쐌 A/T must be warm before D3 to D4 shift will occur. 1

CHECK SYMPTOM

Are “7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position” and “8. Vehicle Cannot Be Started From D1” OK? Yes or No Yes

䊳

GO TO 2.

No

䊳

Go to “7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position” and “8. Vehicle Cannot Be Started From D1”, AT-226, 229.

2

CHECK SELF-DIAGNOSTIC RESULTS

With CONSULT-II Does self-diagnosis, after cruise test, show damage to any of the following circuits? 쐌 PNP switch 쐌 Overdrive control switch 쐌 A/T fluid temperature sensor 쐌 Revolution sensor 쐌 Shift solenoid valve A or B 쐌 Vehicle speed sensor

SAT363HA

Yes or No Yes

䊳

Check damaged circuit. Refer to “DTC P1705 THROTTLE POSITION SENSOR”, AT-179, “DTC P0710 A/T FLUID TEMPERATURE SENSOR”, AT-113, “DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)”, AT-119, “DTC P0750 SHIFT SOLENOID VALVE A”, AT-177, “DTC P0755 SHIFT SOLENOID VALVE B”, AT-172, or “DTC VEHICLE SPEED SENSOR·MTR”, AT-202.

No

䊳

GO TO 3.

AT-238

TROUBLE DIAGNOSES FOR SYMPTOMS 11. A/T Does Not Shift: D3 → D4 (Cont’d)

3

CHECK THROTTLE POSITION SENSOR

Check throttle position sensor. Refer to EC-780 (VG33E only) or EC-1353 (VG33ER only), “DTC P0121, P0122, P0123 TP SENSOR”.

GI MA EM LC EC

AAT495A

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace throttle position sensor.

4

FE CL

CHECK A/T FLUID CONDITION

MT

1. Remove oil pan. 2. Check A/T fluid condition.

TF PD AX SAT171B

OK or NG OK

䊳

GO TO 5.

NG

䊳

GO TO 7.

5

SU BR

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Shift valve B 쐌 Overrun clutch control valve 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter

ST RS BT

OK or NG

HA

OK

䊳

GO TO 6.

NG

䊳

Repair or replace damaged parts.

SC EL

AT-239

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 11. A/T Does Not Shift: D3 → D4 (Cont’d)

6

CHECK SYMPTOM

Check again. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

7

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Shift valve B 쐌 Overrun clutch control valve 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter 3. Disassemble A/T. 4. Check the following items: 쐌 Servo piston assembly 쐌 Brake band 쐌 Torque converter 쐌 Oil pump assembly OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair or replace damaged parts.

AT-240

TROUBLE DIAGNOSES FOR SYMPTOMS 12. A/T Does Not Perform Lock-up

12. A/T Does Not Perform Lock-up

=NGAT0084

SYMPTOM: A/T does not perform lock-up at the specified speed. 1

GI

CHECK SELF-DIAGNOSTIC RESULTS

MA

Does self-diagnosis show damage to torque converter clutch solenoid valve circuit after cruise test?

EM LC EC FE SAT346H

Yes or No Yes

䊳

Check torque converter clutch solenoid valve circuit. Refer to “Diagnostic Procedure”, AT-155.

No

䊳

GO TO 2.

2

CL MT

CHECK THROTTLE POSITION SENSOR

Check throttle position sensor. Refer to EC-780 (VG33E only) or EC-1353 (VG33ER only), “DTC P0121, P0122, P0123 TP SENSOR”.

TF PD AX SU

AAT495A

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace throttle position sensor.

3

BR ST RS

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check following items: 쐌 Torque converter clutch control valve 쐌 Torque converter relief valve 쐌 Torque converter clutch solenoid valve 쐌 Pilot valve 쐌 Pilot filter

BT HA

OK or NG

SC EL

OK

䊳

GO TO 4.

NG

䊳

Repair or replace damaged parts.

AT-241

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 12. A/T Does Not Perform Lock-up (Cont’d)

4

CHECK SYMPTOM

Check again. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-242

TROUBLE DIAGNOSES FOR SYMPTOMS 13. A/T Does Not Hold Lock-up Condition

13. A/T Does Not Hold Lock-up Condition

=NGAT0085

SYMPTOM: A/T does not hold lock-up condition for more than 30 seconds. 1

CHECK DIAGNOSTIC RESULTS

GI MA

Does self-diagnosis show damage to engine speed signal circuit after cruise test?

EM LC EC FE SAT347H

Yes or No Yes

䊳

Check engine speed signal circuit. Refer to “Diagnostic Procedure”, AT-123.

No

䊳

GO TO 2.

2

CL MT

CHECK A/T FLUID CONDITION

1. Remove oil pan. 2. Check A/T fluid condition.

TF PD AX SU SAT171B

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 5.

3

BR ST

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Torque converter clutch control valve 쐌 Pilot valve 쐌 Pilot filter

RS BT

OK or NG

HA SC

OK

䊳

GO TO 4.

NG

䊳

Repair or replace damaged parts.

EL

AT-243

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 13. A/T Does Not Hold Lock-up Condition (Cont’d)

4

CHECK SYMPTOM

Check again. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

5

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Torque converter clutch control valve 쐌 Pilot valve 쐌 Pilot filter 3. Disassemble A/T. 4. Check torque converter and oil pump assembly. OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair or replace damaged parts.

AT-244

TROUBLE DIAGNOSES FOR SYMPTOMS 14. Lock-up Is Not Released

14. Lock-up Is Not Released

=NGAT0086

SYMPTOM: Lock-up is not released when accelerator pedal is released. 1

CHECK THROTTLE POSITION SWITCH CIRCUIT

GI MA

With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to closed throttle position switch circuit?

EM

Without CONSULT-II Does self-diagnosis show damage to closed throttle position switch circuit?

LC EC FE CL SAT367J

Yes or No Yes

䊳

Check closed throttle position switch circuit. Refer to “DTC P1705”, AT-183.

No

䊳

GO TO 2.

2

CHECK SYMPTOM

MT

TF

Check again. OK or NG

PD

OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AX SU BR ST RS BT HA SC EL

AT-245

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 15. Engine Speed Does Not Return To Idle (Light Braking D4 → D3)

15. Engine Speed Does Not Return To Idle (Light Braking D4 → D3)

=NGAT0087

SYMPTOM: 쐌 Engine speed does not smoothly return to idle when A/T shifts from D4 to D3. 쐌 Vehicle does not decelerate by engine brake when turning overdrive control switch OFF. 쐌 Vehicle does not decelerate by engine brake when shifting A/T from D to 2 position. 1

CHECK SELF-DIAGNOSTIC RESULTS

Does self-diagnosis show damage to overrun clutch solenoid valve circuit after cruise test?

SAT348H

Yes or No Yes

䊳

Check overrun clutch solenoid valve circuit. Refer to “Diagnostic Procedure”, AT-191.

No

䊳

GO TO 2.

2

CHECK THROTTLE POSITION SENSOR

Check throttle position sensor. Refer to EC-780 (VG33E only) or EC-1353 (VG33ER only), ″DTC P0121, P0122, P0123 TP SENSOR”..

AAT495A

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair or replace throttle position sensor.

AT-246

TROUBLE DIAGNOSES FOR SYMPTOMS 15. Engine Speed Does Not Return To Idle (Light Braking D4 → D3) (Cont’d)

3

CHECK A/T FLUID CONDITION

1. Remove oil pan. 2. Check A/T fluid condition.

GI MA EM LC SAT171B

EC

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 6.

FE CL

4

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Overrun clutch control valve 쐌 Overrun clutch reducing valve 쐌 Overrun clutch solenoid valve OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair or replace damaged parts.

5

MT

TF PD

CHECK SYMPTOM

AX

Check again. OK or NG

SU

OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

6

BR ST

DETECT MALFUNCTIONING ITEM

1. Remove control valve assembly. Refer to “Control Valve Assembly and Accumulators”, AT-267. 2. Check the following items: 쐌 Overrun clutch control valve 쐌 Overrun clutch reducing valve 쐌 Overrun clutch solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Overrun clutch assembly 쐌 Oil pump assembly OK or NG OK

䊳

GO TO 5.

NG

䊳

Repair or replace damaged parts.

RS BT HA SC EL

AT-247

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 16. Vehicle Does Not Start From D1

16. Vehicle Does Not Start From D1

NGAT0088

SYMPTOM: Vehicle does not start from D1 on Cruise test — Part 2. 1

CHECK SELF-DIAGNOSTIC RESULTS

Does self-diagnosis show damage to vehicle speed sensor·A/T (revolution sensor), shift solenoid valve A, B or vehicle speed sensor·MTR after cruise test?

SAT633I

Yes or No Yes

䊳

Check damaged circuit. Refer to “DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)”, AT-119, “DTC P0750 SHIFT SOLENOID VALVE A”, AT-172, “DTC P0755 SHIFT SOLENOID VALVE B”, AT-177, or “DTC VEHICLE SPEED SENSOR·MTR”, AT-202.

No

䊳

GO TO 2.

2

CHECK SYMPTOM

Check again. OK or NG OK

䊳

Go to “8. Vehicle Cannot Be Started From D1”, AT-229.

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-248

TROUBLE DIAGNOSES FOR SYMPTOMS 17. A/T Does Not Shift: D4 → D3, When Overdrive Control Switch ON → OFF

17. A/T Does Not Shift: D4 → D3, When Overdrive Control Switch ON → OFF

=NGAT0089

SYMPTOM: A/T does not shift from D4 to D3 when changing overdrive control switch to OFF position. 1

GI MA

CHECK OVERDRIVE CONTROL SWITCH CIRCUIT

With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to overdrive control switch circuit?

EM

Without CONSULT-II Does self-diagnosis show damage to overdrive control switch circuit?

LC EC FE CL SAT344H

MT

Yes or No Yes

䊳

Check overdrive control switch circuit. Refer to “Diagnostic Procedure”, AT-253.

No

䊳

Go to “10. A/T Does Not Shift: D2 , D3”, AT-235.

TF PD AX SU BR ST RS BT HA SC EL

AT-249

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 18. A/T Does Not Shift: D3 → 22, When Selector Lever D → 2 Position

18. A/T Does Not Shift: D3 → 22, When Selector Lever D → 2 Position

=NGAT0090

SYMPTOM: A/T does not shift from D3 to 22 when changing selector lever from D to 2 position. 1

CHECK PNP SWITCH CIRCUIT

With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit? Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit?

SAT367J

Yes or No Yes

䊳

Check PNP switch circuit. Refer to “DIAGNOSTIC PROCEDURE”, AT-107.

No

䊳

Go to “9. A/T Does Not Shift: D1 , D2 Or Does Not Kickdown: D4 , D2”, AT-232.

AT-250

TROUBLE DIAGNOSES FOR SYMPTOMS 19. A/T Does Not Shift: 22 → 11, When Selector Lever 2 → 1 Position

19. A/T Does Not Shift: 22 → 11, When Selector Lever 2 → 1 Position

=NGAT0091

SYMPTOM: A/T does not shift from 22 to 11 when changing selector lever from 2 to 1 position. 1

GI MA

CHECK PNP SWITCH CIRCUIT

With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit?

EM

Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit?

LC EC FE CL SAT367J

MT

Yes or No Yes

䊳

Check PNP switch circuit. Refer to “Diagnostic Procedure”, AT-107.

No

䊳

GO TO 2.

TF 2

CHECK SYMPTOM

PD

Check again.

AX SU BR SAT778B

ST

OK or NG OK

䊳

INSPECTION END

RS

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

BT HA SC EL

AT-251

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 20. Vehicle Does Not Decelerate By Engine Brake

20. Vehicle Does Not Decelerate By Engine Brake

NGAT0092

SYMPTOM: Vehicle does not decelerate by engine brake when shifting from 22 (12) to 11. 1

CHECK SYMPTOM

Is “6. Vehicle Does Not Creep Backward In R Position” OK? Yes or No Yes

䊳

Go to “15. Engine Speed Does Not Return To Idle (Light Braking D4 , D3)”, AT-246.

No

䊳

Go to “6. Vehicle Does Not Creep Backward In R Position”, AT-223.

21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks) NGAT0204

SYMPTOM: O/D OFF indicator lamp does not come on in TCM self-diagnostic procedure even the lamp circuit is good.

DESCRIPTION 쐌 AAT478A

쐌 쐌

SAT341I

NGAT0204S01

PNP switch The PNP switch assembly includes a transmission range switch. The transmission range switch detects the selector position and sends a signal to the TCM. Overdrive control switch Detects the overdrive control 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 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.

AAT495A

AT-252

TROUBLE DIAGNOSES FOR SYMPTOMS 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks) (Cont’d)

DIAGNOSTIC PROCEDURE

=NGAT0204S03

NOTE: The diagnostic procedure includes inspections for the overdrive control and throttle position switch circuits. 1

CHECK PNP SWITCH CIRCUIT (With CONSULT-II)

GI MA

With CONSULT-II 1. Turn ignition switch to ON position. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out P, R, N, D, 2 and 1 position switches moving selector lever to each position. Check the signal of the selector lever position is indicated properly.

EM LC EC FE CL

SAT643J

MT

OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following items: 쐌 PNP switch Refer to “Component Inspection”, AT-258. 쐌 Harness for short or open between ignition switch and PNP switch (Main harness) 쐌 Harness for short or open between PNP switch and TCM (Main harness)

TF PD AX SU BR ST RS BT HA SC EL

AT-253

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks) (Cont’d)

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 (26, 27, 34, 35, 36) and ground while moving selector lever through each position.

LAT457

AAT479A

Does battery voltage exist (B) or non-existent (0)? Yes

䊳

GO TO 3.

No

䊳

Check the following items: 쐌 PNP switch Refer to “Component Inspection”, AT-258. 쐌 Harness for short or open between ignition switch and PNP switch (Main harness) 쐌 Harness for short or open between PNP switch and TCM (Main harness)

AT-254

TROUBLE DIAGNOSES FOR SYMPTOMS 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks) (Cont’d)

3

CHECK OVERDRIVE CONTROL SWITCH CIRCUIT

With CONSULT-II 1. Turn ignition switch to ON position. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “OVERDRIVE SWITCH”. Check the signal of the overdrive control switch is indicated properly. (Overdrive control switch ON displayed on CONSULT-II means overdrive OFF.)

GI MA EM LC EC FE SAT645J

CL

Without CONSULT-II 1. Turn ignition switch to ON position. (Do not start engine.) 2. Check voltage between TCM terminal 22 and ground when overdrive control switch is ON and OFF.

MT

TF PD AAT510A

Voltage: Switch position ON: Battery voltage Switch position OFF: 1V or less

AX SU OK or NG

BR

OK (With CONSULT-II)

䊳

GO TO 4.

OK (Without CONSULTII)

䊳

GO TO 5.

NG

䊳

Check the following items: 쐌 Overdrive control switch Refer to “Component Inspection”, AT-257. 쐌 Harness for short or open between TCM and overdrive control switch (Main harness) 쐌 Harness for short or open of ground circuit for overdrive control switch (Main harness)

ST RS BT HA SC EL

AT-255

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks) (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 “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal. Check the signal of throttle position switch is indicated properly.

MTBL0011

SAT646J

OK or NG OK

䊳

GO TO 6.

NG

䊳

Check the following items: 쐌 Throttle position switch Refer to “Component Inspection”, AT-258. 쐌 Harness for short or open between ignition switch and throttle position switch (Main harness) 쐌 Harness for short or open between throttle position switch and TCM (Main harness)

AT-256

TROUBLE DIAGNOSES FOR SYMPTOMS 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks) (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 (BR/W), 17 (OR/B) and ground while depressing, and releasing accelerator pedal slowly. (after warming up engine)

GI MA EM LC EC FE

LAT329

OK or NG

CL

OK

䊳

GO TO 6.

NG

䊳

Check the following items: 쐌 Throttle position switch Refer to “Component Inspection”, AT-258. 쐌 Harness for short or open between ignition switch and throttle position switch (Main harness) 쐌 Harness for short or open between throttle position switch and TCM (Main harness)

6

MT

TF

CHECK DTC

Perform Diagnostic procedure, AT-253.

PD

OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AX SU BR ST RS

COMPONENT INSPECTION Overdrive Control Switch 쐌

Check continuity between terminals 5 and 6. Continuity: Switch position ON: No Switch position OFF: Yes

NGAT0204S04

BT

NGAT0204S0401

HA SC EL

AAT512A

AT-257

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks) (Cont’d)

PNP Switch 1.

NGAT0204S0402

Check continuity between terminals 1 and 2 and between terminals 3 and (4, 5, 6, 7, 8, 9) while moving manual shaft through each position. Lever position P

Terminal No. 1-2

3-4

R

3-5

N SAT517GB

1-2

3-6

D

3-7

2

3-8

1

3-9

AAT482A

2. 3.

If NG, check again with manual control linkage disconnected from manual shaft of A/T assembly. Refer to step 1. If OK on step 2, adjust manual control linkage. Refer to “Manual Control Linkage Adjustment”, AT-270.

AAT551A

4. 5. 6.

If NG on step 2, remove PNP switch from A/T and check continuity of PNP switch terminals. Refer to step 1. If OK on step 4, adjust PNP switch. Refer to “Park/Neutral Position (PNP) Switch Adjustment”, AT-270. If NG on step 4, replace PNP switch.

AAT481A

Throttle Position Switch

NGAT0204S0403

Closed Throttle Position Switch (Idle Position) 쐌 Check continuity between terminals 4 and 5.

쐌

Accelerator pedal condition

Continuity

Released

Yes

Depressed

No

To adjust closed throttle position switch, refer to EC-701 (VG33E only) or EC-1273 (VG33ER only), “Basic Inspection”.

AAT498A

AT-258

TROUBLE DIAGNOSES FOR SYMPTOMS 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks) (Cont’d)

Wide Open Throttle Position Switch 쐌 Check continuity between terminals 5 and 6. Accelerator pedal condition

Continuity

Released

No

Depressed

Yes

GI MA EM LC

AAT499A

EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL

AT-259

IDX

A/T SHIFT LOCK SYSTEM Description

Description 쐌

쐌

NGAT0093

The mechanical key interlock mechanism also operates as a shift lock: With the key switch turned to ON, the selector lever cannot be shifted from P (park) to any other position unless the brake pedal is depressed. With the key removed, the selector lever cannot be shifted from P to any other position. The key cannot be removed unless the selector lever is placed in P. The shift lock and key interlock mechanisms are controlled by the ON-OFF operation of the shift lock solenoid and by the operation of the rotator and slider located inside the key cylinder, respectively.

SAT138JA

AT-260

A/T SHIFT LOCK SYSTEM Wiring Diagram — SHIFT —

Wiring Diagram — SHIFT —

NGAT0094

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC WAT490

AT-261

EL IDX

A/T SHIFT LOCK SYSTEM Diagnostic Procedure

Diagnostic Procedure

NGAT0095

SYMPTOM 1: 쐌 Selector lever cannot be moved from P position with key in ON position and brake pedal applied. 쐌 Selector lever can be moved from P position with key in ON position and brake pedal released. 쐌 Selector lever can be moved from P position when key is removed from key cylinder. SYMPTOM 2: Ignition key cannot be removed when selector lever is set to P position. It can be removed when selector lever is set to any position except P. 1

CHECK KEY INTERLOCK CABLE

Check key interlock cable for damage. OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair key interlock cable. Refer to “Key Interlock Cable”, AT-265.

2

CHECK SELECTOR LEVER POSITION

Check selector lever position for damage. OK or NG OK

䊳

GO TO 3.

NG

䊳

Check selector lever. Refer to “Park/Neutral Position (PNP) Switch Adjustment”, AT-270 and “Manual Control Linkage Adjustment”, AT-270.

3

CHECK POWER SOURCE

1. Turn ignition switch to ON position. (Do not start engine.) 2. Check voltage between ASCD brake switch (shift lock brake switch) harness terminal 1 and ground.

AAT513A

Does battery voltage exist? Yes

䊳

GO TO 4.

No

䊳

Check the following items: 쐌 Harness for short or open between battery and ASCD brake switch (shift lock brake switch) harness terminal 1 쐌 Fuse 쐌 Ignition switch Refer to EL-10, “POWER SUPPLY ROUTING”.

AT-262

A/T SHIFT LOCK SYSTEM Diagnostic Procedure (Cont’d)

4

CHECK INPUT SIGNAL (BRAKE SWITCH)

Turn ignition switch to ON position. (Do not start engine.) 쐌 Check voltage between A/T device harness connector M35 terminal 2 (B/W) and ground.

GI MA EM LC EC LAT330

FE

OK or NG OK

䊳

GO TO 5.

NG

䊳

Check the following items: 쐌 Harness for short or open between A/T device harness connector 2 and ASCD brake switch (shift lock brake switch) harness connector 2 쐌 ASCD brake switch (shift lock brake switch) Refer to “Component Check”, AT-264.

5

CL MT

CHECK GROUND CIRCUIT

1. Turn ignition switch to OFF position. 2. Disconnect A/T device harness connector. 3. Check continuity between A/T device harness terminal 1 and ground.

TF PD AX SU AAT515A

BR

OK or NG OK

䊳

GO TO 6.

NG

䊳

Repair harness or connector.

6

ST RS

CHECK PARK POSITION SWITCH

Refer to “Component Check”, AT-264. OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace park position switch.

BT HA SC EL

AT-263

IDX

A/T SHIFT LOCK SYSTEM Diagnostic Procedure (Cont’d)

7

CHECK SHIFT LOCK SOLENOID

Refer to “Component Check”, AT-264. OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace shift lock solenoid.

8

CHECK SHIFT LOCK OPERATION

1. Reconnect shift lock harness connector. 2. Turn ignition switch from OFF to ON” position. (Do not start engine.) 3. Recheck shift lock operation. OK or NG OK

䊳

INSPECTION END

NG

䊳

1. Perform A/T device input/output signal inspection test. 2. If NG, recheck harness connector connection.

Component Check

NGAT0096

SHIFT LOCK SOLENOID 쐌

NGAT0096S01

Check operation by applying battery voltage between shift lock solenoid connector terminals 1 and 3.

AAT516A

PARK POSITION SWITCH 쐌

NGAT0096S02

Check continuity between A/T device (park position switch) harness connector terminal 1 and A/T device harness connector terminal 1. Condition

Continuity

When selector lever is set in “P” position and selector lever button is released

Yes

Except above

No

AAT517A

ASCD BRAKE SWITCH (SHIFT LOCK BRAKE SWITCH) NGAT0096S03 쐌

Check continuity between ASCD brake switch (shift lock brake switch) harness connector terminals 1 and 2. Condition

Continuity

When brake pedal is depressed

No

When brake pedal is released

Yes

Check ASCD brake switch (shift lock brake switch) after adjusting brake pedal — refer to BR-12, “Adjustment”. AAT518A

AT-264

KEY INTERLOCK CABLE Components

Components

NGAT0097

GI MA EM LC EC FE CL MT

SAT352I

CAUTION: 쐌 Install key interlock cable in such a way that it will not be damaged by sharp bends, twists or interference with adjacent parts. 쐌 After installing key interlock cable to control device, make sure that casing cap and bracket are firmly secured in their positions. If casing cap can be removed with an external load of less than 39.2 N (4.0 kg, 8.8 lb), replace key interlock cable with new one.

TF PD AX SU BR ST RS

Removal

NGAT0098

BT

Unlock slider from adjuster holder and remove rod from cable.

HA SC EL SAT353I

AT-265

IDX

KEY INTERLOCK CABLE Installation

Installation 1.

NGAT0099

3.

Set key interlock cable to steering lock assembly and install lock plate. Clamp cable to steering column and fix to control cable with band. Set selector lever to P position.

4.

Insert interlock rod into adjuster holder.

5. 6.

Install casing cap to bracket. Move slider in order to fix adjuster holder to interlock rod.

2.

SAT354I

SAT355I

SAT356I

AT-266

ON-VEHICLE SERVICE Control Valve Assembly and Accumulators

Control Valve Assembly and Accumulators REMOVAL 1. 2. 3. 쐌

NGAT0100

NGAT0100S01

Drain ATF through drain plug. Remove exhaust front tube. Remove oil pan and gasket. Always replace oil pan bolts as they are self-sealing bolts.

GI MA EM LC

SAT359I

4. 5.

Remove A/T fluid temperature sensor if necessary. Remove oil strainer.

EC FE CL MT

SAT073BA

6.

Remove control valve assembly by removing fixing bolts and disconnecting harness connector. Bolt length and location  mm (in)

TF

A

33 (1.30)

PD

B

45 (1.77)

Bolt symbol

7. 8.

Remove solenoids and valves from valve body if necessary. Remove terminal cord assembly if necessary.

AX SU BR ST RS

SAT353B

9.

Remove accumulator A, B, C and D by applying compressed air if necessary. 쐌 Hold each piston with rag. 10. Reinstall any part removed. 쐌 Always use new sealing parts. 쐌 Always replace oil pan bolts as they are self-sealing bolts.

BT HA SC EL

SAT074BA

AT-267

IDX

ON-VEHICLE SERVICE Revolution Sensor Replacement

Revolution Sensor Replacement —4WD MODEL— 1.

AAT565A

2. 3. 4. 쐌

NGAT0101S01

Remove rear engine mounting member from side member while supporting A/T with transfer case with jack. Tighten rear engine mounting member to the specified torque. Refer to EM-113, “ENGINE REMOVAL”. Lower A/T with transfer case as much as possible. Remove revolution sensor from A/T. Reinstall any part removed. Always use new sealing parts.

—2WD MODEL— 쐌 쐌

NGAT0101

NGAT0101S02

Remove revolution sensor from A/T. Always use new sealing parts.

SAT661I

Turbine Revolution Sensor Replacement (VG33ER only) 1. 2. 3. 쐌

NGAT0219

Remove A/T assembly. Refer to “Removal”, AT-271. Remove turbine revolution sensor from A/T assembly upper side. Reinstall any part removed. Always use new sealing parts.

SAT136K

Rear Oil Seal Replacement —4WD MODEL— 1. 2. 3. 쐌 4.

NGAT0102 NGAT0102S01

Remove transfer case from vehicle. Refer to TF-10, “Removal”. Remove rear oil seal. Install rear oil seal. Apply ATF before installing. Reinstall any part removed.

SAT035E

AT-268

ON-VEHICLE SERVICE Rear Oil Seal Replacement (Cont’d)

—2WD MODEL— 1) 2) 3) 쐌 4)

NGAT0102S02

Remove propeller shaft from vehicle. Refer to PD-8, “Removal”. Remove rear oil seal. Install rear oil seal. Apply ATF before installing. Reinstall any part removed.

GI MA EM LC

SAT662I

Parking Components Inspection —4WD MODEL— 1.

NGAT0103 NGAT0103S01

EC

Remove propeller shaft. Refer to PD-8, “Removal”.

FE CL MT 2. 3.

Remove transfer case from vehicle. Refer to TF-10, “Removal”. Remove A/T control cable bracket from transmission case.

TF PD AX AAT564A

4. 5. 6. 7. 쐌

Support A/T assembly with a jack. Remove adapter case from transmission case. Replace parking components if necessary. Reinstall any part removed. Always use new sealing parts.

—2WD MODEL— 1)

SAT078B

2) 3)

4) 5) 6) 쐌

SU BR NGAT0103S02

Remove propeller shaft from vehicle. Refer to PD-8, “Removal”. Support A/T assembly with jack. Remove rear engine mounting member. Tighten rear engine mounting member to the specified torque. Refer EM-113, “ENGINE REMOVAL”. Remove rear extension from transmission case. Replace parking components if necessary. Reinstall any part removed. Always use new sealing parts.

ST RS BT HA SC EL

AT-269

IDX

ON-VEHICLE SERVICE Park/Neutral Position (PNP) Switch Adjustment

Park/Neutral Position (PNP) Switch Adjustment

NGAT0104

1. 2. 3. 4.

SAT081B

5. 6.

Remove manual control linkage from manual shaft of A/T assembly. Set manual shaft of A/T assembly in N position. Loosen park/neutral position (PNP) switch fixing bolts. Insert pin into adjustment holes in both park/neutral position (PNP) switch and manual shaft of A/T assembly as near vertical as possible. Reinstall any part removed. Check continuity of park/neutral position (PNP) switch. Refer to “Components Inspection”, AT-109.

Manual Control Linkage Adjustment

NGAT0105

Move selector lever from P position to 1 position. You should be able to feel the detents in each position. If the detents cannot be felt or the pointer indicating the position is improperly aligned, the linkage needs adjustment. 1. Place selector lever in P position. 2. Loosen lock nuts.

SAT361I

3. 4.

5.

Tighten turn buckle until aligns with inner cable, pulling selector lever toward R position side without pushing button. Back off turn buckle 1 turn and tighten lock nuts to the specified torque. Lock nut: : 4.4 - 5.9 N·m (0.45 - 0.60 kg-m, 39.1 - 52.1 in-lb) Move selector lever from P position to 1 position. Make sure that selector lever can move smoothly.

SAT032G

AT-270

REMOVAL AND INSTALLATION Removal

Removal —4WD MODEL—

NGAT0106 NGAT0106S01

GI MA EM LC EC FE CL

AAT563A

CAUTION: When removing the A/T assembly from engine, first remove the crankshaft position sensor (OBD) from the A/T assembly upper side. Be careful not to damage sensor edge. 1. Remove battery negative terminal. 2. Remove exhaust front and rear tubes. 3. Remove fluid charging pipe from A/T assembly. 4. Remove oil cooler pipe from A/T assembly. 5. Plug up openings such as the fluid charging pipe hole, etc. 6. Remove propeller shaft. Refer to PD-8, “Removal”. 7. Remove transfer control linkage from transfer. Refer to TF-10, “Removal”. 쐌 Insert plug into rear oil seal after removing rear propeller shaft. 쐌 Be careful not to damage spline, sleeve yoke and rear oil seal. 8. Remove A/T control cable from A/T assembly. 9. Disconnect A/T, turbine revolution sensor (VG33ER only) and vehicle speed sensor harness connectors.

10. Remove starter motor. Tightening torque: Refer to SC-25, “VG33E MODELS”. 11. Remove gusset (if equipped) and rear plate cover securing engine to A/T assembly. 12. Remove bolts securing torque converter to drive plate. 쐌 Remove the bolts by turning crankshaft.

MT

TF PD AX SU BR ST RS BT HA SC EL

SAT800C

AT-271

IDX

REMOVAL AND INSTALLATION Removal (Cont’d)

13. Support A/T and transfer assembly with a jack. 14. Remove rear engine mounting member from body and A/T assembly. Tighten rear engine mounting member to the specified torque. Refer to EM-113, “ENGINE REMOVAL”. 15. Remove bolts securing A/T assembly to engine. 16. Lower A/T assembly with transfer.

SAT801C

—2WD MODEL— 1. 2. 3. 4. 5. 6. 7. SAT663I

쐌 쐌 8. 9. 10.

11. 12. 쐌 13. 14.

15. 16. 쐌 쐌 17.

Installation 쐌

NGAT0106S02

Remove battery negative terminal. Remove exhaust front and rear tubes. Remove fluid charging pipe from A/T assembly. Remove oil cooler pipe from A/T assembly. Plug up openings such as the fluid charging pipe hole, etc. Remove propeller shaft. Refer to PD-8, “Removal”. Remove transfer control linkage from transfer. Refer to TF-10, “Removal”. Insert plug into rear oil seal after removing rear propeller shaft. Be careful not to damage spline, sleeve yoke and rear oil seal. Remove A/T control cable from A/T assembly. Disconnect A/T, turbine revolution sensor (VG33ER only) and vehicle speed sensor harness connectors. Remove starter motor. Tightening torque: Refer to SC-25, “VG33E AND VG33ER MODELS”. Remove gusset and rear plate cover securing engine to A/T assembly. Remove bolts securing torque converter to drive plate. Remove the bolts by turning crankshaft. Support A/T assembly with a jack. Remove rear engine mounting member from body and A/T assembly. Tighten rear engine mounting member to the specified torque. Refer to EM-113, “ENGINE REMOVAL”. Remove bolts securing A/T assembly to engine. Pull A/T assembly backwards. Secure torque converter to prevent it from dropping. Secure A/T assembly to a jack. Lower A/T assembly. NGAT0107

Drive plate runout Maximum allowable runout: Refer to EM-124, “FLYWHEEL/DRIVE PLATE RUNOUT”. If this runout is out of specification, replace drive plate with ring gear.

SAT977H

AT-272

REMOVAL AND INSTALLATION Installation (Cont’d)

쐌

When connecting torque converter to transmission, measure distance “A” to be certain that they are correctly assembled. Distance “A”: VG33E only: 26.0 mm (1.024 in) or more VG33ER only: 25.0 mm (0.984 in) or more

GI MA EM LC

SAT017B

쐌 쐌

Install converter to drive plate. After converter is installed to drive plate, rotate crankshaft several turns and check to be sure that transmission rotates freely without binding.

EC FE CL MT

SAT006G

쐌

SAT553H

Tighten bolts securing transmission. Bolt No.

Tightening torque N·m (kg-m, ft-lb)

Bolt length “” mm (in)

1

39 - 49 (4.0 - 5.0, 29 - 36)

47.5 (1.870)

2

39 - 49 (4.0 - 5.0, 29 - 36)

58.0 (2.283)

3

29 - 39 (3.0 - 4.0, 22 - 29)

25.0 (0.984)

Gusset (if equipped) to engine

29 - 39 (3.0 - 4.0, 22 - 29)

20.0 (0.787)

쐌

TF PD AX

Reinstall any part removed.

SU BR ST RS 쐌 쐌

쐌

Check fluid level in transmission. Move selector lever through all positions to be sure that transmission operates correctly. With parking brake applied, rotate engine at idling. Move selector lever through N to D, to 2, to 1 and to R positions. A slight shock should be felt by hand gripping selector each time transmission is shifted. Perform road test. Refer to “Road Test”, AT-66.

BT HA SC EL

SAT638A

AT-273

IDX

OVERHAUL Components

Components

NGAT0108

WAT515

AT-274

OVERHAUL Components (Cont’d)

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC LAT438

EL

AT-275

IDX

OVERHAUL Oil Channel

Oil Channel

NGAT0109

SAT185B

AT-276

OVERHAUL Locations of Needle Bearings, Thrust Washers and Snap Rings

Locations of Needle Bearings, Thrust Washers and Snap Rings

NGAT0110

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL WAT378

AT-277

IDX

NGAT0111

DISASSEMBLY 1. 2. 3.

Drain ATF through drain plug. Remove turbine revolution sensor (VG33ER only). Remove torque converter by holding it firmly and turning while pulling straight out.

4. a. b.

Check torque converter one-way clutch. Insert Tool into spline of one-way clutch inner race. Hook bearing support unitized with one-way clutch outer race with suitable wire. Check that one-way clutch inner race rotates only clockwise with Tool while holding bearing support with wire.

SAT018B

c.

SAT521G

5.

Remove park/neutral position (PNP) switch from transmission case.

6. 쐌

Remove oil pan. Always place oil pan straight down so that foreign particles inside will not move. Always replace oil pan bolts as they are self-sealing bolts.

AAT562A

쐌

SAT186BA

SAT754IA

AT-278

DISASSEMBLY 7.

Place transmission into Tool with the control valve facing up.

GI MA EM LC

SAT522G

8.

쐌

Check foreign materials in oil pan to help determine cause of malfunction. If the fluid is very dark, smells burned, or contains foreign particles, the frictional material (clutches, band) may need replacement. A tacky film that will not wipe clean indicates varnish build up. Varnish can cause valves, servo, and clutches to stick and may inhibit pump pressure. If frictional material is detected, replace radiator after repair of A/T. Refer to LC-14, “Radiator”.

EC FE CL MT

SAT171B

9. 쐌

Remove torque converter clutch solenoid valve and A/T fluid temperature sensor connectors. Be careful not to damage connector.

TF PD AX AAT561A

10. Remove oil strainer. a. Remove oil strainer from control valve assembly. Then remove O-ring from oil strainer.

SU BR ST RS

SAT008B

b.

Check oil strainer screen for damage.

BT HA SC EL

SAT025B

AT-279

IDX

DISASSEMBLY 11. Remove control valve assembly. a. Straighten terminal clips to free terminal cords then remove terminal clips.

SAT009B

b.

Remove bolts A and B, and remove control valve assembly from transmission. Bolt symbol

Length mm (in)

A

33 (1.30)

B

45 (1.77)

SAT353B

c. 쐌

Remove solenoid connector. Be careful not to damage connector.

d.

Remove manual valve from control valve assembly.

SAT026B

SAT127B

AT-280

DISASSEMBLY 12. Remove terminal cord assembly from transmission case while pushing on stopper. 쐌 Be careful not to damage cord. 쐌 Do not remove terminal cord assembly unless it is damaged.

GI MA EM LC

SAT128B

13. Remove converter housing from transmission case. 쐌 Be careful not to scratch converter housing.

EC FE CL MT

SAT999A

14. Remove O-ring from input shaft.

TF PD AX SAT995A

15. Remove oil pump assembly. a. Attach Tool to oil pump assembly and extract it evenly from transmission case.

SU BR ST RS

SAT027B

b. c. 쐌

Remove O-ring from oil pump assembly. Remove traces of sealant from oil pump housing. Be careful not to scratch pump housing.

BT HA SC EL

SAT028B

AT-281

IDX

DISASSEMBLY d.

Remove needle bearing and thrust washer from oil pump assembly.

SAT108B

16. Remove input shaft and oil pump gasket.

SAT988A

17. Remove brake band and band strut. a. Loosen lock nut and remove band servo anchor end pin from transmission case.

SAT029B

b.

Remove brake band and band strut from transmission case.

c.

Hold brake band in a circular shape with clip.

SAT986A

SAT655

AT-282

DISASSEMBLY 18. Remove front side clutch and gear components. a. Remove clutch pack (reverse clutch, high clutch and front sun gear) from transmission case.

GI MA EM LC

SAT030B

b. c.

Remove front bearing race from clutch pack. Remove rear bearing race from clutch pack.

EC FE CL MT

SAT113B

d.

Remove front planetary carrier from transmission case.

TF PD AX SAT031B

e. f.

Remove front needle bearing from front planetary carrier. Remove rear bearing from front planetary carrier.

SU BR ST RS

SAT968A

g.

Remove rear sun gear from transmission case.

BT HA SC EL

SAT974A

AT-283

IDX

DISASSEMBLY 19. Remove rear extension or adapter case. a. Remove rear extension or adapter case from transmission case. b. Remove rear extension or adapter case gasket from transmission case.

SAT716C

c. 쐌

Remove oil seal from adapter case or rear extension. Do not remove oil seal unless it is to be replaced.

d.

Remove revolution sensor from adapter case or rear extension. Remove O-ring from revolution sensor.

SAT146GA

e.

SAT147G

20. Remove output shaft and parking gear. a. Remove rear snap ring from output shaft.

SAT960A

AT-284

DISASSEMBLY b. 쐌 c.

Slowly push output shaft all the way forward. Do not use excessive force. Remove snap ring from output shaft.

GI MA EM LC

SAT957A

d. e.

Remove output shaft and parking gear as a unit from transmission case. Remove parking gear from output shaft.

EC FE CL MT

SAT109B

f.

Remove needle bearing from transmission case.

TF PD AX SAT033B

21. Remove rear side clutch and gear components. a. Remove front internal gear.

SU BR ST RS

SAT954A

b.

Remove bearing race from front internal gear.

BT HA SC EL

SAT110B

AT-285

IDX

DISASSEMBLY c.

Remove needle bearing from rear internal gear.

d.

Remove rear internal gear, forward clutch hub and overrun clutch hub as a set from transmission case.

e. f.

Remove needle bearing from overrun clutch hub. Remove overrun clutch hub from rear internal gear and forward clutch hub.

g.

Remove thrust washer from overrun clutch hub.

h.

Remove forward clutch assembly from transmission case.

SAT111B

SAT951A

SAT148G

SAT036B

SAT037B

AT-286

DISASSEMBLY 22. Remove band servo and accumulator components. a. Remove band servo retainer from transmission case.

GI MA EM LC

SAT038B

b. 쐌 c.

Apply compressed air to oil hole until band servo piston comes out of transmission case. Hold piston with a rag and gradually direct air to oil hole. Remove return springs.

EC FE CL MT

SAT039B

d. e. 쐌

Remove springs from accumulator pistons B, C and D. Apply compressed air to each oil hole until piston comes out. Hold piston with a rag and gradually direct air to oil hole.

Identification of accumulator pistons

A

B

C

D

Identification of oil holes

a

b

c

d

TF PD AX

SAT040BA

f.

Remove O-ring from each piston.

SU BR ST RS

SAT523GA

23. Remove manual shaft components, if necessary. a. Hold width across flats of manual shaft (outside the transmission case) and remove lock nut from shaft.

BT HA SC EL

SAT041B

AT-287

IDX

DISASSEMBLY b.

Remove retaining pin from transmission case.

c.

While pushing detent spring down, remove manual plate and parking rod from transmission case.

d.

Remove manual shaft from transmission case.

e.

Remove spacer and detent spring from transmission case.

f.

Remove oil seal from transmission case.

SAT042B

SAT935A

SAT043B

SAT934A

SAT044B

AT-288

REPAIR FOR COMPONENT PARTS Oil Pump

Oil Pump COMPONENTS

NGAT0112

GI MA EM LC EC FE CL

WAT379

DISASSEMBLY 1.

MT

NGAT0113

Loosen bolts in numerical order and remove oil pump cover.

TF PD AX SAT649A

2. 쐌

Remove rotor, vane rings and vanes. Inscribe a mark on back of rotor for identification of foreaft direction when reassembling rotor. Then remove rotor.

SU BR ST RS

SAT650A

3. 쐌

While pushing on cam ring remove pivot pin. Be careful not to scratch oil pump housing.

BT HA SC EL

SAT651A

AT-289

IDX

REPAIR FOR COMPONENT PARTS Oil Pump (Cont’d)

4. 쐌 쐌

While holding cam ring and spring lift out cam ring spring. Be careful not to damage oil pump housing. Hold cam ring spring to prevent it from jumping.

5.

Remove cam ring and cam ring spring from oil pump housing.

6.

Remove pivot pin from control piston and remove control piston assembly.

7. 쐌

Remove oil seal from oil pump housing. Be careful not to scratch oil pump housing.

SAT652A

SAT653A

SAT654A

SAT655A

INSPECTION NGAT0114 Oil Pump Cover, Rotor, Vanes, Control Piston, Side Seals, Cam Ring and Friction Ring NGAT0114S01 쐌

Check for wear or damage.

SAT656A

AT-290

REPAIR FOR COMPONENT PARTS Oil Pump (Cont’d)

Side Clearances 쐌

쐌

SAT657A

쐌

Seal Ring Clearance 쐌

SAT658A

쐌

GI MA EM LC EC

NGAT0114S03

Measure clearance between seal ring and ring groove. Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Wear limit: 0.25 mm (0.0098 in) If not within wear limit, replace oil pump cover assembly.

ASSEMBLY 1. 쐌

NGAT0114S02

Measure side clearances between end of oil pump housing and cam ring, rotor, vanes and control piston. Measure in at least four places along their circumferences. Maximum measured values should be within specified positions. Before measurement, check that friction rings, O-ring, control piston side seals and cam ring spring are removed. Standard clearance (Cam ring, rotor, vanes and control piston): Refer to “SERVICE DATA AND SPECIFICATIONS (SDS)”, AT-353. If not within standard clearance, replace oil pump assembly except oil pump cover assembly.

FE CL MT

NGAT0115

Drive oil seal into oil pump housing. Apply ATF to outer periphery and lip surface.

TF PD AX SAT081E

2. a. 쐌 쐌 b.

Install cam ring in oil pump housing by the following Install side seal on control piston. Pay attention to its direction — Black surface goes toward control piston. Apply petroleum jelly to side seal. Install control piston on oil pump.

SU BR ST RS

SAT654A

c. 쐌

Install O-ring and friction ring on cam ring. Apply petroleum jelly to O-ring.

BT HA SC EL

SAT660A

AT-291

IDX

REPAIR FOR COMPONENT PARTS Oil Pump (Cont’d)

d.

Assemble cam ring, cam ring spring and spring seat. Install spring by pushing it against pump housing.

e.

While pushing on cam ring install pivot pin.

3. 쐌

Install rotor, vanes and vane rings. Pay attention to direction of rotor.

4. a.

Install oil pump housing and oil pump cover. Wrap masking tape around splines of oil pump cover assembly to protect seal. Position oil pump cover assembly in oil pump housing assembly, then remove masking tape. Tighten bolts in a criss-cross pattern.

SAT661A

SAT651A

SAT662A

b.

SAT649A

5. 쐌

쐌

Install new seal rings carefully after packing ring grooves with petroleum jelly. Press rings down into jelly to a close fit. Seal rings come in two different diameters. Check fit carefully in each groove. Small dia. seal ring: No mark Large dia. seal ring: Yellow mark in area shown by arrow Do not spread gap of seal ring excessively while installing. It may deform ring.

SAT663A

AT-292

REPAIR FOR COMPONENT PARTS Control Valve Assembly

Control Valve Assembly COMPONENTS

NGAT0116

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SC EL WAT380

AT-293

IDX

REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont’d)

DISASSEMBLY 1. a.

NGAT0117

b.

Remove solenoids. Remove torque converter clutch solenoid valve and side plate from lower body. Remove O-ring from solenoid.

c. d.

Remove line pressure solenoid valve from upper body. Remove O-ring from solenoid.

e. f.

Remove 3-unit solenoid assembly from upper body. Remove O-rings from solenoids.

2. a.

Disassemble upper and lower bodies. Place upper body facedown, and remove bolts, reamer bolts, side plate and support plates. Remove lower body and separator plate as a unit from upper body. Be careful not to drop pilot filter, orifice check valve, spring and steel balls.

SAT194B

SAT667A

SAT043G

b. 쐌

SAT195B

c. d.

Place lower body facedown, and remove separator plate. Remove pilot filter, orifice check valve and orifice check spring.

SAT670A

AT-294

REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont’d)

e.

Check to see that steel balls are properly positioned in upper body. Then remove them from upper body.

GI MA EM LC

SAT671A

INSPECTION Lower and Upper Bodies 쐌

NGAT0118 NGAT0118S01

Check to see that there are pins and retainer plates in lower body.

EC FE CL MT

SAT672A

쐌 쐌

Check to see that there are pins and retainer plates in upper body. Be careful not to lose these parts.

TF PD AX SAT673A

쐌 쐌

Check to make sure that oil circuits are clean and free from damage. Check tube brackets and tube connectors for damage.

SU BR ST RS

SAT674A

Separator Plate 쐌

NGAT0118S02

Make sure that separator plate is free of damage and not deformed and oil holes are clean.

BT HA SC EL

SAT675A

AT-295

IDX

REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont’d)

Pilot Filter 쐌

NGAT0118S03

Check to make sure that filter is not clogged or damaged.

SAT676A

Torque Converter Clutch Solenoid Valve 쐌 쐌

Line Pressure Solenoid Valve 쐌 쐌

NGAT0118S04

Check that filter is not clogged or damaged. Measure resistance. Refer to “Component Inspection”, AT-152. NGAT0118S05

Check that filter is not clogged or damaged. Measure resistance. Refer to “Component Inspection”, AT-164.

SAT149G

3-Unit Solenoid Assembly (Overrun Clutch Solenoid Valve and Shift Solenoid Valves A and B) NGAT0118S06 쐌

Measure resistance of each solenoid. Refer to “Component Inspection”, AT-173, 178, 192.

SAT095B

A/T Fluid Temperature Sensor 쐌

NGAT0118S07

Measure resistance. Refer to “Component Inspection”, AT-115.

SAT196BA

ASSEMBLY 1. a.

NGAT0119

Install upper and lower bodies. Place oil circuit of upper body face up. Install steel balls in their proper positions.

SAT671A

AT-296

REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont’d)

b.

Install reamer bolts from bottom of upper body.

GI MA EM LC

SAT681A

c.

Place oil circuit of lower body face up. Install orifice check spring, orifice check valve and pilot filter.

EC FE CL MT

TF PD AX SAT682A

d. e.

Install separator plate on lower body. Install and temporarily tighten support plates, fluid temperature sensor and tube brackets.

SU BR ST RS

SAT197B

f. 쐌

Temporarily assemble lower and upper bodies, using reamer bolt as a guide. Be careful not to dislocate or drop steel balls, orifice check spring, orifice check valve and pilot filter.

BT HA SC EL

SAT198B

AT-297

IDX

REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont’d)

g.

Install and temporarily tighten bolts and tube brackets in their proper locations. Bolt length and location: Bolt symbol Bolt length mm (in)

a

b

c

d

70 (2.76)

50 (1.97)

33 (1.30)

27 (1.06)

SAT199BA

2. a.

Install solenoids. Attach O-ring and install torque converter clutch solenoid valve and side plates onto lower body.

b.

Attach O-rings and install 3-unit solenoids assembly onto upper body. Attach O-ring and install line pressure solenoid valve onto upper body. Tighten all bolts.

SAT200B

c. 3.

SAT150G

AT-298

REPAIR FOR COMPONENT PARTS Control Valve Upper Body

Control Valve Upper Body COMPONENTS

NGAT0120

GI MA EM LC EC FE CL MT

TF PD AX SU BR ST RS BT HA SAT142J

Apply ATF to all components before their installation. Numbers preceding valve springs correspond with those shown in SDS on page AT-349.

AT-299

SC EL IDX

REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont’d)

DISASSEMBLY

NGAT0121

1. 쐌

Remove valves at parallel pins. Do not use a magnetic hand.

a.

Use a wire paper clip to push out parallel pins.

b.

Remove parallel pins while pressing their corresponding plugs and sleeves. Remove plug slowly to prevent internal parts from jumping out.

SAT834A

SAT822A

쐌

SAT823A

c.

쐌

Place mating surface of valve facedown, and remove internal parts. If a valve is hard to remove, place valve body facedown and lightly tap it with a soft hammer. Be careful not to drop or damage valves and sleeves.

2. a.

Remove valves at retainer plates. Pry out retainer plate with wire paper clip.

쐌

SAT824A

SAT825A

AT-300

REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont’d)

b.

Remove retainer plates while holding spring.

GI MA EM LC

SAT826A

c. 쐌 쐌

Place mating surface of valve facedown, and remove internal parts. If a valve is hard to remove, lightly tap valve body with a soft hammer. Be careful not to drop or damage valves, sleeves, etc.

EC FE CL MT

SAT827A

쐌 쐌

4-2 sequence valve and relay valve are located far back in upper body. If they are hard to remove, carefully push them out using stiff wire. Be careful not to scratch sliding surface of valve with wire.

TF PD AX

SAT828A

INSPECTION Valve Springs 쐌

쐌

SU

NGAT0122S01

Measure free length and outer diameter of each valve spring. Also check for damage or deformation. Inspection standard: Refer to “Return Springs”, AT-349. Replace valve springs if deformed or fatigued.

Control Valves 쐌

NGAT0122

NGAT0122S02

Check sliding surfaces of valves, sleeves and plugs.

BR ST RS

SAT829A

ASSEMBLY 1. 쐌

NGAT0123

Lubricate the control valve body and all valves with ATF. Install control valves by sliding them carefully into their bores. Be careful not to scratch or damage valve body.

BT HA SC EL

SAT830A

AT-301

IDX

REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont’d)

쐌

Wrap a small screwdriver with vinyl tape and use it to insert the valves into proper position.

SAT831A

Pressure regulator valve 쐌 If pressure regulator plug is not centered properly, sleeve cannot be inserted into bore in upper body. If this happens, use vinyl tape wrapped screwdriver to center sleeve until it can be inserted. 쐌 Turn sleeve slightly while installing.

SAT832A

Accumulator control plug 쐌 Align protrusion of accumulator control sleeve with notch in plug. 쐌 Align parallel pin groove in plug with parallel pin, and install accumulator control valve.

SAT833A

2.

Install parallel pins and retainer plates.

쐌

While pushing plug, install parallel pin.

SAT834A

SAT823A

AT-302

REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont’d)

4-2 sequence valve and relay valve 쐌 Push 4-2 sequence valve and relay valve with wire wrapped in vinyl tape to prevent scratching valve body. Install parallel pins.

GI MA EM LC

SAT835A

쐌

Insert retainer plate while pushing spring.

EC FE CL MT

SAT836A

TF PD AX SU BR ST RS BT HA SC EL

AT-303

IDX

REPAIR FOR COMPONENT PARTS Control Valve Lower Body

Control Valve Lower Body COMPONENTS

NGAT0124

SAT966I

Apply ATF to all components before their installation. Numbers preceding valve springs correspond with those shown in SDS on page AT-349.

AT-304

REPAIR FOR COMPONENT PARTS Control Valve Lower Body (Cont’d)

DISASSEMBLY 1. 2.

NGAT0125

Remove valves at parallel pins. Remove valves at retainer plates. For removal procedures, refer to “DISASSEMBLY”, AT-300.

GI MA EM LC

SAT838A

INSPECTION Valve Springs 쐌

쐌

SAT829A

EC FE CL

NGAT0126S02

Check sliding surfaces of control valves, sleeves and plugs for damage.

ASSEMBLY 쐌

NGAT0126S01

Check each valve spring for damage or deformation. Also measure free length and outer diameter. Inspection standard: Refer to “Return Springs”, AT-349. Replace valve springs if deformed or fatigued.

Control Valves 쐌

NGAT0126

MT

NGAT0127

Install control valves. For installation procedures, refer to “ASSEMBLY”, AT-301.

TF PD AX SAT838A

SU BR ST RS BT HA SC EL

AT-305

IDX

REPAIR FOR COMPONENT PARTS Reverse Clutch

Reverse Clutch COMPONENTS

NGAT0128

LAT441

DISASSEMBLY 1. a. b. c. 쐌 쐌 쐌

NGAT0129

Check operation of reverse clutch. Install seal ring onto oil pump cover and install reverse clutch. Apply compressed air to oil hole. Check to see that retaining plate moves to snap ring. If retaining plate does not contact snap ring, D-ring might be damaged. Oil seal might be damaged. Fluid might be leaking past piston check ball.

SAT841A

2.

Remove drive plates, driven plates, retaining plate, dish plate and snap ring.

SAT842A

AT-306

REPAIR FOR COMPONENT PARTS Reverse Clutch (Cont’d)

3. 쐌 4.

Remove snap ring from clutch drum while compressing clutch springs. Do not expand snap ring excessively. Remove spring retainer and return spring.

GI MA EM LC

SAT524G

5. 쐌 6.

Install seal ring onto oil pump cover and install reverse clutch drum. While holding piston, gradually apply compressed air to oil hole until piston is removed. Do not apply compressed air abruptly. Remove D-ring and oil seal from piston.

EC FE CL MT

SAT844A

INSPECTION Reverse Clutch Snap Ring and Spring Retainer 쐌

NGAT0130 NGAT0130S01

Check for deformation, fatigue or damage.

TF PD AX Reverse Clutch Return Springs (VG33E only) 쐌

NGAT0130S02

Check for deformation or damage. Also measure free length and outside diameter. Inspection standard: Refer to “Return Springs”, AT-349.

SU BR ST RS

SAT829A

Reverse Clutch Drive Plates 쐌 쐌

쐌

Reverse Clutch Dish Plate 쐌

NGAT0130S03

Check facing for burns, cracks or damage. Measure thickness of facing. Thickness of drive plate: Standard value: 1.90 - 2.05 mm (0.0748 - 0.0807 in) Wear limit: 1.80 mm (0.0709 in) If not within wear limit, replace. NGAT0130S04

BT HA SC EL

Check for deformation or damage.

SAT845A

AT-307

IDX

REPAIR FOR COMPONENT PARTS Reverse Clutch (Cont’d)

Reverse Clutch Piston 쐌 쐌 쐌

NGAT0130S05

Shake piston to assure that balls are not seized. Apply compressed air to check ball oil hole opposite the return spring. Make sure there is no air leakage. Also apply compressed air to oil hole on return spring side to assure that air leaks past ball.

SAT846A

ASSEMBLY

NGAT0131

1. 쐌

Install D-ring and oil seal on piston. Apply ATF to both parts.

2. 쐌

Install piston assembly by turning it slowly and evenly. Apply ATF to inner surface of drum.

3.

Install return springs and spring retainer (VG33E only) or spring retainer (VG33ER only).

4.

Install snap ring while compressing clutch springs.

SAT847A

SAT848A

SAT849A

SAT524G

AT-308

REPAIR FOR COMPONENT PARTS Reverse Clutch (Cont’d)

쐌

Do not align snap ring gap with spring retainer stopper.

GI MA EM LC

SAT850A

5. 6.

Install drive plates, driven plates, retaining plate and dish plate. Install snap ring.

EC FE CL MT

SAT842A

7.

Measure clearance between retaining plate and snap ring. If not within allowable limit, select proper retaining plate. Specified clearance: Standard 0.5 - 0.8 mm (0.020 - 0.031 in) Allowable limit 1.2 mm (0.047 in) Retaining plate: Refer to “REVERSE CLUTCH”, AT-350.

TF PD AX

SAT852A

8.

Check operation of reverse clutch. Refer to “DISASSEMBLY”, AT-306.

SU BR ST RS

SAT841A

BT HA SC EL

AT-309

IDX

REPAIR FOR COMPONENT PARTS High Clutch

High Clutch COMPONENTS

NGAT0132

LAT437

DISASSEMBLY AND ASSEMBLY

NGAT0133

Service procedures for high clutch are essentially the same as those for reverse clutch, with the following exception:

SAT853A

쐌

Check of high clutch operation

SAT854A

AT-310

REPAIR FOR COMPONENT PARTS High Clutch (Cont’d)

쐌

Removal and installation of return spring

GI MA EM LC

SAT525G

쐌

Inspection of high clutch return springs Inspection standard: Refer to “Return Springs”, AT-349.

EC FE CL MT

SAT829A

쐌

Inspection of high clutch drive plate Thickness of drive plate: Standard 1.52 - 1.67 mm (0.0598 - 0.0657 in) Wear limit 1.40 mm (0.0551 in)

TF PD AX

SAT845A

쐌

SAT858A

Measurement of clearance between retaining plate and snap ring Specified clearance: Standard 1.8 - 2.2 mm (0.071 - 0.087 in) Allowable limit VG33E only: 2.8 mm (0.110 in) VG33ER only: 2.2 mm (0.087 in) Retaining plate: Refer to “HIGH CLUTCH”, AT-351.

SU BR ST RS BT HA SC EL

AT-311

IDX

REPAIR FOR COMPONENT PARTS Forward and Overrun Clutches

Forward and Overrun Clutches COMPONENTS

NGAT0134

LAT422

AT-312

REPAIR FOR COMPONENT PARTS Forward and Overrun Clutches (Cont’d)

DISASSEMBLY AND ASSEMBLY

NGAT0135

Forward and overrun clutches are serviced essentially the same way as reverse clutch is serviced. However, note the following exceptions. 쐌 Check of forward clutch operation

GI MA EM LC

SAT860A

쐌

Check of overrun clutch operation

EC FE CL MT

SAT861A

쐌

Removal of forward clutch drum Remove forward clutch drum from transmission case by holding snap ring.

TF PD AX SAT865A

쐌 a)

Removal of forward clutch and overrun clutch pistons While holding overrun clutch piston, gradually apply compressed air to oil hole.

SU BR ST RS

SAT862A

b)

Remove overrun clutch from forward clutch.

BT HA SC EL

SAT863A

AT-313

IDX

REPAIR FOR COMPONENT PARTS Forward and Overrun Clutches (Cont’d)

쐌

Removal and installation of return springs

쐌

Inspection of forward clutch and overrun clutch return springs Inspection standard: Refer to “Return Springs”, AT-349.

쐌

Inspection of forward clutch drive plates Thickness of drive plate: Standard 1.52 - 1.67 mm (0.0598 - 0.0657 in) Wear limit 1.40 mm (0.0551 in)

쐌

Inspection of overrun clutch drive plates Thickness of drive plate: Standard 1.90 - 2.05 mm (0.0748 - 0.0807 in) Wear limit 1.80 mm (0.0709 in)

쐌 a) 쐌

Installation of forward clutch piston and overrun clutch piston Install forward clutch piston by turning it slowly and evenly. Apply ATF to inner surface of clutch drum.

SAT526G

SAT829A

SAT845A

SAT845A

SAT866A

AT-314

REPAIR FOR COMPONENT PARTS Forward and Overrun Clutches (Cont’d)

쐌

Align notch in forward clutch piston with groove in forward clutch drum.

GI MA EM LC

SAT867A

b) 쐌

Install overrun clutch by turning it slowly and evenly. Apply ATF to inner surface of forward clutch piston.

EC FE CL MT

SAT868A

쐌

SAT869A

쐌

SAT870A

Measurement of clearance between retaining plate and snap ring of overrun clutch Specified clearance: Standard 1.0 - 1.4 mm (0.039 - 0.055 in) Allowable limit VG33E only: 2.0 mm (0.079 in) VG33ER only: 2.4 mm (0.094 in) Retaining plate: Refer to “FORWARD CLUTCH”, AT-352. Measurement of clearance between retaining plate and snap ring of forward clutch Specified clearance: Standard 0.35 - 0.75 mm (0.0138 - 0.0295 in) Allowable limit VG33E only: Model 43X64 (2WD) 1.95 mm (0.077 in) VG33E only: Model 4EX01, 4FX06 (4WD) 2.15 mm (0.085 in) VG33ER only: Model 4EX67 (2WD) 2.15 mm (0.085 in) VG33ER only: Model 4EX68, 4FX07 (4WD) 2.35 mm (0.093 in) Retaining plate: Refer to “FORWARD CLUTCH”, AT-351.

TF PD AX SU BR ST RS BT HA SC EL

AT-315

IDX

REPAIR FOR COMPONENT PARTS Low & Reverse Brake

Low & Reverse Brake COMPONENTS

NGAT0136

LAT423

DISASSEMBLY 1. a. b. c. 쐌 쐌 쐌

NGAT0137

Check operation of low and reverse brake. Install seal ring onto oil pump cover and install reverse clutch. Apply compressed air to oil hole. Check to see that retaining plate moves to snap ring. If retaining plate does not contact snap ring, D-ring might be damaged. Oil seal might be damaged. Fluid might be leaking past piston check ball.

SAT872A

2.

Remove snap ring, low and reverse brake drive plates, driven plates and dish plate.

SAT873A

AT-316

REPAIR FOR COMPONENT PARTS Low & Reverse Brake (Cont’d)

3. 4. 5.

Remove low one-way clutch inner race, spring retainer and return spring from transmission case. Remove seal rings from low one-way clutch inner race. Remove needle bearing from low one-way clutch inner race.

GI MA EM LC

SAT382I

6. 7.

Remove low and reverse brake piston using compressed air. Remove oil seal and D-ring from piston.

EC FE CL MT

SAT876A

INSPECTION NGAT0138 Low and Reverse Brake Snap Ring and Spring Retainer NGAT0138S01 쐌

Check for deformation, or damage.

TF PD AX Low and Reverse Brake Return Springs 쐌

NGAT0138S02

Check for deformation or damage. Also measure free length and outside diameter. Inspection standard: Refer to “Return Springs”, AT-349.

SU BR ST RS

SAT829A

Low and Reverse Brake Drive Plates 쐌 쐌

쐌

Check facing for burns, cracks or damage. Measure thickness of facing. Thickness of drive plate: Standard value 1.52 - 1.67 mm (0.0598 - 0.0657 in) Wear limit 1.40 mm (0.0551 in) If not within wear limit, replace.

NGAT0138S03

BT HA SC EL

SAT845A

AT-317

IDX

REPAIR FOR COMPONENT PARTS Low & Reverse Brake (Cont’d)

Low One-way Clutch Inner Race

NGAT0138S04

쐌

Check frictional surface of inner race for wear or damage.

쐌 쐌 쐌

Install a new seal rings onto low one-way clutch inner race. Be careful not to expand seal ring gap excessively. Measure seal ring-to-groove clearance. Inspection standard: Standard value: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Allowable limit: 0.25 mm (0.0098 in) If not within allowable limit, replace low one-way clutch inner race.

SAT877A

쐌

SAT878A

ASSEMBLY 1. 쐌

NGAT0139

쐌

Install needle bearing onto one-way clutch inner race. Pay attention to its direction — Black surface goes to rear side. Apply petroleum jelly to needle bearing.

2. 쐌

Install oil seal and D-ring onto piston. Apply ATF to oil seal and D-ring.

3. 쐌

Install piston by rotating it slowly and evenly. Apply ATF to inner surface of transmission case.

SAT112B

SAT879A

SAT880A

AT-318

REPAIR FOR COMPONENT PARTS Low & Reverse Brake (Cont’d)

4. 5. 6.

Install return springs, spring retainer and low one-way clutch inner race onto transmission case. Install dish plate, low and reverse brake drive plates, driven plates and retaining plate. Install snap ring on transmission case.

GI MA EM LC

SAT881A

7.

Check operation of low and reverse brake clutch piston. Refer to “DISASSEMBLY”, AT-316.

EC FE CL MT

SAT872A

8.

SAT885A

9. 쐌 쐌

Measure clearance between retaining plate and snap ring. If not within allowable limit, select proper retaining plate. Specified clearance: Standard 0.8 - 1.1 mm (0.031 - 0.043 in) Allowable limit VG33E only: 2.5 mm (0.098 in) VG33ER only: 2.7 mm (0.106 in) Retaining plate: Refer to “LOW & REVERSE BRAKE”, AT-352. Install low one-way clutch inner race seal ring. Apply petroleum jelly to seal ring. Make sure seal rings are pressed firmly into place and held by petroleum jelly.

TF PD AX SU BR ST RS

SAT884A

BT HA SC EL

AT-319

IDX

REPAIR FOR COMPONENT PARTS Forward Clutch Drum Assembly

Forward Clutch Drum Assembly COMPONENTS

NGAT0140

SAT211GA

DISASSEMBLY 1. 2.

Remove snap ring from forward clutch drum. Remove side plate from forward clutch drum.

3. 4.

Remove low one-way clutch from forward clutch drum. Remove snap ring from forward clutch drum.

5.

Remove needle bearing from forward clutch drum.

SAT212G

SAT213G

SAT891A

AT-320

NGAT0141

REPAIR FOR COMPONENT PARTS Forward Clutch Drum Assembly (Cont’d)

INSPECTION Forward Clutch Drum 쐌 쐌

NGAT0142 NGAT0142S01

Check spline portion for wear or damage. Check frictional surfaces of low one-way clutch and needle bearing for wear or damage.

GI MA EM LC

SAT892A

Needle Bearing and Low One-way Clutch 쐌

NGAT0142S02

Check frictional surface for wear or damage.

EC FE CL MT

SAT893A

ASSEMBLY 1. 2.

NGAT0143

Install needle bearing in forward clutch drum. Install snap ring onto forward clutch drum.

TF PD AX SAT214G

3.

Install low one-way clutch onto forward clutch drum by pushing the roller in evenly.

SU BR ST RS

SAT894A

쐌

Install low one-way clutch with flange facing rearward.

BT HA SC EL

SAT895A

AT-321

IDX

REPAIR FOR COMPONENT PARTS Forward Clutch Drum Assembly (Cont’d)

4. 5.

Install side plate onto forward clutch drum. Install snap ring onto forward clutch drum.

SAT887A

Rear Internal Gear and Forward Clutch Hub COMPONENTS

NGAT0144

SAT896AA

DISASSEMBLY

NGAT0145

1.

Remove rear internal gear by pushing forward clutch hub forward.

2.

Remove thrust washer from rear internal gear.

SAT897A

SAT898A

AT-322

REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub (Cont’d)

3.

Remove snap ring from forward clutch hub.

GI MA EM LC

SAT899A

4.

Remove end bearing.

EC FE CL MT

SAT900A

5.

Remove forward one-way clutch and end bearing as a unit from forward clutch hub.

TF PD AX SAT955A

6.

Remove snap ring from forward clutch hub.

SU BR ST RS

SAT901A

INSPECTION Rear Internal Gear and Forward Clutch Hub 쐌 쐌 쐌

NGAT0146

BT

NGAT0146S01

Check gear for excessive wear, chips or cracks. Check frictional surfaces of forward one-way clutch and thrust washer for wear or damage. Check spline for wear or damage.

HA SC EL

SAT902A

AT-323

IDX

REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub (Cont’d)

Snap Ring and End Bearing 쐌

NGAT0146S02

Check for deformation or damage.

ASSEMBLY

NGAT0147

1.

Install snap ring onto forward clutch hub.

2.

Install end bearing.

3. 쐌 4. 5.

Install forward one-way clutch onto clutch hub. Install forward one-way clutch with flange facing rearward. Install end bearing. Install snap ring onto forward clutch hub.

6. 쐌 쐌

Install thrust washer onto rear internal gear. Apply petroleum jelly to thrust washer. Securely insert pawls of thrust washer into holes in rear internal gear.

7.

Position forward clutch hub in rear internal gear.

SAT903A

SAT901A

SAT904A

SAT906A

SAT907A

AT-324

REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub (Cont’d)

8.

After installing, check to assure that forward clutch hub rotates clockwise.

GI MA EM LC

SAT905A

Band Servo Piston Assembly COMPONENTS

NGAT0148

EC FE CL MT

TF PD SAT908AC

DISASSEMBLY 1. 2. 3.

NGAT0149

Block one oil hole in OD servo piston retainer and the center hole in OD band servo piston. Apply compressed air to the other oil hole in piston retainer to remove OD band servo piston from retainer. Remove D-ring from OD band servo piston.

AX SU BR ST RS

SAT909A

4.

Remove band servo piston assembly from servo piston retainer by pushing it forward.

BT HA SC EL

SAT910A

AT-325

IDX

REPAIR FOR COMPONENT PARTS Band Servo Piston Assembly (Cont’d)

5.

Place piston stem end on a wooden block. While pushing servo piston spring retainer down, remove E-ring.

6.

Remove servo piston spring retainer, return spring C and piston stem from band servo piston.

7.

Remove E-ring from band servo piston.

SAT911A

SAT912A

SAT913A

8. Remove servo cushion spring retainer from band servo piston. 9. Remove D-rings from band servo piston. 10. Remove O-rings from servo piston retainer.

SAT914A

INSPECTION Pistons, Retainers and Piston Stem 쐌

NGAT0150 NGAT0150S01

Check frictional surfaces for abnormal wear or damage.

SAT915A

AT-326

REPAIR FOR COMPONENT PARTS Band Servo Piston Assembly (Cont’d)

Return Springs 쐌

NGAT0150S02

Check for deformation or damage. Measure free length and outer diameter. Inspection standard: Refer to “Return Springs”, AT-349.

GI MA EM LC

SAT916AA

ASSEMBLY 1. 쐌 쐌

NGAT0151

Install O-rings onto servo piston retainer. Apply ATF to O-rings. Pay attention to position of each O-ring.

EC FE CL MT

SAT917A

2.

Install servo cushion spring retainer onto band servo piston.

TF PD AX SAT918A

3.

Install E-ring onto servo cushion spring retainer.

SU BR ST RS

SAT919A

4. 쐌

Install D-rings onto band servo piston. Apply ATF to D-rings.

BT HA SC EL

SAT920A

AT-327

IDX

REPAIR FOR COMPONENT PARTS Band Servo Piston Assembly (Cont’d)

5.

Install servo piston spring retainer, return spring C and piston stem onto band servo piston.

6.

Place piston stem end on a wooden block. While pushing servo piston spring retainer down, install E-ring.

7.

Install band servo piston assembly onto servo piston retainer by pushing it inward.

8. 쐌

Install D-ring on OD band servo piston. Apply ATF to D-ring.

9.

Install OD band servo piston onto servo piston retainer by pushing it inward.

SAT912A

SAT921A

SAT922A

SAT923A

SAT924A

AT-328

REPAIR FOR COMPONENT PARTS Parking Pawl Components

Parking Pawl Components COMPONENTS

NGAT0152

GI MA EM LC EC FE CL MT

TF PD SAT379I

DISASSEMBLY 1. 2. 3.

NGAT0153

Slide return spring to the front of adapter case or rear extension flange. Remove return spring, pawl spacer and parking pawl from adapter case or rear extension. Remove parking pawl shaft from adapter case or rear extension.

AX SU BR ST RS

SAT226H

4.

Remove parking actuator support from adapter case or rear extension.

BT HA SC EL

SAT228H

AT-329

IDX

REPAIR FOR COMPONENT PARTS Parking Pawl Components (Cont’d)

ASSEMBLY 1. 2. 3.

NGAT0154

Install parking actuator support onto adapter case or rear extension. Insert parking pawl shaft into adapter case or rear extension. Install return spring, pawl spacer and parking pawl onto parking pawl shaft.

SAT229H

4.

Bend return spring upward and install it onto adapter case or rear extension.

SAT226H

AT-330

ASSEMBLY Assembly (1)

Assembly (1) 1. a. 쐌 쐌 b.

NGAT0155

c.

Install manual shaft components. Install oil seal onto manual shaft. Apply ATF to oil seal. Wrap threads of manual shaft with masking tape. Insert manual shaft and oil seal as a unit into transmission case. Remove masking tape.

d.

Push oil seal evenly and install it onto transmission case.

GI MA EM LC

SAT931A

EC FE CL MT

SAT932A

e.

Align groove in shaft with drive pin hole, then drive pin into position as shown in figure at left.

TF PD AX SAT933A

f. g.

Install detent spring and spacer. While pushing detent spring down, install manual plate onto manual shaft.

SU BR ST RS

SAT901E

h.

Install lock nuts onto manual shaft.

BT HA SC EL

SAT936A

AT-331

IDX

ASSEMBLY Assembly (1) (Cont’d)

2. Install accumulator piston. a. Install O-rings onto accumulator piston. 쐌 Apply ATF to O-rings. Accumulator piston O-rings Unit: mm (in) Accumulator

A

B

C

D

Small diameter end

29 (1.14)

32 (1.26)

45 (1.77)

29 (1.14)

Large diameter end

45 (1.77)

50 (1.97)

50 (1.97)

45 (1.77)

SAT523GA

b.

Install return spring for accumulator A onto transmission case. Free length of return spring: Refer to “Return Springs”, AT-349.

c. 쐌

Install accumulator pistons A, B, C and D. Apply ATF to transmission case.

3. a.

Install band servo piston. Install return springs onto servo piston.

b. 쐌

Install band servo piston onto transmission case. Apply ATF to O-ring of band servo piston and transmission case. Install gasket for band servo onto transmission case.

SAT938A

SAT939AA

SAT941A

c.

SAT942A

AT-332

ASSEMBLY Assembly (1) (Cont’d)

d.

Install band servo retainer onto transmission case.

GI MA EM LC

SAT940A

4. a.

Install rear side clutch and gear components. Place transmission case in vertical position.

EC FE CL MT

SAT943A

b.

Slightly lift forward clutch drum assembly. Then slowly rotate it clockwise until its hub passes fully over clutch inner race inside transmission case.

TF PD AX SAT944A

c.

Check to be sure that rotation direction of forward clutch assembly is correct.

SU BR ST RS

SAT945A

d. 쐌 쐌

Install thrust washer onto front of overrun clutch hub. Apply petroleum jelly to the thrust washer. Insert pawls of thrust washer securely into holes in overrun clutch hub.

BT HA SC EL

SAT946A

AT-333

IDX

ASSEMBLY Assembly (1) (Cont’d)

e.

Install overrun clutch hub onto rear internal gear assembly.

f. 쐌

Install needle bearing onto rear of overrun clutch hub. Apply petroleum jelly to needle bearing.

g.

Check that overrun clutch hub rotates as shown while holding forward clutch hub.

h.

Place transmission case into horizontal position.

i.

Install rear internal gear, forward clutch hub and overrun clutch hub as a unit onto transmission case.

SAT947A

SAT948A

SAT949A

SAT527G

SAT951A

AT-334

ASSEMBLY Assembly (1) (Cont’d)

j. 쐌

Install needle bearing onto rear internal gear. Apply petroleum jelly to needle bearing.

GI MA EM LC

SAT952A

k. 쐌 쐌

Install bearing race onto rear of front internal gear. Apply petroleum jelly to bearing race. Securely engage pawls of bearing race with holes in front internal gear.

EC FE CL MT

SAT953A

l.

Install front internal gear on transmission case.

TF PD AX SAT954A

5. a. 쐌

Install output shaft and parking gear. Insert output shaft from rear of transmission case while slightly lifting front internal gear. Do not force output shaft against front of transmission case.

SU BR ST RS

SAT216B

b. 쐌

Carefully push output shaft against front of transmission case. Install snap ring on front of output shaft. Check to be sure output shaft cannot be removed in rear direction.

BT HA SC EL

SAT957A

AT-335

IDX

ASSEMBLY Assembly (1) (Cont’d)

c. 쐌 쐌

Install needle bearing on transmission case. Pay attention to its direction — Black side goes to rear. Apply petroleum jelly to needle bearing.

d.

Install parking gear on transmission case.

e. 쐌

Install snap ring on rear of output shaft. Check to be sure output shaft cannot be removed in forward direction.

6. a. 쐌

Install adapter case or rear extension. Install oil seal on adapter case or rear extension. Apply ATF to oil seal.

b. 쐌 c.

Install O-ring on revolution sensor. Apply ATF to O-ring. Install revolution sensor on adapter case or rear extension.

SAT217B

SAT218B

SAT960A

SAT157G

SAT147G

AT-336

ASSEMBLY Assembly (1) (Cont’d)

d.

Install rear extension gasket on transmission case.

GI MA EM LC

SAT963A

e.

Install parking rod on transmission case.

EC FE CL MT

SAT964A

f.

Install rear extension or adapter case on transmission case.

TF PD AX SU BR ST RS SAT716C

7. a. 쐌

Install front side clutch and gear components. Install rear sun gear on transmission case. Pay attention to its direction.

BT HA SC EL

SAT974A

AT-337

IDX

ASSEMBLY Assembly (1) (Cont’d)

b. 쐌 c. 쐌 쐌

Make sure needle bearing is on front of front planetary carrier. Apply petroleum jelly to needle bearing. Make sure needle bearing is on rear of front planetary carrier. Apply petroleum jelly to bearing. Pay attention to its direction — Black side goes to front.

d.

While rotating forward clutch drum clockwise, install front planetary carrier on forward clutch drum.

쐌

Check that portion A of front planetary carrier protrudes approximately 2 mm (0.08 in) beyond portion B of forward clutch assembly.

e. 쐌 쐌

Make sure bearing races are on front and rear of clutch pack. Apply petroleum jelly to bearing races. Securely engage pawls of bearing races with holes in clutch pack.

f.

Install clutch pack into transmission case.

SAT967A

SAT969A

SAT970A

SAT971A

SAT973A

AT-338

ASSEMBLY Adjustment

Adjustment

NGAT0156

When any parts listed in the following table are replaced, total end play or reverse clutch end play must be adjusted. Part name

Total end play

Reverse clutch end play

Transmission case

쐌

쐌

Low one-way clutch inner race

쐌

쐌

Overrun clutch hub

쐌

쐌

Rear internal gear

쐌

쐌

Rear planetary carrier

쐌

쐌

Rear sun gear

쐌

쐌

Front planetary carrier

쐌

쐌

Front sun gear

쐌

쐌

High clutch hub

쐌

쐌

High clutch drum

쐌

쐌

Oil pump cover

쐌

쐌

Reverse clutch drum

—

쐌

1.

GI MA EM LC EC FE CL MT

Adjust total end play. Total end play “T1”: 0.25 - 0.55 mm (0.0098 - 0.0217 in)

TF PD AX SAT975A

a.

With needle bearing installed, place J34291-1 (bridge), J34291-2 (legs) and the J34291-5 (gauging cylinder) onto oil pump. The long ends of legs should be placed firmly on machined surface of oil pump assembly. The gauging cylinder should rest on top of the needle bearing. Lock gauging cylinder in place with set screw.

SU BR ST RS

SAT976A

b.

Install J34291-23 (gauging plunger) into gauging cylinder.

BT HA SC EL

SAT977A

AT-339

IDX

ASSEMBLY Adjustment (Cont’d)

c.

Install original bearing race inside reverse clutch drum. Place shim selecting gauge with its legs on machined surface of transmission case (no gasket). Allow gauging plunger to rest on bearing race. Lock gauging plunger in place with set screw.

d.

Remove Tool and use feeler gauge to measure gap between gauging cylinder and gauging plunger. This measurement should give exact total end play. Total end play “T1”: 0.25 - 0.55 mm (0.0098 - 0.0217 in) If end play is out of specification, decrease or increase thickness of oil pump cover bearing race as necessary. Available oil pump cover bearing race: Refer to “Total End Play”, AT-353.

SAT978A

쐌

SAT979A

2.

Adjust reverse clutch drum end play. Reverse clutch drum end play “T2”: 0.55 - 0.90 mm (0.0217 - 0.0354 in)

a.

Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of transmission case (no gasket). Allow gauging cylinder to rest on front thrust surface of reverse clutch drum. Lock cylinder in place with set screw.

b.

Install J34291-23 (gauging plunger) into gauging cylinder.

SAT980A

SAT981A

SAT982AA

AT-340

ASSEMBLY Adjustment (Cont’d)

c.

Install original thrust washer on oil pump. Place shim setting gauge legs onto machined surface of oil pump assembly. Allow gauging plunger to rest on thrust washer. Lock plunger in place with set screw.

GI MA EM LC

SAT983A

d.

쐌

Use feeler gauge to measure gap between gauging plunger and gauging cylinder. This measurement should give you exact reverse clutch drum end play. Reverse clutch drum end play “T2”: 0.55 - 0.90 mm (0.0217 - 0.0354 in) If end play is out of specification, decrease or increase thickness of oil pump thrust washer as necessary. Available oil pump thrust washer: Refer to “Reverse Clutch Drum End Play”, AT-353.

EC FE CL MT

SAT984A

Assembly (2) 1. a. 쐌

NGAT0157

Install brake band and band strut. Install band strut on brake band. Apply petroleum jelly to band strut.

TF PD AX

SAT985A

b.

Place brake band on periphery of reverse clutch drum, and insert band strut into end of band servo piston stem.

SU BR ST RS

SAT986A

c.

Install anchor end pin on transmission case. Then, tighten anchor end pin just enough so that reverse clutch drum (clutch pack) will not tilt forward.

BT HA SC EL

SAT987A

AT-341

IDX

ASSEMBLY Assembly (2) (Cont’d)

2. 쐌 3.

Install input shaft on transmission case. Pay attention to its direction — O-ring groove side is front. Install gasket on transmission case.

4. a. 쐌 b. 쐌

Install oil pump assembly. Install needle bearing on oil pump assembly. Apply petroleum jelly to the needle bearing. Install selected thrust washer on oil pump assembly. Apply petroleum jelly to thrust washer.

c.

Carefully install seal rings into grooves and press them into the petroleum jelly so that they are a tight fit.

d. 쐌

Install O-ring on oil pump assembly. Apply petroleum jelly to O-ring.

e.

Apply petroleum jelly to mating surface of transmission case and oil pump assembly.

SAT988A

SAT989A

SAT990A

SAT991A

SAT992A

AT-342

ASSEMBLY Assembly (2) (Cont’d)

f. 쐌

Install oil pump assembly. Install two converter housing securing bolts in bolt holes in oil pump assembly as guides.

GI MA EM LC

SAT993A

쐌

Insert oil pump assembly to the specified position in transmission, as shown at left.

EC FE CL MT

SAT994A

5. 쐌

Install O-ring on input shaft. Apply ATF to O-rings.

TF PD AX SAT114B

6. a. 쐌 쐌

Install converter housing. Apply sealant to outer periphery of bolt holes in converter housing. Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to GI-50, “RECOMMENDED CHEMICALPRODUCTSAND SEALANTS”. Do not apply too much sealant.

SU BR ST RS

SAT397C

b. 쐌 c. 7.

Apply sealant to seating surfaces of bolts that secure front cover of converter housing. Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to GI-50, “RECOMMENDED CHEMICALPRODUCTSAND SEALANTS”. Install converter housing on transmission case. Install turbine revolution sensor (VG33ER only).

BT HA SC EL

SAT158G

AT-343

IDX

ASSEMBLY Assembly (2) (Cont’d)

8. a.

b.

Adjust brake band. Tighten anchor end bolt to specified torque. Anchor end bolt: : 4 - 6 N·m (0.4 - 0.6 kg-m, 35 - 52 in-lb) Back off anchor end bolt two and a half turns.

c.

While holding anchor end pin, tighten lock nut.

9. a. 쐌 b.

Install terminal cord assembly. Install O-ring on terminal cord assembly. Apply petroleum jelly to O-ring. Compress terminal cord assembly stopper and install terminal cord assembly on transmission case.

SAT001B

SAT002B

SAT115B

10. Install control valve assembly. a. Install accumulator piston return springs B, C and D. Free length of return springs: Refer to “Return Springs”, AT-349.

SAT004BA

b. 쐌

Install manual valve on control valve. Apply ATF to manual valve.

SAT005B

AT-344

ASSEMBLY Assembly (2) (Cont’d)

c. d.

Place control valve assembly on transmission case. Connect solenoid connector for upper body. Install connector clip.

GI MA EM LC

SAT006B

e. f. 쐌

Install control valve assembly on transmission case. Install connector tube brackets and tighten bolts A and B. Check that terminal assembly does not catch. Bolt symbol

 mm (in)

A

33 (1.30)

B

45 (1.77)

EC FE CL MT

TF PD AX SAT353B

g. 쐌 h.

Install O-ring on oil strainer. Apply petroleum jelly to O-ring. Install oil strainer on control valve.

SU BR ST RS

SAT221B

i.

Securely fasten terminal harness with clips.

BT HA SC EL

SAT009B

AT-345

IDX

ASSEMBLY Assembly (2) (Cont’d)

j.

Install torque converter clutch solenoid valve and fluid temperature sensor connectors.

SAT010B

11. Install oil pan. a. Attach a magnet to oil pan.

SAT011B

b. c. 쐌 쐌 쐌 d.

Install new oil pan gasket on transmission case. Install oil pan and bracket on transmission case. Always replace oil pan bolts as they are self-sealing bolts. Before installing bolts, remove traces of sealant and oil from mating surface and thread holes. Tighten four bolts in a criss-cross pattern to prevent dislocation of gasket. Tighten drain plug.

SAT365I

12. Install park/neutral position (PNP) switch. a. Check that manual shaft is in 1 position. b. Temporarily install park/neutral position (PNP) switch on manual shaft. c. Move manual shaft to N.

SAT299I

d.

Tighten bolts while inserting 4.0 mm (0.157 in) dia. pin vertically into locating holes in park/neutral position (PNP) switch and manual shaft.

SAT014B

AT-346

ASSEMBLY Assembly (2) (Cont’d)

13. Install torque converter. a. Pour ATF into torque converter. 쐌 Approximately 2 liters (2-1/8 US qt, 1-3/4 Imp qt) of fluid are required for a new torque converter. 쐌 When reusing old torque converter, add the same amount of fluid as was drained.

GI MA EM LC

SAT428DA

b.

Install torque converter while aligning notches and oil pump.

EC FE CL MT

SAT016B

c.

Measure distance A to check that torque converter is in proper position. Distance “A”: VG33E only: 26.0 mm (1.024 in) or more VG33ER only: 25.0 mm (0.984 in) or more

TF PD AX

SAT017B

SU BR ST RS BT HA SC EL

AT-347

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

General Specifications

NGAT0160

VG33E engine

VG33ER engine

Applied model 2WD

4WD

Automatic transmission model

2WD

4WD

4EX67

4EX68, 4FX07

RE4R01A

Transmission model code number

43X64

4EX01, 4FX06

Stall torque ratio

2.0 : 1

Transmission gear ratio

1st

2.785

2nd

1.545

Top

1.000

O/D

0.694

Reverse

2.272 Nissan Matic “D” (Continental U.S. and Alaska) or Genuine Nissan Automatic Transmission Fluid (Canada)*1

Recommended fluid

8.3 (8-3/4 US qt, 7-1/4 Imp qt)

Fluid capacity

8.5 (9 US qt, 7-1/2 Imp qt)

8.3 (8-3/4 US qt, 7-1/4 Imp qt)

8.5 (9 US qt, 7-1/2 Imp qt)

*1: Refer to MA-13, “Fluids and Lubricants”.

Shift Schedule

NGAT0178

VEHICLE SPEED WHEN SHIFTING GEARS THROTTLE POSITION

NGAT0178S01

Vehicle speed km/h (MPH) Throttle position D1, D2

D2, D3

D3, D4

D4, D3

D3, D2

D2, D1

12, 11

47 - 51 (29 - 32)

92 - 100 (57 - 62)

146 - 156 (91 - 97)

141 - 151 (88 - 94)

87 - 95 (54 - 59)

42 - 46 (26 - 29)

43 - 47 (27 - 29)

VG33ER only

49 - 53 (30 - 33)

94 - 102 (58 - 63)

151 - 161 (94 - 100)

147 - 157 (91 - 98)

87 - 95 (54 - 59)

43 - 47 (27 - 29)

54 - 58 (34 - 36)

VG33E only

34 - 38 (21 - 24)

68 - 74 (42 - 46)

132 - 140 (82 - 87)

59 - 67 (37 - 42)

31 - 37 (19 - 23)

10 - 14 (6 - 9)

43 - 47 (27 - 29)

VG33ER only

41 - 45 (25 - 28)

68 - 74 (42 - 46)

121 - 129 (75 - 80)

76 - 84 (47 - 52)

41 - 47 (25 - 29)

11 - 15 (7 - 9)

54 - 58 (34 - 36)

VG33E only Full throttle

Half throttle

VEHICLE SPEED WHEN PERFORMING AND RELEASING LOCK-UP Throttle position

Overdrive control switch [Shift position]

NGAT0178S02

Vehicle speed km/h (MPH) Lock-up “ON”

Lock-up “OFF”

ON [D4]

147 - 155 (91 - 96)

142 - 150 (88 - 93)

OFF [D3]

74 - 82 (46 - 51)

71 - 79 (44 - 49)

ON [D4]

152 - 160 (94 - 99)

148 -156 (92 - 97)

OFF [D3]

86 - 94 (53 - 58)

83 - 91 (52 - 57)

ON [D4]

139 - 147 (86 - 91)

84 - 92 (52 - 57)

OFF [D3]

74 - 82 (46 - 51)

71 - 79 (44 - 49)

ON [D4]

134 - 142 (83 - 88)

103 - 111 (64 - 69)

OFF [D3]

86 - 94 (53 - 58)

83 - 91 (52 - 57)

VG33E only Full throttle VG33ER only

VG33E only Half throttle VG33ER only

Stall Revolution Stall revolution

rpm

NGAT0163

2,420 - 2,620

AT-348

SERVICE DATA AND SPECIFICATIONS (SDS) Line Pressure

Line Pressure

NGAT0164

GI

2

Line pressure kPa (kg/cm , psi)

Engine speed rpm

D, 2 and 1 positions

R position

Idle

422 - 461 (4.3 - 4.7, 61 - 67)

667 - 706 (6.8 - 7.2, 97 - 102)

Stall

1,020 - 1,098 (10.4 - 11.2, 148 - 159)

1,422 - 1,500 (14.5 - 15.3, 206 - 218)

MA EM LC

Return Springs

NGAT0165

Unit: mm (in)

EC

Item Parts

Upper body

Free length

Outer diameter

FE

1

Torque converter relief valve spring

31742-41X23

38.0 (1.496)

9.0 (0.354)

2

Pressure regulator valve spring

31742-41X24

44.02 (1.7331)

14.0 (0.551)

3

Pressure modifier valve spring

31742-41X19

31.95 (1.2579)

6.8 (0.268)

—

Accumulator control valve spring

—

—

—

4

Shuttle shift valve D spring

31762-41X01

25.0 (0.984)

7.0 (0.276)

5

4-2 sequence valve spring

31756-41X00

29.1 (1.146)

6.95 (0.2736)

6

Shift valve B spring

31762-41X01

25.0 (0.984)

7.0 (0.276)

7

4-2 relay valve spring

31756-41X00

29.1 (1.146)

6.95 (0.2736)

8

Shift valve A spring

31762-41X01

25.0 (0.984)

7.0 (0.276)

9

Overrun clutch control valve spring

31762-41X03 (VG33E only)

23.6 (0.929) (VG33E only)

7.0 (0.276)

PD

10

Overrun clutch reducing valve spring

31762-41X14 (VG33ER only) 31742-41X20

38.9 (1.531) (VG33ER only) 32.5 (1.280)

7.0 (0.276)

AX

11

Shuttle shift valve S spring

31762-41X04

51.0 (2.008)

5.65 (0.2224)

12

Pilot valve spring

31742-41X13

25.7 (1.012)

9.0 (0.354)

13

Lock-up control valve spring

31742-41X22

18.5 (0.728)

13.0 (0.512)

1

Modifier accumulator piston spring

31742-27X70

31.4 (1.236)

9.8 (0.386)

2

1st reducing valve spring

31756-41X05 (VG33E only) 31756-60X60 (VG33ER only)

25.4 (1.000) (VG33E only) 29.5 (1.161) (VG33ER only)

6.75 (0.2657) (VG33E only) 7.00 (0.2756) (VG33ER only)

3

3-2 timing valve spring

31742-41X06

23.0 (0.906)

6.7 (0.264)

4

Servo charger valve spring

31742-41X06

23.0 (0.906)

6.7 (0.264)

31521-41X02 (Assembly) (VG33E only) 31505-41X07 (Assembly) (VG33ER only)

19.7 (0.7756) (VG33E only) — (VG33ER only)

11.6 (0.457) (VG33E only) — (VG33ER only)

Control valve

Lower body

Part No.*

MT

TF

SU BR ST RS BT

Reverse clutch

16 pcs VG33E only 1 pc VG33ER only

High clutch

10 pcs

31521-41X03 (Assembly)

24.2 (0.9528)

11.6 (0.457)

Forward clutch (Overrun clutch)

20 pcs

31521-41X04 (Assembly)

35.77 (1.4083)

9.7 (0.382)

AT-349

CL

HA SC EL IDX

SERVICE DATA AND SPECIFICATIONS (SDS) Return Springs (Cont’d) Item Parts

Low & reverse brake

Part No.*

Free length

Outer diameter

31655-41X00 (Assembly)

22.3 (0.878)

11.2 (0.441)

Spring A

31605-41X05 (VG33E only) 31605-41X14 (VG33ER only)

45.6 (1.795) (VG33E only) 47.6 (1.874) (VG33ER only)

34.3 (1.350) (VG33E only) 26.5 (1.043) (VG33ER only)

Spring B

31605-41X00 (VG33E only)

53.8 (2.118) (VG33E only)

40.3 (1.587) (VG33E only)

Spring C

31605-41X01

29.7 (1.169)

27.6 (1.087)

Accumulator A

31605-41X02

43.0 (1.693)

18.0 (0.709)

Accumulator B

31605-41X10 (VG33E only) 31605-4AX03 (VG33ER only)

66.0 (2.598)

20.0 (0.787)

Accumulator C

31605-41X09

45.0 (1.772)

29.3 (1.154)

Accumulator D

31605-41X06

58.4 (2.299)

17.3 (0.681)

18 pcs

Band servo

Accumulator

*: Always check with the Parts Department for the latest parts information.

Accumulator O-ring

NGAT0166

Diameter mm (in) Accumulator A

B

C

D

Small diameter end

29 (1.14)

32 (1.26)

45 (1.77)

29 (1.14)

Large diameter end

45 (1.77)

50 (1.97)

50 (1.97)

45 (1.77)

Clutches and Brakes

NGAT0167

REVERSE CLUTCH Code number

NGAT0167S01

43X64 (VG33E only)

4EX01, 4FX06 (VG33E only)

4EX67 (VG33ER only)

Number of drive plates

2

Number of driven plates

2

Thickness of drive plate mm (in)

Standard

1.90 - 2.05 (0.0748 - 0.0807)

Wear limit

1.80 (0.0709)

Standard

0.5 - 0.8 (0.020 - 0.031)

4EX68, 4FX07 (VG33ER only)

Clearance mm (in) Allowable limit

1.2 (0.047) Thickness mm (in)

Thickness of retaining plate

4.8 5.0 5.2 5.4 5.6

(0.189) (0.197) (0.205) (0.213) (0.220)

Part No.* 31537-42X02 31537-42X03 31537-42X04 31537-42X05 31537-42X06

*: Always check with the Parts Department for the latest parts information.

AT-350

Thickness mm (in) 4.6 4.8 5.0 5.2 5.4

(0.181) (0.189) (0.197) (0.205) (0.213)

Part No.* 31537-42X20 31537-42X21 31537-42X22 31537-42X23 31537-42X24

SERVICE DATA AND SPECIFICATIONS (SDS) Clutches and Brakes (Cont’d)

HIGH CLUTCH

NGAT0167S02

Code number

43X64

4EX01, 4FX06

Number of drive plates

4EX67

4EX68, 4FX07

GI

5

Number of driven plates Thickness of drive plate mm (in)

5

MA

6

Standard

1.52 - 1.67 (0.0598 - 0.0657)

Wear limit

1.40 (0.0551)

Standard

1.8 - 2.2 (0.071 - 0.087)

EM

Clearance mm (in) Allowable limit

3.2 (0.126) Thickness mm (in) 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8

Thickness of retaining plate

Part No.*

(0.134) (0.142) (0.150) (0.157) (0.165) (0.173) (0.181) (0.189)

LC

2.2 (0.087) Thickness mm (in)

31537-41X71 31537-41X61 31537-41X62 31537-41X63 31537-41X64 31537-41X65 31537-41X66 31537-41X67

4.0 4.2 4.4 4.6 4.8 5.0

Part No.*

(0.157) (0.165) (0.173) (0.181) (0.189) (0.197)

31537-41X63 31537-41X64 31537-41X65 31537-41X66 31537-41X67 31537-41X68

EC FE CL

*: Always check with the Parts Department for the latest parts information.

FORWARD CLUTCH

NGAT0167S03

43X64 (VG33E only)

Code number

4EX01, 4FX06 (VG33E 4EX67 (VG33ER only) only)

4EX68, 4FX07 (VG33ER only)

Number of drive plates

6

7

7

8

Number of driven plates

6

7

7

8

Thickness of drive plate mm (in)

Standard

1.52 - 1.67 (0.0598 - 0.0657)

Wear limit

1.40 (0.0551)

Standard

0.35 - 0.75 (0.0138 - 0.0295)

MT

TF PD

Clearance mm (in) Allowable limit

1.95 (0.0768) Thickness mm (in)

Thickness of retaining plate

8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 9.0 9.1 9.2

(0.315) (0.319) (0.323) (0.327) (0.331) (0.335) (0.339) (0.343) (0.346) (0.350) (0.354) (0.358) (0.362)

2.15 (0.0846)

Part No.* 3153741X00 3153742X60 3153741X01 3153742X61 3153741X02 3153742X62 3153741X03 3153742X63 3153741X04 3153742X64 3153741X05 3153742X65 3153741X06

Thickness mm (in) 4.6 4.8 5.0 5.2 5.4 5.6

(0.181) (0.189) (0.197) (0.205) (0.213) (0.220)

Part No.* 3153742X13 3153742X14 3153742X15 315374AX00 315374AX01 315374AX02

2.15 (0.0846) Thickness mm (in) 4.6 4.8 5.0 5.2 5.4 5.6

(0.181) (0.189) (0.197) (0.205) (0.213) (0.220)

Part No.* 3153742X13 3153742X14 3153742X15 315374AX00 315374AX01 315374AX02

2.35 (0.0925) Thickness mm (in) 4.2 4.4 4.6 4.8 5.0 5.2 5.4

(0.165) (0.173) (0.181) (0.189) (0.197) (0.205) (0.213)

AX

Part No.* 3153742X11 3153742X12 3153742X13 3153742X14 3153742X15 315374AX00 315374AX01

SU BR ST RS BT HA SC EL

*: Always check with the Parts Department for the latest parts information.

AT-351

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) Clutches and Brakes (Cont’d)

OVERRUN CLUTCH

NGAT0167S04

4EX01, 4FX06 (VG33E only)

43X64 (VG33E only)

Code number

4EX67 (VG33ER only)

Number of drive plates

3

Number of driven plates

5 Standard

1.90 - 2.05 (0.0748 - 0.0807)

Wear limit

1.80 (0.0709)

Standard

1.0 - 1.4 (0.039 - 0.055)

4EX68, 4FX07 (VG33ER only)

Thickness of drive plate mm (in)

Clearance mm (in) Allowable limit

2.4 (0.094) Thickness mm (in) 4.2 4.4 4.6 4.8 5.0

Thickness of retaining plate

Part No.*

(0.165) (0.173) (0.181) (0.189) (0.197)

31537-41X80 31537-41X81 31537-41X82 31537-41X83 31537-41X84

*: Always check with the Parts Department for the latest parts information.

LOW & REVERSE BRAKE Code number

NGAT0167S05

4EX01, 4FX06 (VG33E only)

43X64 (VG33E only)

4EX68, 4FX07 (VG33ER only)

4EX67 (VG33ER only)

Number of drive plates

7

8

Number of driven plates

7

8

Thickness of drive plate mm (in)

Standard

1.52 - 1.67 (0.0598 - 0.0657)

Wear limit

1.40 (0.0551)

Standard

0.8 - 1.1 (0.031 - 0.043)

Clearance mm (in) Allowable limit

2.5 (0.098)

2.7 (0.106)

Thickness mm (in)

Thickness of retaining plate

6.6 6.8 7.0 7.2 7.4 7.6 7.8 8.0 8.2 8.4 8.6 8.8 9.0

(0.260) (0.268) (0.276) (0.283) (0.291) (0.299) (0.307) (0.315) (0.323) (0.331) (0.339) (0.346) (0.354)

Part No.*

Thickness mm (in)

31667-41X17 31667-41X11 31667-41X12 31667-41X13 31667-41X14 31667-41X07 31667-41X08 31667-41X00 31667-41X01 31667-41X02 31667-41X03 31667-41X04 31667-41X05

7.6 7.8 8.0 8.2 8.4 8.6 8.8 9.0 9.2 9.4 9.6

(0.299) (0.307) (0.315) (0.323) (0.331) (0.339) (0.346) (0.354) (0.362) (0.370) (0.378)

Part No.* 31667-41X07 31667-41X08 31667-41X00 31667-41X01 31667-41X02 31667-41X03 31667-41X04 31667-41X05 31667-41X06 31667-41X09 31667-41X10

*: Always check with the Parts Department for the latest parts information.

BRAKE BAND

NGAT0167S06

Anchor end bolt tightening torque

4 - 6 N·m (0.4 - 0.6 kg-m, 35 - 52 in-lb)

Number of returning revolution for anchor end bolt

2.5

AT-352

SERVICE DATA AND SPECIFICATIONS (SDS) Oil Pump and Low One-way Clutch

Oil Pump and Low One-way Clutch

NGAT0168

Unit: mm (in)

Oil pump clearance

Cam ring — oil pump housing

Standard

0.01 - 0.024 (0.0004 - 0.0009)

Rotor, vanes and control piston — oil pump housing

Standard

0.03 - 0.044 (0.0012 - 0.0017)

Standard

0.10 - 0.25 (0.0039 - 0.0098)

Seal ring clearance Allowable limit

Total end play “T1”

MA EM

0.25 (0.0098)

Total End Play

GI

NGAT0169

LC

0.25 - 0.55 mm (0.0098 - 0.0217 in) Thickness mm (in) 0.8 1.0 1.2 1.4 1.6 1.8 2.0

Thickness of oil pump cover bearing race

Part No.*

(0.031) (0.039) (0.047) (0.055) (0.063) (0.071) (0.079)

EC

31435-41X01 31435-41X02 31435-41X03 31435-41X04 31435-41X05 31435-41X06 31435-41X07

FE CL

*: Always check with the Parts Department for the latest parts information.

MT

Reverse Clutch Drum End Play Reverse clutch drum end play “T2”

NGAT0170

0.55 - 0.90 mm (0.0217 - 0.0354 in) Thickness mm (in) 0.9 1.1 1.3 1.5 1.7 1.9

Thickness of oil pump thrust washer

Part No.*

(0.035) (0.043) (0.051) (0.059) (0.067) (0.075)

31528-21X01 31528-21X02 31528-21X03 31528-21X04 31528-21X05 31528-21X06

TF PD

*: Always check with the Parts Department for the latest parts information.

AX

Removal and Installation Number of returning revolutions for lock nut

NGAT0171

2

Manual control linkage

SU

4.4 - 5.9 N·m (0.45 - 0.60 kg-m, 39.1 - 52.1 in-lb)

Lock nut tightening torque

26.0 mm (1.024 in) or more (VG33E only) 25.0 mm (0.984 in) or more (VG33ER only)

Distance between end of clutch housing and torque converter

ST

Shift Solenoid Valves

NGAT0210

Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

Solenoid Valves Solenoid valves

Resistance (Approx.)

Terminal No.

Shift solenoid valve A

20 - 40

3

Shift solenoid valve B

20 - 40

2

Overrun clutch solenoid valve

20 - 40

4

Line pressure solenoid valve

2.5 - 5

6

AT-353

RS BT NGAT0211

Ω

BR

HA SC EL IDX

SERVICE DATA AND SPECIFICATIONS (SDS) A/T Fluid Temperature Sensor Torque converter clutch solenoid valve

10 - 20

7

A/T Fluid Temperature Sensor

NGAT0212

Remarks: Specification data are reference values. Monitor item

Condition

A/T fluid temperature sensor

Specification (Approx.)

Cold [20°C (68°F)] " Hot [80°C (176°F)]

1.5V " 0.5V

2.5 kΩ " 0.3 kΩ

Turbine Revolution Sensor Terminal No.

NGAT0220

Resistance (Approx.)

1

2

2.4 - 2.8 KΩ

1

3

No continuity

2

3

No continuity

Revolution Sensor Terminal No.

NGAT0213

Resistance (Approx.)

1

2

500 - 650Ω

2

3

No continuity

1

3

No continuity

Dropping Resistor Resistance

NGAT0214

Approx. 12Ω

AT-354

TRANSFER SECTION

TF

GI MA EM LC EC

CONTENTS PREPARATION ...............................................................2 Special Service Tools ..................................................2 Commercial Service Tools ...........................................3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................5 NVH Troubleshooting Chart.........................................5 TRANSFER ...............................................................5 DESCRIPTION .................................................................6 Cross-sectional View ...................................................6 ON-VEHICLE SERVICE ..................................................7 Replacing Oil Seal .......................................................7 CENTER CASE OIL SEAL ..........................................7 SHIFT SHAFT OIL SEAL ............................................8 REAR OIL SEAL ........................................................8 Position Switch Check .................................................9 REMOVAL AND INSTALLATION .................................10 Removal.....................................................................10 Installation..................................................................10 M/T MODEL ............................................................10 A/T MODEL .............................................................10 OVERHAUL ...................................................................11 Transfer Gear Control................................................11 Case Components .....................................................12 Gear Components .....................................................13 Shift Control Components .........................................14 DISASSEMBLY..............................................................15 REPAIR FOR COMPONENT PARTS ...........................20 Mainshaft ...................................................................20 DISASSEMBLY ........................................................20 INSPECTION ...........................................................21 ASSEMBLY .............................................................22 Front Drive Shaft .......................................................22 DISASSEMBLY ........................................................22 INSPECTION ...........................................................22 ASSEMBLY .............................................................22 Counter Gear .............................................................23 DISASSEMBLY ........................................................23 INSPECTION ...........................................................23

ASSEMBLY .............................................................23

Main Gear ..................................................................23 DISASSEMBLY ........................................................23 INSPECTION ...........................................................24 ASSEMBLY .............................................................24 Front Case .................................................................25 REMOVAL ...............................................................25 INSTALLATION........................................................25 Front Case Cover ......................................................25 REMOVAL ...............................................................25 INSTALLATION........................................................25 Bearing Retainer........................................................26 REMOVAL ...............................................................26 INSTALLATION........................................................26 Center Case...............................................................26 REMOVAL ...............................................................26 INSTALLATION........................................................26 Rear Case..................................................................26 REMOVAL ...............................................................26 INSTALLATION........................................................27 Shift Control Components .........................................27 INSPECTION ...........................................................27 ASSEMBLY....................................................................29 SERVICE DATA AND SPECIFICATIONS (SDS) .........37 General Specifications...............................................37 Inspection and Adjustment ........................................37

FE CL MT AT

PD AX SU BR ST RS

CLEARANCE BETWEEN FRONT DRIVE SPROCKET AND 2-4 COUPLING SLEEVE................37 GEAR END PLAY ....................................................37 CLEARANCE BETWEEN BAULK RING AND CLUTCH GEAR .......................................................37

BT

Available Shim ...........................................................37 COUNTER GEAR REAR BEARING ...........................37 Available Snap Ring ..................................................37 MAINSHAFT FRONT BEARING ................................37 MAIN GEAR BEARING.............................................38 MAINSHAFT REAR BEARING ..................................38

SC

HA

EL IDX

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 (Kent-Moore No.) Tool name

Description Removing companion flange nut Installing companion flange nut

KV38108300 ( — ) Companion Flange wrench

NT771

Removing counter gear front bearing (Use with ST36710010) Removing L & H hub a: 110 mm (4.33 in) dia. b: 68 mm (2.68 in) dia.

ST30021000 (J22912-01) Puller

NT411

Removing counter gear rear bearing (Use with ST36710010) a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia.

ST30031000 (J22912-01) Puller

NT411

Removing center case oil seal Removing rear oil seal a: 250 mm (9.84 in) b: 160 mm (6.30 in)

ST33290001 (J34286) Puller

NT414

Removing companion flange a: 135 mm (5.31 in) b: 100 mm (3.94 in) c: 130 mm (5.12 in)

ST33051001 (J22888) Puller

NT657

1 Installing center case oil seal 2 Installing rear oil seal a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia.

ST30720000 1 (J25273) 2 (J25405) Drift

NT658

TF-2

NGTF0001

PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name ST36710010 ( — Drift

Description

GI Removing counter gear front bearing (Use with ST30021000) Removing counter gear rear bearing (Use with ST30031000) a: 34.5 mm (1.358 in) dia.

)

MA EM

NT063

Removing main gear bearing a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia.

ST33061000 (J8107-2) Drift

LC EC

NT116

1 Installing main gear bearing 2 Installing front case cover oil seal a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia.

ST30613000 1 (J25742-3) 2 (J34339) Drift

FE CL

NT073

MT

Installing shift shaft oil seal a: 26 mm (1.02 in) dia. b: 20 mm (0.79 in) dia. c: 150 mm (5.91 in)

(J35864) Drift

AT

NT117

Seating counter gear assembly a: 44.5 mm (1.752 in) dia. b: 38.5 mm (1.516 in) dia.

(J26092) Drift

PD

NT065

AX

Selecting counter gear rear bearing shim

(J34291) Shim setting gauge set

SU BR

NT101

Selecting counter gear rear bearing shim

(J34291-20) Plunger-shim setting gauge

ST RS

NT118

Commercial Service Tools

NGTF0002

BT

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool name

HA

Description

Puller

Removing front drive shaft front bearing Removing front drive shaft rear bearing Removing main gear bearing

SC EL

NT077

TF-3

IDX

PREPARATION Commercial Service Tools (Cont’d) Tool name

Description

Drift

1 Installing mainshaft rear bearing 2 Installing L & H hub 1 a: 50 mm (1.97 in) dia. b: 42 mm (1.65 in) dia. c: 180 mm (7.09 in) 2 a: 60 mm (2.36 in) dia. b: 50 mm (1.97 in) dia. c: 60 mm (2.36 in)

NT117

TF-4

NGTF0039

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart

NVH Troubleshooting Chart

NGTF0039S01

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection. If necessary, repair or replace these parts.

TRANSFER MA-40, ″Checking Transfer Fluid″.

NGTF0039S0101

Noise

1

TF-13

TF-13

TF-13

TF-13

TF-14

TF-12, 14

TF-12

TF-12

LC EC

1

Hard to shift or will not shift

1

1

2

SHIFTING INSERT (Damaged)

Bearing (Worn or damaged)

GEAR (Worn or damaged) 3

3

MT AT

PD AX

2

Fluid leakage

BAULK RING (Worn or damaged)

CL

SHIFT FORK (Worn)

LIQUID GASKET (Damaged)

OIL SEAL (Worn or damaged)

CHECK SPRING AND CHECK BALL (Worn damaged)

FE

FLUID (Level too high)

SUSPECTED PARTS (Possible cause)

MA EM

FLUID (Wrong)

FLUID (Level low)

Reference page

GI

3

SU

2

Symptom Jumps out of gear

2 1

2

2

BR

2

ST RS BT HA SC EL

TF-5

IDX

DESCRIPTION Cross-sectional View

Cross-sectional View

NGTF0003

ATF021

TF-6

ON-VEHICLE SERVICE Replacing Oil Seal

Replacing Oil Seal CENTER CASE OIL SEAL 1. 2.

NGTF0004 NGTF0004S01

Remove front propeller shaft. Refer to PD-8, “Removal and Installation”. Remove companion flange nut.

GI MA EM LC

SMT844D

3.

Remove companion flange.

EC FE CL MT

SMT486A

4. 5. 쐌 6.

Remove center case oil seal. Install center case oil seal. Before installing, apply multi-purpose grease to seal lip. Install companion flange.

AT

PD AX AMT086

7. 8.

Tighten companion flange nut. : 226 - 324 N·m (23 - 33 kg-m, 166 - 239 ft-lb) Install front propeller shaft. Refer to PD-8, “Removal and Installation”.

SU BR ST RS

SMT845D

BT HA SC EL

TF-7

IDX

ON-VEHICLE SERVICE Replacing Oil Seal (Cont’d)

SHIFT SHAFT OIL SEAL 1. 2. 3.

NGTF0004S02

Remove front propeller shaft. Refer to PD-8, “Removal and Installation”. Remove companion flange. Refer to “CENTER CASE OIL SEAL”, TF-7. Remove transfer control lever from transfer outer shift lever. Then remove outer shift lever.

ATF007

4. 쐌

Remove shift shaft oil seal. Be careful not to damage cross shaft.

5. 쐌 6. 7.

Install shift shaft oil seal. Before installing, apply multi-purpose grease to seal lip. Install transfer control linkage. Install companion flange. Refer to “CENTER CASE OIL SEAL”, TF-7. Install front propeller shaft. Refer to PD-8, “Removal and Installation”.

SMT491A

8.

SMT492A

REAR OIL SEAL 1. 2.

NGTF0004S03

Remove rear propeller shaft. Refer to PD-8, “Removal and Installation”. Remove rear oil seal.

AMT087

3. 쐌 4.

Install rear oil seal. Before installing apply multi-purpose grease to seal lip. Install rear propeller shaft. Refer to PD-8, “Removal and Installation”.

SMT494A

TF-8

ON-VEHICLE SERVICE Position Switch Check

Position Switch Check Switch

NGTF0042

Gear Position

Continuity

4WD

Yes

Except 4WD

NO

Neutral

NO

Except Neutral

Yes

4WD Switch

Neutral Position Switch

GI MA EM LC

SMT790CA

EC FE CL MT AT

PD AX SU BR ST RS BT HA SC EL

TF-9

IDX

REMOVAL AND INSTALLATION Removal

Removal

NGTF0006

1. 2.

ATF007

Drain fluid from transfer, and drain oil from transmission. Remove front and rear propeller shaft. Refer to PD-8, “Removal and Installation”. Insert plug into rear oil seal after removing propeller shaft. 쐌 Be careful not to damage spline, sleeve yoke and rear oil seal, when removing propeller shaft. 3. Remove torsion bar spring. Refer to SU-12, “Torsion Bar Spring”. Then remove second crossmember. 4. Remove exhaust front and rear tubes. Refer to FE-9, “EXHAUST SYSTEM”. 5. Disconnect vehicle speed sensor, transfer neutral position switch and 4WD switch harness connectors. 6. Remove air breather hose. 7. Remove transfer control lever from transfer outer shift lever. 8. Separate transfer from transmission. WARNING: Support transfer while removing it.

Installation

NGTF0007

쐌

Apply sealant to mating surface to transmission. (M/T model only) Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.

쐌

Tighten bolts securing transfer.

SMT495A

M/T MODEL

NGTF0007S01

Bolt No.

Tightening torque N·m (kg-m, ft-lb)

1

31 - 42 (3.2 - 4.3, 23 - 31)

60 (2.36)

2

31 - 42 (3.2 - 4.3, 23 - 31)

45 (1.77)




A/T MODEL WTF004

쐌

mm (in)

NGTF0007S02

Bolt No.

Tightening torque N·m (kg-m, ft-lb)

1

31 - 42 (3.2 - 4.3, 23 - 31)

45 (1.77)

2

31 - 42 (3.2 - 4.3, 23 - 31)

45 (1.77)




mm (in)

Adjust the torsion bars for the correct vehicle height. Refer to SU-13, “INSTALLATION AND ADJUSTMENT”.

TF-10

OVERHAUL Transfer Gear Control

Transfer Gear Control

NGTF0008

GI MA EM LC EC FE CL MT AT

PD AX SU BR ST RS BT HA SC ATF022

TF-11

EL IDX

OVERHAUL Case Components

Case Components

NGTF0009

WTF005

TF-12

OVERHAUL Gear Components

Gear Components

NGTF0010

GI MA EM LC EC FE CL MT AT

PD AX SU BR ST RS BT HA SC WTF006

TF-13

EL IDX

OVERHAUL Shift Control Components

Shift Control Components

NGTF0011

WTF007

TF-14

NGTF0012

DISASSEMBLY 1. 2.

Remove companion flange nut. Remove companion flange.

GI MA EM LC

SMT846D

3. 4. 쐌

Remove 4WD switch. Remove rear case. Be careful not to damage the mating surface.

EC FE CL MT

SMT270A

5. 6.

Remove oil cover and oil gutter. Remove snap ring and retainer ring from 2-4 shift rod.

AT

PD AX SMT435C

7.

Using calipers, measure the difference between front drive sprocket and 2–4 coupling sleeve as outlined under measuring method below. If it is outside specifications, check front drive sprocket, 2–4 coupling sleeve, clutch gear, 2–4 shift fork and 2–4 fork rod for abnormalities. Replace faulty part(s) as required. Measuring method Move Coupling sleeve until it is in contact with sprocket, then measure dimension A. Move coupling sleeve until it is in contact with clutch gear, then measure dimension B. Obtain dimension difference C between two measurements A and B. A–B=C To determine dimension A, measure at 3 or 4 different points by rotating sprocket and obtain average value of 3 or 4 measurements. Specification C: Refer to “Clearance Between Front Drive Sprocket and 2–4 Coupling Sleeve”, TF-37.

SU BR ST RS BT HA SC EL

SMT799CA

TF-15

IDX

DISASSEMBLY 8. 쐌

Remove bolts securing bearing retainer. This step is necessary to remove mainshaft from center case.

9.

Remove bolts securing center case to front case and then separate center case and front case.

SMT273A

SMT274A

10. Measure low gear end play. Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in) 쐌 If end play is beyond the maximum value, check low gear and L & H hub for wear.

SMT342A

11. Disassemble center case assembly. a. Remove snap ring from mainshaft.

SMT275A

b.

Pull out low gear with L & H hub.

SMT757A

TF-16

DISASSEMBLY c.

Remove needle bearing from main shaft.

GI MA EM LC

SMT758A

d.

Make sure of the direction of the drive chain before removing it. (It must be reinstalled in the same direction.)

EC FE CL MT

SMT788C

e. 쐌

Remove mainshaft, front drive and drive chain as a set by tapping front end of mainshaft and front drive shaft alternately. Be careful not to bend drive chain.

AT

PD AX SMT279A

12. Disassemble front case assembly. a. Remove transfer neutral position switch, plugs, check springs and check balls.

SU BR ST RS

WTF010

b.

Remove lock pin from outer shift lever, then remove outer shift lever.

BT HA SC EL

ATF013

TF-17

IDX

DISASSEMBLY c.

Remove lock pin of inner shift lever and drive out cross shaft with plug.

d.

Remove 2-4 shift rod.

e.

Remove L & H shift rod and fork assembly with coupling sleeve.

f.

Remove needle bearing from main gear.

g.

Remove bolts securing front case cover and then remove case.

SMT282A

SMT283A

SMT284A

SMT286A

SMT287A

TF-18

DISASSEMBLY h.

Remove counter gear by tapping lightly.

GI MA EM LC

SMT759A

i.

Remove main gear by tapping lightly.

EC FE CL MT

SMT288A

AT

PD AX SU BR ST RS BT HA SC EL

TF-19

IDX

REPAIR FOR COMPONENT PARTS Mainshaft

Mainshaft DISASSEMBLY 1.

쐌

NGTF0013

Check front drive sprocket end play. Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in) If end play is not within specification, check front drive sprocket and clutch gear for wear.

SMT347A

2. 쐌

Remove retainer ring, speedometer drive gear and steel ball. Be careful not to lose the steel ball.

3.

Remove snap ring and spacer.

4. 5.

Use a press to remove front drive sprocket with mainshaft rear bearing and clutch gear together. Remove needle bearing.

6.

Remove bearing retainer and then remove snap ring.

SMT289A

SMT290A

SMT291A

SMT292A

TF-20

REPAIR FOR COMPONENT PARTS Mainshaft (Cont’d)

7.

Use a press to remove mainshaft front bearing from mainshaft.

GI MA EM LC

SMT293A

INSPECTION Gear and Shaft 쐌 쐌 쐌

NGTF0014 NGTF0014S01

Check gears for excessive wear, chips or cracks. Check shaft for cracks, wear or bending. Check coupling sleeve for wear or damage.

EC FE CL MT

SMT348A

Baulk ring 쐌

NGTF0014S03

Check baulk ring for cracks or deformation.

AT

PD AX SMT349A

쐌

Measure clearance between baulk ring and clutch gear. Baulk ring to clutch gear clearance: Refer to “CLEARANCE BETWEEN BAULK RING AND CLUTCH GEAR”, TF-37.

SU BR ST RS

SMT350A

Bearing 쐌

NGTF0014S02

Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

BT HA SC EL

WTF008

TF-21

IDX

REPAIR FOR COMPONENT PARTS Mainshaft (Cont’d)

ASSEMBLY

NGTF0015

1. 쐌

Press mainshaft front bearing onto mainshaft. Pay special attention to its direction.

2.

Select snap ring with proper thickness. Allowable clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 in) Available snap ring for mainshaft front bearing: Refer to “MAINSHAFT FRONT BEARING”, TF-37. Regarding to further procedures, refer to “ASSEMBLY”, TF-29.

SMT294A

3.

SMT295A

Front Drive Shaft DISASSEMBLY 쐌

NGTF0016

Using a gear puller, remove front drive shaft front and rear bearings

SMT437C

INSPECTION Sprocket and Shaft 쐌 쐌

NGTF0017S01

Check sprocket for excessive wear, chips or cracks. Check shaft for cracks or wear.

Bearing 쐌

NGTF0017

NGTF0017S02

Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

SMT357A

ASSEMBLY 쐌

NGTF0018

Press front drive shaft front and rear bearings onto front drive shaft.

SMT438C

TF-22

REPAIR FOR COMPONENT PARTS Counter Gear

Counter Gear DISASSEMBLY 1. 쐌

NGTF0019

Press out counter gear front bearing. Remove front sub-gear, dish plate and spacer (M/T model only).

GI MA EM LC

WTF009

2. 쐌

Press out counter gear rear bearing. Remove rear sub-gear, dish plate and spacer (M/T model only).

EC FE CL MT

SMT301A

INSPECTION Gear and Shaft 쐌 쐌

AT

NGTF0020S01

Check gears for excessive wear, chips or cracks. Check shaft for cracks or wear.

Bearing 쐌

NGTF0020

NGTF0020S02

Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

PD AX

SMT358A

ASSEMBLY 1. 2. 3. 4.

NGTF0021

Install front sub-gear, dish plate and spacer (M/T model only). Press on counter gear front bearing. Install rear sub-gear, dish plate and spacer (M/T model only). Press on counter gear rear bearing.

SU BR ST RS

SMT439C

Main Gear DISASSEMBLY Main Gear Bearing 1.

Remove snap ring.

BT NGTF0022 NGTF0022S01

HA SC EL

SMT304A

TF-23

IDX

REPAIR FOR COMPONENT PARTS Main Gear (Cont’d)

2.

Pull out main gear bearing.

SMT305A

Plug 쐌

NGTF0022S02

Always replace it with new one whenever it has been removed.

SMT306A

INSPECTION Gear and Shaft 쐌 쐌

NGTF0023S01

Check gears for excessive wear, chips or cracks. Check shaft for cracks or wear.

Bearing 쐌

NGTF0023

NGTF0023S02

Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

SMT359A

ASSEMBLY Main Gear Bearing

NGTF0024 NGTF0024S01

1.

Press on main gear bearing.

2.

Select and install snap ring with proper thickness. Allowable clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 in) Available snap ring for main gear bearing: Refer to “MAIN GEAR BEARING”, TF-38.

SMT307A

ATF014

TF-24

REPAIR FOR COMPONENT PARTS Main Gear (Cont’d)

Plug

NGTF0024S02

Apply sealant to plug, then install. 쐌 Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite part No. 51813 or equivalent.

GI MA EM LC

SMT309A

Front Case REMOVAL Shift Shaft Oil Seal 쐌 쐌 쐌

NGTF0025

EC

NGTF0025S01

Use a screwdriver to pry out old seal. Be careful not to damage case. Always replace with a new one whenever it has been removed.

FE CL MT

SMT310A

INSTALLATION Shift Shaft Oil Seal 쐌 쐌

NGTF0026

AT

NGTF0026S01

Install new shift shaft oil seal until flush with case. Before installing, apply multi-purpose grease to seal lip.

PD AX SMT311A

Front Case Cover REMOVAL Cover Oil Seal 쐌 쐌

SU NGTF0027 NGTF0027S01

Drive out old seal from inside of front case cover. Be careful not to damage front case cover.

BR ST RS

SMT312A

INSTALLATION Cover Oil Seal 쐌 쐌

NGTF0028

BT

NGTF0028S01

Install new front case cover oil seal until it stops. Before installing, apply multi-purpose grease to seal lip.

HA SC EL

SMT313A

TF-25

IDX

REPAIR FOR COMPONENT PARTS Bearing Retainer

Bearing Retainer REMOVAL Oil Catcher 쐌 쐌

NGTF0029 NGTF0029S01

Drive out oil catcher from inside of bearing retainer. Be careful not to damage bearing retainer.

SMT314A

INSTALLATION Oil Catcher 쐌 쐌 쐌

NGTF0030 NGTF0030S01

Install oil catcher until it stops. Be careful not to damage or distort oil catcher or bearing retainer. Before installing, apply multi-purpose grease to seal lip.

SMT315A

Center Case REMOVAL Center Case Oil Seal 쐌

NGTF0044 NGTF0044S01

Remove center case oil seal.

SMT863D

INSTALLATION Center Case Oil Seal 쐌

NGTF0045 NGTF0045S01

Install center case oil seal.

SMT864D

Rear Case REMOVAL Rear Oil Seal 쐌

Pull out rear oil seal.

AMT094

TF-26

NGTF0031 NGTF0031S01

REPAIR FOR COMPONENT PARTS Rear Case (Cont’d)

INSTALLATION Rear Oil Seal 쐌 쐌

NGTF0032 NGTF0032S01

Install new rear oil seal until it stops. Before installing, apply multi-purpose grease to seal lip.

GI MA EM LC

SMT317A

Air Breather

NGTF0032S02

Install as shown in illustration.

EC FE CL MT

SMT799A

Shift Control Components INSPECTION 쐌

AT NGTF0033

Check contact surface and sliding surface for wear, scratches, projections or other faulty conditions.

PD AX SMT360A

L & H Shift Rod & Fork 쐌

NGTF0033S01

Assemble as shown in illustration. * Retaining pin is the same size as the one for 2-4 shift rod.

SU BR ST RS

SMT319A

2-4 Shift Rod & Fork 쐌

Assemble as shown in illustration. * Retaining pins are the same size.

NGTF0033S02

BT HA SC EL

SMT320A

TF-27

IDX

REPAIR FOR COMPONENT PARTS Shift Control Components (Cont’d)

쐌

Pay special attention to the direction of fork guide collar.

SMT321A

TF-28

NGTF0034

ASSEMBLY 1. a.

Assemble front case. Install main gear assembly by tapping lightly.

GI MA EM LC

SMT323A

b. 쐌 쐌

Apply sealant to the mating surface and bolts of front case cover, then attach it to the front case. Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent. These ten bolts should be coated with sealant. Bolts A: 20 - 24 N·m (2.0 - 2.4 kg-m, 14 - 17 ft-lb) Bolts B: 24 - 28 N·m (2.4 - 2.9 kg-m, 17 - 21 ft-lb)

EC FE CL MT

SMT325A

c.

Apply ATF to needle bearing and install it into main gear.

AT

PD AX SMT326A

d.

Install counter gear assembly by tapping lightly.

SU BR ST RS

SMT327A

e. 쐌

Install cross shaft and inner shift lever. When replacing cross shaft, outer shift lever or outer shift lever lock pin, replace them as a set.

BT HA SC EL

SMT798A

TF-29

IDX

ASSEMBLY f.

Apply sealant to plug and install it into front case. Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.

g.

Insert interlock plunger into front case.

h.

Install L & H shift rod and fork assembly with coupling sleeve.

i.

Install 2-4 shift rod.

j.

Install transfer neutral position switch, check balls, check springs and plugs. Apply sealant to switches and plugs. Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.

SMT330A

SMT331A

SMT332A

ATF015

쐌 쐌

WTF010

TF-30

ASSEMBLY 2. a.

Select counter gear rear bearing shim. Seat counter gear assembly.

GI MA EM LC

SMT590A

b.

Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of center case, allowing gauging cylinder to rest on top outer portion of counter gear rear bearing. Lock gauging cylinder in place.

EC FE CL MT

SMT591A

c.

Insert J34291-20 (gauging plunger) into J34291-5 (gauging cylinder).

AT

PD AX SMT592A

d.

Place bridge, legs, gauging cylinder and gauging plunger onto machined surface of front case assembly, allowing gauging plunger to drop until it contacts counter gear rear bearing mating surface.

SU BR ST RS BT HA SC EL

SMT593A

TF-31

IDX

ASSEMBLY e. f.

Lock gauging plunger in place and use feeler gauge to measure end play between gauging cylinder and gauging plunger. Use measured distance to select correct counter gear rear bearing shim. Allowable counter gear end play: 0 - 0.2 mm (0 - 0.008 in) Allowable counter gear rear bearing shim: Refer to “COUNTER GEAR REAR BEARING”, TF-37.

SMT594A

3. 4.

Place suitable shim with grease on counter gear rear bearing. Apply ATF to each part in front case.

5. a. 쐌

Assemble center case assembly. Install mainshaft on center case by tapping lightly. Apply ATF to mainshaft front bearing.

b.

Install bearing retainer. : 16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)

SMT336A

SMT406A

SMT407A

TF-32

ASSEMBLY c.

Put drive chain onto the front drive sprocket and front drive shaft, and then put them in center case.

GI MA EM LC

SMT408A

EC FE CL MT

SMT409A

d. 쐌

Install front drive shaft by tapping lightly. Make sure shafts are aligned in the case.

AT

PD AX SMT410A

e. 쐌

Apply ATF to needle bearings and install them into front drive sprocket. These needle bearings can be installed more easily if front drive sprocket is rotated while installing them.

SU BR ST RS

SMT411A

f. 쐌

Install 2-4 coupling sleeve with 2-4 shift fork. Pay special attention to direction of coupling sleeve.

BT HA SC EL

SMT412A

TF-33

IDX

ASSEMBLY g. 쐌

Install shifting inserts and spread spring. Pay attention to the direction of shifting inserts.

h.

Install baulk ring, then install clutch gear and mainshaft rear bearing. Place wooden block under mainshaft in order to protect mainshaft front bearing.

SMT353A

쐌

SMT413A

i. j.

Install spacer. Select and install snap ring with proper thickness. Allowable clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 in) Available snap ring for mainshaft rear bearing: Refer to “MAINSHAFT REAR BEARING”, TF-38.

k. 쐌

Install steel ball, speedometer drive gear and retainer ring. Steel ball is the smallest of check balls for this unit.

l. 쐌

Install low gear and its bearing onto mainshaft. Apply ATF to needle bearing.

SMT414A

SMT415A

SMT340A

TF-34

ASSEMBLY m. Install L & H hub and snap ring to mainshaft. 쐌 Pay attention to direction of L & H hub.

GI MA EM LC

SMT760A

n.

Measure low gear end play. Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in)

EC FE CL MT

SMT342A

6. 쐌

Apply sealant to mating surface of center case then attach to front case and tighten bolts. Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.

AT

PD AX SMT343A

7.

Install snap ring to 2-4 shift rod.

SU BR ST RS

SMT272A

8. 9.

Install oil gutter and oil cover. Apply ATF to each part in center case.

BT HA SC EL

SMT344A

TF-35

IDX

ASSEMBLY 10. Apply sealant to mating surface of rear case then attach it to center case and tighten bolts. 쐌 Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent. 11. Install 4WD switch. 쐌 Apply sealant to switch threads. 쐌 Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.

SMT497C

12. Install the companion flange and the companion flange nut. 쐌 Tighten the companion flange to specification. Refer to “Gear Components”, TF-13.

WTF003

TF-36

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

General Specifications

NGTF0035

Transfer model

GI

TX10A High

1.000

Low

2.020

Gear ratio

Number of teeth

Fluid capacity

Main gear

29

Low gear

37 High

38

Low

24

MA EM

Counter gear Front drive sprocket

41

Front drive shaft

41


(US qt, Imp qt)

LC EC

2.2 (2-3/8, 2)

Inspection and Adjustment CLEARANCE BETWEEN FRONT DRIVE SPROCKET AND 2-4 COUPLING SLEEVE

FE NGTF0040 NGTF0040S01

Unit: mm (in) Allowable clearance ″C″

CL

0.2 - 0.54 (0.008 - 0.0213)

MT

GEAR END PLAY

NGTF0040S02

Unit: mm (in) Front drive sprocket

0.2 - 0.35 (0.008 - 0.0138)

Low gear

0.2 - 0.35 (0.008 - 0.0138)

Counter gear

AT

0 - 0.2 (0 - 0.008)

CLEARANCE BETWEEN BAULK RING AND CLUTCH GEAR

NGTF0040S03

Unit: mm (in) Standard

Wear limit

1.0 - 1.5 (0.039 - 0.059)

0.5 (0.020)

Available Shim

AX NGTF0040S04

COUNTER GEAR REAR BEARING

SU

NGTF0040S0401

Allowable clearance

BR

0 - 0.2 mm (0 - 0.008 in) Thickness mm (in) 0.1 0.2 0.3 0.4 0.5 0.6

PD

Part No.*

(0.004) (0.008) (0.012) (0.016) (0.020) (0.024)

ST

33112-C6900 33112-C6901 33112-C6902 33112-C6903 33112-33G00 33112-33G01

RS

*: Always check with the Parts Department for the latest parts information.

BT

Available Snap Ring

NGTF0040S05

MAINSHAFT FRONT BEARING

NGTF0040S0501

Allowable clearance

HA

0 - 0.15 mm (0 - 0.0059 in) Thickness mm (in)

Part No.*

SC

3.10 (0.1220) 3.19 (0.1256) 3.28 (0.1291)

33138-73P10 33138-73P11 33138-73P12

EL

*: Always check with the Parts Department for the latest parts information.

TF-37

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) Available Snap Ring (Cont’d)

MAIN GEAR BEARING

NGTF0040S0502

Allowable clearance

0 - 0.15 mm (0 - 0.0059 in) Thickness mm (in)

Part No.*

2.60 (0.1024) 2.69 (0.1059) 2.78 (0.1094)

33114-73P00 33114-73P01 33114-73P02

*: Always check with the Parts Department for the latest parts information.

MAINSHAFT REAR BEARING

NGTF0040S0503

Allowable clearance

0 - 0.15 mm (0 - 0.0059 in) Thickness mm (in) 1.80 1.89 1.98 2.07 2.16

Part No.*

(0.0709) (0.0744) (0.0780) (0.0815) (0.0850)

33138-73P20 33138-73P21 33138-73P22 33138-73P23 33138-73P24

*: Always check with the Parts Department for the latest parts information.

TF-38

PROPELLER SHAFT & DIFFERENTIAL CARRIER SECTION

PD

GI MA EM LC EC

CONTENTS PROPELLER SHAFT ......................................................3 Preparation ..................................................................3 SPECIAL SERVICE TOOLS ........................................3 Noise, Vibration and Harshness (NVH) Troubleshooting ...........................................................4 NVH TROUBLESHOOTING CHART ............................4 Components.................................................................5 FRONT PROPELLER SHAFT .....................................5 REAR PROPELLER SHAFT .......................................6 On-vehicle Service.......................................................7 PROPELLER SHAFT VIBRATION ...............................7 APPEARANCE CHECKING ........................................8 Removal and Installation .............................................8 Inspection.....................................................................9 Disassembly.................................................................9 CENTER BEARING ....................................................9 JOURNAL ...............................................................10 Assembly ...................................................................11 CENTER BEARING ..................................................11 JOURNAL ...............................................................11 Service Data and Specifications (SDS).....................13 GENERAL SPECIFICATIONS ...................................13 SERVICE DATA .......................................................13 R200A FRONT FINAL DRIVE ...................................................14 Preparation ................................................................14 SPECIAL SERVICE TOOLS ......................................14 Noise, Vibration and Harshness (NVH) Troubleshooting .........................................................16 On-vehicle Service.....................................................16 FRONT OIL SEAL REPLACEMENT...........................16 REAR COVER GASKET REPLACEMENT..................17 Components...............................................................18 Removal and Installation ...........................................19 REMOVAL ...............................................................19 INSTALLATION........................................................19 Disassembly...............................................................20 PRE-INSPECTION ...................................................20 FINAL DRIVE HOUSING ..........................................20

FE

DIFFERENTIAL CASE ..............................................23 DIFFERENTIAL SIDE SHAFT ...................................24

Inspection...................................................................25 RING GEAR AND DRIVE PINION .............................25 DIFFERENTIAL CASE ASSEMBLY ...........................25 BEARING ................................................................25 Adjustment .................................................................25 SIDE BEARING PRELOAD .......................................26 PINION GEAR HEIGHT AND PINION BEARING PRELOAD ...............................................................27 TOOTH CONTACT ...................................................31

Assembly ...................................................................32 DIFFERENTIAL SIDE SHAFT ...................................32 DIFFERENTIAL CASE ..............................................33 FINAL DRIVE HOUSING ..........................................34 Service Data and Specifications (SDS).....................38 R200A.....................................................................38

CL MT AT TF

AX SU

C200 REAR FINAL DRIVE .....................................................40 Preparation ................................................................40 SPECIAL SERVICE TOOLS ......................................40 Noise, Vibration and Harshness (NVH) Troubleshooting .........................................................42 On-vehicle Service.....................................................43 FRONT OIL SEAL REPLACEMENT...........................43 REAR COVER GASKET REPLACEMENT..................43 Components...............................................................44 Removal and Installation ...........................................45 REMOVAL ...............................................................45 INSTALLATION........................................................45 Disassembly...............................................................45 PRE-INSPECTION ...................................................45 DIFFERENTIAL CARRIER ........................................46 DIFFERENTIAL CASE ..............................................48 Inspection...................................................................49 RING GEAR AND DRIVE PINION .............................49 DIFFERENTIAL CASE ASSEMBLY ...........................49 BEARING ................................................................49 Adjustment .................................................................49

BR ST RS BT HA SC EL IDX

CONTENTS

(Cont’d)

SIDE BEARING PRELOAD .......................................50 PINION GEAR HEIGHT ............................................51 TOOTH CONTACT ...................................................56

PRE-INSPECTION ...................................................69 DIFFERENTIAL CARRIER ........................................70 DIFFERENTIAL CASE ..............................................72

Assembly ...................................................................57 DIFFERENTIAL CASE ..............................................57 DIFFERENTIAL CARRIER ........................................58 Service Data and Specifications (SDS).....................62 C200 .......................................................................62

Inspection...................................................................73 RING GEAR AND DRIVE PINION .............................73 DIFFERENTIAL CASE ASSEMBLY ...........................73 BEARING ................................................................74 Limited Slip Differential..............................................74 PREPARATION FOR DISASSEMBLY ........................74 DISASSEMBLY ........................................................74 INSPECTION ...........................................................76 ADJUSTMENT .........................................................77 ASSEMBLY .............................................................78 Adjustment .................................................................80 PINION GEAR HEIGHT ............................................80 TOOTH CONTACT ...................................................83 Assembly ...................................................................84 DIFFERENTIAL CASE ..............................................84 DIFFERENTIAL CARRIER ........................................86 Service Data and Specifications (SDS).....................89 H233B.....................................................................89

H233B REAR FINAL DRIVE .....................................................64 Preparation ................................................................64 SPECIAL SERVICE TOOLS ......................................64 Noise, Vibration and Harshness (NVH) Troubleshooting .........................................................66 On-vehicle Service.....................................................66 FRONT OIL SEAL REPLACEMENT...........................66 Components...............................................................68 Removal and Installation ...........................................69 REMOVAL ...............................................................69 INSTALLATION........................................................69 Disassembly...............................................................69

PD-2

PROPELLER SHAFT Preparation

Preparation SPECIAL SERVICE TOOLS

NGPD0001

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

MA

Description

KV38108300 (J44195) Companion flange wrench

Removing and installing propeller shaft lock nut, and drive pinion lock nut

EM LC EC

NT771

ST3090S000 ( — ) Drive pinion rear inner race puller set 1 ST30031000 (J22912-01) Puller 2 ST30901000 (J26010-01) Base

GI

Removing and installing drive pinion rear inner cone a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35 mm (1.38 in) dia.

FE CL MT

NT527

Removing wheel bearing, wheel bearing lock nut and ABS sensor rotor

KV40106500 (J-45073) Rear axle shaft bearing puller

AT TF

LPD022

AX SU BR ST RS BT HA SC EL

PD-3

IDX

Symptom PROPELLER SHAFT

DIFFERENTIAL

Vibration

Noise — — PD-7 PD-7 PD-25, 73 PD-31, 83 PD-25, 73 PD-20, 69

Center bearing mounting (insulator) cracks, damage or deterioration Excessive joint angle Rotation imbalance Excessive runout Rough gear tooth Improper gear contact Tooth surfaces worn Incorrect backlash

× × × × × × ×

Shake

× ×

×

×

×

×

×

×

×: Applicable

PD-4

×

×

×

×

×

Refer to NVH, AX-4 Refer to NVH, AX-4 Refer to NVH, SU-3 Refer to NVH, SU-3 Refer to NVH, SU-3 Refer to NVH, BR-5 Refer to NVH, ST-5

AXLE SUSPENSION TIRES ROAD WHEEL BRAKES STEERING

× DRIVE SHAFT

×

Refer to DIFFERENTIAL in this chart.

× DIFFERENTIAL

Refer to PROPELLER SHAFT in this chart.

—

Improper gear oil PROPELLER SHAFT

—

Companion flange excessive runout

PD-6 —

Noise Excessive center bearing axial end play

Possible cause and SUSPECTED PARTS Center bearing improper installation

—

Reference page

Uneven rotation torque

Noise, Vibration and Harshness (NVH) Troubleshooting

PROPELLER SHAFT Noise, Vibration and Harshness (NVH) Troubleshooting

NVH TROUBLESHOOTING CHART =NGPD0049

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. NGPD0049S01

× × × × × × × ×

× × × × × × ×

×

×

×

×

×

×

×

×

×

×

×

×

PROPELLER SHAFT Components

Components FRONT PROPELLER SHAFT

NGPD0002 NGPD0002S01

GI MA EM LC EC FE CL MT AT TF

WPD016

AX SU BR ST RS BT HA SC EL

PD-5

IDX

PROPELLER SHAFT Components (Cont’d)

REAR PROPELLER SHAFT

NGPD0002S02

WPD001

WPD002

PD-6

PROPELLER SHAFT Components (Cont’d)

GI MA EM LC EC FE CL MT AT WPD021

TF

AX

On-vehicle Service PROPELLER SHAFT VIBRATION

SU NGPD0003

If vibration is present at high speed, inspect propeller shaft runout first. 1. Raise rear end of vehicle until wheels are clear of the ground. 2. Measure propeller shaft runout at several points along propeller shaft by rotating final drive companion flange with hands. Runout limit: 0.6 mm (0.024 in)

BR ST RS

SPD356A

BT HA SC EL

PD-7

IDX

PROPELLER SHAFT On-vehicle Service (Cont’d)

Propeller shaft runout measuring points: Unit: mm (in) Distance 3S1310 (2WD, KA24DE)

A

B

C

M/T

276 (10.87)

341 (13.43)

—

A/T

243 (9.57)

338 (13.31)

—

M/T

290 (11.42)

338 (13.31)

—

A/T

162 (6.38)

240 (9.45)

240 (9.45)

M/T

162 (6.38)

240 (9.45)

240 (9.45)

All

—

474 (18.66)

—

All

271 (10.67)

—

—

3S1310 (2WD, VG33E)

3S80B-2BJ (2WD, VG33ER) 2S1310 (4WD, Rear)

2F1310 (4WD, Front)

3.

WPD009

4. 5.

If runout exceeds specifications, disconnect propeller shaft at final drive companion flange; then rotate companion flange 180 degrees and reconnect propeller shaft. Check runout again. If runout still exceeds specifications, replace propeller shaft assembly. Perform road test.

APPEARANCE CHECKING 쐌 쐌

NGPD0004

Inspect propeller shaft tube surface for dents or cracks. If damaged, replace propeller shaft assembly. If center bearing is noisy or damaged, replace center bearing.

Removal and Installation

NGPD0005

1)

Put match marks on flanges and separate propeller shaft from final drive.

2)

Remove propeller shaft. Insert plug into rear oil seal after removing rear propeller shaft.

SPD103

SPD359

PD-8

PROPELLER SHAFT Inspection

Inspection 쐌

NGPD0006

Inspect propeller shaft runout. If runout exceeds specifications, replace propeller shaft assembly. Runout limit: 0.6 mm (0.024 in)

GI MA EM LC

SPD106

쐌

If the play exceeds specifications, replace propeller shaft assembly. Journal axial play: 0.02 mm (0.0008 in) or less

EC FE CL MT

SPD874

Disassembly CENTER BEARING 1.

NGPD0007

AT

NGPD0007S01

Put match marks on flanges, and separate 2nd tube from 1st tube.

TF

AX SPD109

2.

Put match marks on the flange and shaft.

SU BR ST RS

SPD110

3.

4.

Remove locking nut with Tool. Tool number: KV38108300 (J44195) Remove companion flange with puller.

BT HA SC EL

SPD475A

PD-9

IDX

PROPELLER SHAFT Disassembly (Cont’d)

5.

Remove center bearing with Tool and press. Tool number: ST30031000 (J22912-01)

SPD113

JOURNAL

NGPD0007S02

1.

Put match marks on shaft and flange or yoke.

2.

Remove snap ring.

3.

Remove pushed out journal bearing by lightly tapping yoke with a hammer, taking care not to damage journal and yoke hole.

SPD128

APD011

SPD732

4. Remove bearing at opposite side in above operation. Put marks on disassembled parts so that they can be reinstalled in their original positions from which they were removed.

SPD131

PD-10

PROPELLER SHAFT Assembly

Assembly CENTER BEARING 쐌 쐌

NGPD0008 NGPD0008S01

When installing center bearing, position the “F” mark on center bearing toward front of vehicle. Apply a coat of multi-purpose lithium grease containing molybdenum disulfide to the end face of the center bearing and both sides of the washer.

GI MA EM LC

SPD114

쐌 쐌

Stake the nut. Always use new one. Align match marks when assembling tubes.

EC FE CL MT

SPD117

JOURNAL

NGPD0008S02

1.

Assemble journal bearing. Apply recommended multi-purpose grease on bearing inner surface. When assembling, be careful that needle bearing does not fall down.

AT TF

AX WPD019

2.

Install new snap rings.

SU BR ST RS

APD012

3.

Adjust thrust clearance between bearing and snap ring to zero by tapping yoke.

BT HA SC EL

SPD732

PD-11

IDX

PROPELLER SHAFT Assembly (Cont’d)

4.

Check to see that journal moves smoothly and check for axial play. Axial play: 0.02 mm (0.0008 in) or less

SPD874

PD-12

PROPELLER SHAFT Service Data and Specifications (SDS)

Service Data and Specifications (SDS) GENERAL SPECIFICATIONS 2WD Model (KA24DE and VG33E Engines) Engine

=NGPD0009

KA24DE

Transmission

VG33E

M/T

MA

M/T

Propeller shaft model

A/T

3S1310

Number of joints

EM

3

Coupling method with transmission

Sleeve type

Type of journal bearings Distance between yokes

LC

Solid type (disassembly type) mm (in)

71 (2.80)

1st

640 (25.20)

2nd

687 (27.05)

Shaft length (Spider to spider) mm (in) Shaft outer diameter (in)

mm

80 (3.15)

EC

665 (26.18)

570 (22.44) 684 (26.93)

1st

63.5 (2.50)

2nd

63.5 (2.50)

FE CL

2WD Model (VG33ER Engine)

NGPD0009S03

Transmission

M/T

MT

A/T

Propeller shaft model

3S80B-2BJ

Number of joints

AT

3

Coupling method with transmission

Sleeve type

Type of journal bearings Distance between yokes

TF

Solid type (disassembly type) mm (in)

80 (3.15) 1st

Shaft length (Spider to spider) mm (in)

Shaft outer diameter

GI

NGPD0009S01

681 (26.81)

586 (23.07)

2nd

685 (26.97)

1st

75 (2.95)

2nd

65 (2.56)

AX

mm (in)

SU 4WD Model

NGPD0009S02

Location Propeller shaft model Number of joints Coupling method with transmission Type of journal bearings Distance between yokes

Rear

2F1310

2S1310

2

2

Flange type

Sleeve type

ST RS

Solid type (disassembly type) mm (in)

Shaft length (Spider to spider) Shaft outer diameter

BR

Front

mm (in)

mm (in)

71 (2.80)

80 (3.15)

522 (20.60)

954.3 (37.57)

50.8 (2.0)

76.2 (3.0)

BT HA

SERVICE DATA

NGPD0010

Unit: mm (in) Propeller shaft runout limit

0.6 (0.024)

Journal axial play

SC

0.02 (0.0008) or less

EL

PD-13

IDX

FRONT FINAL DRIVE

R200A

Preparation

Preparation SPECIAL SERVICE TOOLS

NGPD0013

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name ST3127S000 (See J25765-A) Preload gauge 1 GG91030000 (J25765) Torque wrench 2 HT62940000 ( — ) Socket adapter 3 HT62900000 ( — ) Socket adapter

Description Measuring pinion bearing preload and total preload

NT124

Mounting final drive (To use, make a new hole.) a: 152 mm (5.98 in)

KV38100800 (J34310, J25604-01) Differential attachment

NT119

Removing and installing propeller shaft lock nut, and drive pinion lock nut

KV38108300 (J44195) Companion flange wrench

NT771

ST3090S000 ( — ) Drive pinion rear inner race puller set 1 ST30031000 (J22912-01) Puller 2 ST30901000 (J26010-01) Base ST3306S001 Differential side bearing puller set 1 ST33051001 (J22888-20) Body 2 ST33061000 (J8107-2) Adapter

Removing and installing drive pinion rear inner cone a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35 mm (1.38 in) dia.

NT527

Removing and installing differential side bearing inner cone a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia.

NT072

Installing side bearing inner cone a: 54 mm (2.13 in) dia. b: 46 mm (1.81 in) dia. c: 32 mm (1.26 in) dia.

KV38100300 (J25523) Differential side bearing drift

NT085

PD-14

FRONT FINAL DRIVE

R200A Preparation (Cont’d)

Tool number (Kent-Moore No.) Tool name

Description

GI

KV38100600 (J25267) Side bearing spacer drift

Installing side bearing spacer a: 8 mm (0.31 in) b: R42.5 mm (1.673 in)

MA EM

NT528

Installing pinion rear bearing outer race (Use with ST30621000 or ST30613000)

ST30611000 (J25742-1) Drift

LC EC

NT090

Installing pinion rear bearing outer race (Use with ST30611000) a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia.

ST30621000 (J25742-5) Drift

FE CL

NT073

Installing pinion front bearing outer race (Use with ST30611000) a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia.

ST30613000 (J25742-3) Drift

MT AT TF

NT073

Installing front oil seal a: 85 mm (3.35 in) dia. b: 60 mm (2.36 in) dia.

KV38100500 (J25273) Gear carrier front oil seal drift

AX

NT115

Installing side oil seal

KV38100200 (J26233) Gear carrier side oil seal drift

SU BR NT120

Adjusting bearing pre-load and gear height

(J34309) Differential shim selector

ST RS BT HA

NT134

Selecting pinion height adjusting washer

(J25269-4) Side bearing discs (2 Req’d)

SC EL

NT136

PD-15

IDX

FRONT FINAL DRIVE

R200A

Preparation (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

(J8129) Spring gauge

Measuring carrier turning torque

NT127

Noise, Vibration and Harshness (NVH) Troubleshooting

NGPD0050

Refer to “NVH TROUBLESHOOTING CHART”, PD-4.

On-vehicle Service FRONT OIL SEAL REPLACEMENT (Front final drive: Model R200A) 1. Remove front propeller shaft. 2. Loosen drive pinion nut. Tool number: KV38108300 (J44195)

SPD476A

3.

Remove companion flange.

4.

Remove front oil seal.

SPD734

SPD735

PD-16

NGPD0014

FRONT FINAL DRIVE

R200A On-vehicle Service (Cont’d)

5. 6. 7.

Apply multi-purpose grease to cavity at sealing lips of oil seal. Press front oil seal into carrier. Install companion flange and drive pinion nut. Install propeller shaft. Tool number: KV38100500 (J25273)

GI MA EM LC

SPD736

REAR COVER GASKET REPLACEMENT 1. 2. 3. 4.

Drain gear oil. Remove rear cover and rear cover gasket. Install new rear cover gasket and rear cover. Fill final drive with recommended gear oil.

NGPD0015

EC FE CL MT

SPD740-A

AT TF

AX SU BR ST RS BT HA SC EL

PD-17

IDX

FRONT FINAL DRIVE

R200A

Components

Components

NGPD0016

WPD007

PD-18

FRONT FINAL DRIVE

R200A Removal and Installation

Removal and Installation REMOVAL

NGPD0017 NGPD0017S01

1) 2)

SPD741

Remove propeller shaft. Separate drive shaft from front final drive. Refer to AX-7, “Drive Shaft”. 3) Remove engine mounting bolts and raise up engine. 4) Remove front final drive together with differential mounting member. CAUTION: Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft. Before removing the final drive assembly or rear axle assembly, disconnect the ABS sensor harness connector from the assembly and move it away from the final drive/rear axle assembly area. Failure to do so may result in the sensor wires being damaged and the sensor becoming inoperative.

GI MA EM LC EC FE CL MT

INSTALLATION 1)

NGPD0017S02

Install front final drive assembly together with differential mounting member.

AT TF

AX SPD742

2) a) b) c) d) e) f) g) 3) 4)

Tighten front final drive securing bolts and nuts by following the procedure to prevent drive train vibration. Temporarily tighten nut A. Temporarily tighten nut B. Tighten bolt C to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m, 50 to 64 ft-lb). Tighten bolt D to the torque of 68 to 87 N·m(6.9 to 8.9 kg-m, 50 to 64 ft-lb). Tighten bolt A to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m, 50 to 64 ft-lb). Tighten bolt B to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m, 50 to 64 ft-lb). Tighten bolt E to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m, 50 to 64 ft-lb). Install drive shaft. Refer to AX-7, “Drive Shaft”. Install propeller shaft. Refer to “Removal and Installation”, PD-8.

SU BR ST RS BT HA SC EL

SPD743

PD-19

IDX

FRONT FINAL DRIVE

R200A

Disassembly

Disassembly PRE-INSPECTION

SPD664

NGPD0018 NGPD0018S01

Before disassembling final drive, perform the following inspection. 쐌 Total preload a) Turn drive pinion in both directions several times to set bearing rollers. b) Check total preload with Tool. Tool number: ST3127S000 (J25765-A) Total preload: 1.4 - 1.7 N·m (14 - 17 kg-cm, 12 - 15 in-lb) 쐌

Ring gear to drive pinion backlash Check backlash of ring gear with a dial indicator at several points. Ring gear-to-drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)

쐌

Ring gear runout Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm (0.0020 in) Tooth contact Check tooth contact. Refer to “TOOTH CONTACT”, PD-31.

SPD513

쐌

SPD524

쐌

Side gear to pinion mate gear backlash Using a feeler gauge, measure clearance between side gear thrust washer and differential case. Clearance between side gear thrust washer and differential case: Less than 0.15 mm (0.0059 in)

SPD665

FINAL DRIVE HOUSING 1.

NGPD0018S02

Using three spacers [20 mm (0.79 in)], mount final drive assembly on Tool. Tool number: KV38100800 (J34310, J25604-01)

SPD666

PD-20

FRONT FINAL DRIVE

R200A Disassembly (Cont’d)

2.

Remove differential side shaft assembly.

GI MA EM LC

SPD644

3.

Remove differential side flange.

EC FE CL MT

SPD667

4.

Put match marks on one side of side bearing cap with paint or punch to ensure that it is replaced in proper position during reassembly. Bearing caps are line-bored during manufacture and should be put back in their original places.

AT TF

AX SPD526

5.

Remove side bearing caps.

SU BR ST RS

PD343

6.

Remove differential case assembly with a pry bar.

BT HA SC EL

SPD668

PD-21

IDX

FRONT FINAL DRIVE

R200A

Disassembly (Cont’d)

Be careful to keep the side bearing outer races together with their respective inner cones — do not mix them up. CAUTION: Side bearing spacer is placed on either the left or right depending upon final drive gear ratio. It should be labeled so that it may be replaced correctly.

SPD527

7. 8.

Loosen drive pinion nut. Tool number: KV38108300 (J44195) Remove companion flange with puller.

SPD477A

9.

Take out drive pinion together with rear bearing inner cone, drive pinion bearing spacer and pinion bearing adjusting washer. 10. Remove front oil seal and pinion front bearing inner cone.

SPD670

11. Remove pinion bearing outer races with a brass drift.

PD349

12. Remove pinion rear bearing inner cone and drive pinion height adjusting washer. Tool number: ST30031000 (J22912-01)

SPD209

PD-22

FRONT FINAL DRIVE

R200A Disassembly (Cont’d)

DIFFERENTIAL CASE

NGPD0018S03

1. Remove side bearing inner cones. To prevent damage to bearing, engage puller jaws in grooves. Tool number: A ST33051001 (J22888-20) B ST33061000 (J8107-2)

GI MA EM LC EC FE CL MT

SPD529

Be careful not to confuse the right-hand and left-hand parts. Keep bearing and bearing race for each side together.

AT TF

AX SPD022

2. Loosen ring gear bolts in a crisscross pattern. 3. Tap ring gear off the differential case with a soft hammer. Tap evenly all around to keep ring gear from binding.

SU BR ST RS

SPD024

4.

Punch off pinion mate shaft lock pin from ring gear side. Lock pin is caulked at pin hole mouth on differential case.

BT HA SC EL

SPD025

PD-23

IDX

FRONT FINAL DRIVE

R200A

Disassembly (Cont’d)

DIFFERENTIAL SIDE SHAFT

NGPD0018S04

1.

Cut collar with cold chisel. Be careful not to damage differential side shaft.

2.

Reinstall differential side shaft into extension tube and secure with bolts. Remove rear axle bearing by drawing out differential side shaft from rear axle bearing with puller.

3.

Remove grease seal and oil seal.

SPD236A

SPD672

SPD647

SPD781

PD-24

FRONT FINAL DRIVE

R200A Inspection

Inspection RING GEAR AND DRIVE PINION

NGPD0019 NGPD0019S01

Check gear teeth for scoring, cracking or chipping. If any damaged part is evident, replace ring gear and drive pinion as a set (hypoid gear set).

GI MA EM LC

DIFFERENTIAL CASE ASSEMBLY

NGPD0019S02

Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft and thrust washers.

EC FE CL MT

SPD097AA

BEARING 1. 2.

NGPD0019S03

Thoroughly clean bearing. Check bearing for wear, scratches, pitting or flaking. Check tapered roller bearing for smooth rotation. If damaged, replace outer race and inner cone as a set.

AT TF

AX SPD715

Adjustment

NGPD0020

For quiet and reliable final drive operation, the following five adjustments must be made correctly: 1. Side bearing preload. Refer to “Side Bearing Adjustment”, PD-38. 2. Pinion gear height. Refer to “Drive Pinion Height Adjustment”, PD-39. 3. Pinion bearing preload. Refer to “Drive Pinion Preload Adjustment”, PD-39. 4. Ring gear-to-pinion backlash. Refer to “Total Preload Adjustment”, PD-38. 5. Ring and pinion gear tooth contact pattern. Refer to “TOOTH CONTACT”, PD-31.

SU BR ST RS BT HA SC EL

PD-25

IDX

FRONT FINAL DRIVE

R200A

Adjustment (Cont’d)

SIDE BEARING PRELOAD

NGPD0020S01

A selection of carrier side bearing adjusting washer is required for successful completion of this procedure. 1. Make sure all parts are clean and that the bearings are well lubricated with light oil or “DEXRONTM” type automatic transmission fluid. 2. Place the differential carrier, with side bearings and bearing races installed, into the final drive housing.

SPD527

3. Put the side bearing spacer in place. CAUTION: Side bearing spacer is placed on either the right or left depending upon final drive gear ratio. Be sure to replace it on the correct side.

SPD894

4.

Using Tool, install original carrier side bearing preload shims on the carrier end, opposite the ring gear. Tool number: KV38100600 (J25267)

5.

Install the side bearing caps in their correct locations and torque the bearing cap retaining bolts. Specification: 88 - 98 N·m (9 - 10 kg-m, 65 - 72 ft-lb) Turn the carrier several times to seat the bearings.

SPD986

6.

SPD526

7.

Measure the turning torque of the carrier at the ring gear retaining bolts with a spring gauge, J8129. Specification: 34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) of pulling force at the ring gear bolt

SPD194A

PD-26

FRONT FINAL DRIVE

R200A Adjustment (Cont’d)

8.

9.

If the carrier turning torque is not within the specification range, increase or decrease the total thickness of the side bearing adjusting washers until the turning torque is correct. If the turning torque is less than the specified range, install washers of greater thickness; if the turning torque is greater than the specification, install thinner washers to side bearing. Side bearing adjustment: Refer to “Side Bearing Adjustment”, PD-38. Record the total amount of washer thickness required for the correct carrier side bearing preload.

GI MA EM LC

SPD772

10. Remove the carrier from the final drive housing, saving the selected preload washers for later use during the assembly of the final drive unit.

EC FE CL MT

SPD668

PINION GEAR HEIGHT AND PINION BEARING PRELOAD 1. 2.

NGPD0020S02

Make sure all parts are clean and that the bearings are well lubricated. Assemble the pinion gear bearings into the pinion preload shim selector Tool, J34309.

AT TF

AX SPD769

쐌

쐌

Front Pinion Bearing — make sure the J34309-3 front pinion bearing seat is secured tightly against the J34309-2 gauge anvil. Then turn the front pinion bearing pilot, J34309-5, to secure the bearing in its proper position. Rear Pinion Bearing — the rear pinion bearing pilot, J3430915, is used to center the rear pinion bearing only. The rear pinion bearing locking seat, J34309-4, is used to lock the bearing to the assembly.

SU BR ST RS

SPD197A

3.

Place the pinion preload shim selector Tool, J34309-1, gauge screw assembly with the pinion rear bearing inner cone installed into the final drive housing.

BT HA SC EL

SPD893

PD-27

IDX

FRONT FINAL DRIVE

R200A

Adjustment (Cont’d)

4.

Assemble the front pinion bearing inner cone and the J34309-2 gauge anvil together with the J34309-1 gauge screw in the final drive housing. Make sure that the pinion height gauge plate, J34309-16, will turn a full 360 degrees, and tighten the two sections together by hand.

5.

Turn the assembly several times to seat the bearings.

6.

Measure the turning torque at the end of the J34309-2 gauge anvil using torque wrench J25765A. Turning torque specification: 1.0 - 1.3 N·m (10 - 13 kg-cm, 8.7 - 11.3 in-lb)

SPD199A

SPD770

SPD234A

7.

Place the J34309-1 “R200A” pinion height adapter onto the gauge plate and tighten it by hand. CAUTION: Make sure all machined surfaces are clean.

SPD208A

PINION BEARING PRELOAD WASHER SELECTION 8. Place the solid pinion bearing spacer, small end first, over the J34309-2 gauge anvil and seat the small end squarely against the tip of the J34309-1 gauge screw in the tool recessed portion.

SPD209A

PD-28

FRONT FINAL DRIVE

R200A Adjustment (Cont’d)

GI MA EM LC

SPD773

9.

Select the correct thickness of pinion bearing preload adjusting washer using a standard gauge of 3.5 mm (0.138 in) and J34309-101 feeler gauge. The exact measure is the thickness of the adjusting washer required. Select the correct washer. Drive pinion bearing preload adjusting washer: Refer to “Drive Pinion Preload Adjustment”, PD-39. 10. Set your selected, correct pinion bearing preload adjusting washer aside for use when assembling the pinion gear and bearings into the final drive.

EC FE CL MT

SPD210A

AT TF

AX SPD774

PINION HEIGHT ADJUSTING WASHER SELECTION 11. Now, position the side bearing discs, J25269-4, and arbor firmly into the side bearing bores.

SU BR ST RS

SPD211A

12. Install the side bearing caps and tighten the cap bolts. Specification: 88 - 98 N·m (9 - 10 kg-m, 65 - 72 ft-lb)

BT HA SC EL

SPD212A

PD-29

IDX

FRONT FINAL DRIVE

R200A

Adjustment (Cont’d)

13. Select the correct standard pinion height adjusting washer thickness by using a standard gauge of 3.0 mm (0.118 in) and your J34309-101 feeler gauge. Measure the gap between the J34309-11 “R200A” pinion height adapter and the arbor. 14. Write down the exact total measurement.

SPD204A

15. Correct the pinion height washer size by referring to the “pinion head number”. There are two numbers painted on the pinion gear. The first one refers to the pinion and ring gear as a matched set and should be the same as the number on the ring gear. The second number is the “pinion head height number”, and it refers to the ideal pinion height from standard for quietest operation. Use the following chart to determine the correct pinion height washer. Refer to “Drive Pinion Height Adjustment”, PD-39. SPD542

Pinion Head Height Number

Add or Remove from the Standard Pinion Height Washer Thickness Measurement

−6

Add 0.06 mm (0.0024 in)

−5

Add 0.05 mm (0.0020 in)

−4

Add 0.04 mm (0.0016 in)

−3

Add 0.03 mm (0.0012 in)

−2

Add 0.02 mm (0.0008 in)

−1

Add 0.01 mm (0.0004 in)

0

Use the selected washer thickness

+1

Subtract 0.01 mm (0.0004 in)

+2

Subtract 0.02 mm (0.0008 in)

+3

Subtract 0.03 mm (0.0012 in)

+4

Subtract 0.04 mm (0.0016 in)

+5

Subtract 0.05 mm (0.0020 in)

+6

Subtract 0.06 mm (0.0024 in)

16. Select the correct drive pinion height washer. Drive pinion height adjusting washer: Refer to “Drive Pinion Height Adjustment”, PD-39.

PD-30

FRONT FINAL DRIVE

R200A Adjustment (Cont’d)

17. Remove the J34309 pinion preload shim selector tool from the final drive housing and disassemble to retrieve the pinion bearings.

GI MA EM LC

SPD205A

TOOTH CONTACT

NGPD0020S03

Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion. Hypoid gear sets which are not positioned properly in relation to one another may be noisy, or have short life, or both. With a pattern check, the most desirable contact for low noise level and long life can be assured.

EC FE CL MT

1. 2.

Thoroughly clean ring gear and drive pinion teeth. Sparingly apply a mixture of powdered ferric oxide and oil or equivalent to 3 or 4 teeth of ring gear drive side.

AT TF

AX SPD357

3.

Hold companion flange steady by hand and rotate the ring gear in both directions.

SU BR ST RS

SPD677

BT HA SC EL

PD-31

IDX

FRONT FINAL DRIVE

R200A

Adjustment (Cont’d)

SPD007-B

Assembly DIFFERENTIAL SIDE SHAFT

NGPD0021 NGPD0021S01

1.

Install oil seal and grease seal. Tool number: KV38100200 (J26233)

2.

Install extension tube retainer, rear axle bearing and rear axle shaft bearing collar on differential side shaft.

SPD782-A

SPD654-A

SPD655

PD-32

FRONT FINAL DRIVE

R200A Assembly (Cont’d)

DIFFERENTIAL CASE 1.

NGPD0021S02

Install side gears, pinion mate gears and thrust washers into differential case.

GI MA EM LC

SPD552

2. 3.

Fit pinion mate shaft to differential case so that it meets lock pin holes. Adjust backlash between side gear and pinion mate gear by selecting side gear thrust washer. Refer to “Side Gear Adjustment”, PD-38. Backlash between side gear and pinion mate gear (Clearance between side gear thrust washer and differential case): Less than 0.15 mm (0.0059 in)

EC FE CL MT

SPD258

4. Install pinion mate shaft lock pin with a punch. Make sure lock pin is flush with case.

AT TF

AX SPD030

5.

Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.

SU BR ST RS

SPD322

6. 7.

Install differential case assembly on ring gear. Apply locking agent [Loctite (stud lock) or equivalent] to ring gear bolts, and install them. Tighten bolts in a crisscross pattern.

BT HA SC EL

SPD554

PD-33

IDX

FRONT FINAL DRIVE

R200A

Assembly (Cont’d)

8.

Press-fit side bearing inner cones on differential case with Tool. Tool number: A KV38100300 (J25523) B ST33061000 (J8107-2)

PD353

FINAL DRIVE HOUSING

NGPD0021S03

1.

Press-fit front and rear bearing outer races with Tools. Tool number: A ST30611000 (J25742-1) B ST30621000 (J25742-5) C ST30613000 (J25742-3)

2.

Select drive pinion height adjusting washer and pinion bearing adjusting washer. Refer to “PINION GEAR HEIGHT AND PINION BEARING PRELOAD”, PD-27. Install drive pinion height adjusting washer in drive pinion, and press-fit pinion rear bearing inner cone in it, using press and Tool. Tool number: ST30901000 (J26010-01)

SPD679

3.

SPD377

4.

Place pinion front bearing inner cone in final drive housing.

SPD581

PD-34

FRONT FINAL DRIVE

R200A Assembly (Cont’d)

5.

Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal. Tool number: KV38100500 (J25273)

GI MA EM LC

SPD680

6.

Place drive pinion bearing spacer, drive pinion bearing adjusting washer and drive pinion in final drive housing.

EC FE CL MT

SPD658

7.

Insert companion flange into drive pinion by tapping the companion flange with a soft hammer.

AT TF

AX SPD681

8. Tighten pinion nut to the specified torque. The threaded portion of drive pinion and pinion nut should be free from oil or grease. Tool number: KV38108300 (J44195)

SU BR ST RS

SPD478A

9.

Turn drive pinion in both directions several revolutions, and measure pinion bearing preload. Tool number: ST3127S000 (J25765-A) Pinion bearing preload: 1.1 - 1.4 N·m (11 - 14 kg-cm, 9.5 - 12.2 in-lb) When pinion bearing preload is outside the specifications, replace pinion bearing adjusting washer and spacer with a different thickness.

BT HA SC EL

SPD664

PD-35

IDX

FRONT FINAL DRIVE

R200A

Assembly (Cont’d)

10. Select side bearing adjusting washer. Refer to “SIDE BEARING PRELOAD”, PD-26. 11. Install differential case assembly with side bearing outer races into final drive housing.

SPD527

12. Insert left and right side bearing adjusting washers in place between side bearings and final drive housing.

SPD558

13. Drive in side bearing spacer with Tool. Tool number: KV38100600 (J25267)

SPD559

14. Align mark on bearing cap with that on final drive housing and install bearing cap on final drive housing.

SPD526

15. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install side oil seal. Tool number: KV38100200 (J26233)

SPD560

PD-36

FRONT FINAL DRIVE

R200A Assembly (Cont’d)

16. Measure ring gear-to-pinion backlash with a dial indicator. Ring gear-to-drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in) 쐌 If backlash is too small, decrease thickness of right shim and increase thickness of left shim by the same amount. If backlash is too great, reverse the above procedure. Never change the total amount of shims as it will change the bearing preload.

GI MA EM LC

SPD513

17. Check total preload with Tool. When checking preload, turn drive pinion in both directions several times to set bearing rollers. Tool number: ST3127S000 (J25765-A) Total preload: 1.4 - 1.7 N·m (14 - 17 kg-cm, 12 - 15 in-lb)

EC FE CL MT

SPD664

쐌

If preload is too great, remove the same amount of shim from each side. 쐌 If preload is too small, add the same amount of shim to each side. Never add or remove a different number of shims for each side as it will change ring gear to drive pinion backlash. 18. Recheck ring gear-to-pinion backlash because increase or decrease in thickness of shims will cause change of ring gearto-pinion backlash.

AT TF

AX SPD561

SPD524

19. Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm (0.0020 in) 쐌 If backlash varies excessively in different places, the variance may have resulted from foreign matter caught between the ring gear and the differential case. 쐌 If the backlash varies greatly when the runout of the ring gear is within a specified range, the hypoid gear set or differential case should be replaced. 20. Check tooth contact. Refer to “TOOTH CONTACT”, PD-31. 21. Install rear cover and gasket. 22. Install differential side shaft assembly.

SU BR ST RS BT HA SC EL

SPD682

PD-37

IDX

FRONT FINAL DRIVE

R200A

Service Data and Specifications (SDS)

Service Data and Specifications (SDS) R200A General Specifications

=NGPD0022

Engine

VG33E

Vehicle grade

VG33ER

XE Standard

SE Optional

Front final drive

SC Standard

R200A 2-pinion

Gear ratio

4.636

4.900

4.900

4.636

Number of teeth (Ring gear/drive pinion)

51/11

49/10

49/10

51/11

Oil capacity (Approx.)
(US pt, lmp pt)

1.75 (3-3/4, 3-1/8)

Ring Gear Runout Ring gear runout limit

NGPD0023

mm (in)

0.05 (0.0020)

Side Gear Adjustment

NGPD0024

Side gear backlash (Clearance between side gear and differential case) (in)

mm

Thickness mm (in) 0.75 0.78 0.81 0.84 0.87 0.90 0.93

Available side gear thrust washers

Less than 0.15 (0.0059) Part number*

(0.0295) (0.0307) (0.0319) (0.0331) (0.0343) (0.0354) (0.0366)

38424-N3110 38424-N3111 38424-N3112 38424-N3113 38424-N3114 38424-N3115 38424-N3116

*Always check with the Parts Department for the latest parts information.

Side Bearing Adjustment

NGPD0025

Differential carrier assembly turning resistance

N (kg, lb)

34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8)

Thickness mm (in) 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60

Available side bearing adjusting washers

Part number*

(0.0787) (0.0807) (0.0827) (0.0846) (0.0866) (0.0886) (0.0906) (0.0925) (0.0945) (0.0965) (0.0984) (0.1004) (0.1024)

38453-N3100 38453-N3101 38453-N3102 38453-N3103 38453-N3104 38453-N3105 38453-N3106 38453-N3107 38453-N3108 38453-N3109 38453-N3110 38453-N3111 38453-N3112

*Always check with the Parts Department for the latest parts information.

Total Preload Adjustment Total preload

NGPD0026

N·m (kg-cm, in-lb)

Ring gear-to-pinion backlash

1.4 - 1.7 (14 - 17, 12 - 15)

mm (in)

0.10 - 0.15 (0.0039 - 0.0059)

PD-38

FRONT FINAL DRIVE

R200A

Service Data and Specifications (SDS) (Cont’d)

Drive Pinion Height Adjustment

Available pinion height adjusting washers

NGPD0027

Thickness mm (in)

Part number*

3.09 (0.1217) 3.12 (0.1228) 3.15 (0.1240) 3.18 (0.1252) 3.21 (0.1264) 3.24 (0.1276) 3.27 (0.1287) 3.30 (0.1299) 3.33 (0.1311) 3.36 (0.1323) 3.39 (0.1335) 3.42 (0.1346) 3.45 (0.1358) 3.48 (0.1370) 3.51 (0.1382) 3.54 (0.1394) 3.57 (0.1406) 3.60 (0.1417) 3.63 (0.1429) 3.66 (0.1441)

38154-P6017 38154-P6018 38154-P6019 38154-P6020 38154-P6021 38154-P6022 38154-P6023 38154-P6024 38154-P6025 38154-P6026 38154-P6027 38154-P6028 38154-P6029 38154-P6030 38154-P6031 38154-P6032 38154-P6033 38154-P6034 38154-P6035 38154-P6036

GI MA EM LC EC FE CL

*Always check with the Parts Department for the latest parts information.

Drive Pinion Preload Adjustment

NGPD0028

Drive pinion bearing preload adjusting method

Adjusting washer and spacer

Drive pinion preload with front oil seal

N·m (kg-cm, in-lb)

1.1 - 1.4 (11 - 14, 9.5 - 12.2)

Thickness mm (in)

Part number*

Available drive pinion bearing preload adjusting washers

Available drive pinion bearing preload adjusting spacers

3.81 3.83 3.85 3.87 3.89 3.91 3.93 3.95 3.97 3.99 4.01 4.03 4.05 4.07 4.09

(0.1500) (0.1508) (0.1516) (0.1524) (0.1531) (0.1539) (0.1547) (0.1555) (0.1563) (0.1571) (0.1579) (0.1587) (0.1594) (0.1602) (0.1610)

38125-61001 38126-61001 38127-61001 38128-61001 38129-61001 38130-61001 38131-61001 38132-61001 38133-61001 38134-61001 38135-61001 38136-61001 38137-61001 38138-61001 38139-61001

Length mm (in)

Part number*

54.50 (2.1457) 54.80 (2.1575) 55.10 (2.1693) 55.40 (2.1811) 55.70 (2.1929) 56.00 (2.2047)

38165-B4000 38165-B4001 38165-B4002 38165-B4003 38165-B4004 38165-61001

*Always check with the Parts Department for the latest parts information.

MT AT TF

AX SU BR ST RS BT HA SC EL

PD-39

IDX

REAR FINAL DRIVE

C200

Preparation

Preparation SPECIAL SERVICE TOOLS

NGPD0052

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name ST3127S000 (See J25765-A) Preload gauge 1 GG91030000 (J25765) Torque wrench 2 HT62940000 ( — ) Socket adapter 3 HT62900000 ( — ) Socket adapter

Description Measuring pinion bearing preload and total preload

NT124

Removing and installing propeller shaft lock nut and drive pinion lock nut

KV38108300 (J44195) Companion flange wrench

NT771

ST3090S000 ( — ) Drive pinion rear inner race puller set 1 ST30031000 (J22912-01) Puller 2 ST30901000 (J26010-01) Base ST3306S001 Differential side bearing puller set 1 ST33051001 (J22888-20) Body 2 ST33061000 (J8107-2) Adapter

Removing and installing drive pinion rear inner cone a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35 mm (1.38 in) dia.

NT527

Removing and installing differential side bearing inner cone a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia.

NT072

Installing side bearing inner cone a: 51 mm (2.01 in) dia. b: 41 mm (1.61 in) dia. c: 28.5 mm (1.122 in) dia.

ST33230000 (J25805-01) Differential side bearing drift

NT085

Installing side bearing inner cone a: 43 mm (1.69 in) dia. b: 33.5 mm (1.319 in) dia.

ST33081000 ( — ) Side bearing puller adapter

NT431

PD-40

REAR FINAL DRIVE

C200 Preparation (Cont’d)

Tool number (Kent-Moore No.) Tool name

Description

GI

KV38100600 (J25267) Side bearing spacer drift

Installing side bearing spacer a: 8 mm (0.31 in) b: R42.5 mm (1.673 in)

MA EM

NT528

Installing pinion rear bearing outer race

ST30611000 (J25742-1) Drift

LC EC NT090

Installing pinion rear bearing outer race a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia.

ST30621000 (J25742-5) Drift

FE CL

NT073

Installing pinion front bearing outer race a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia.

ST30613000 (J25742-3) Drift

MT AT TF

NT073

Installing front oil seal a: 85 mm (3.35 in) dia. b: 60 mm (2.36 in) dia.

KV38100500 (J25273) Gear carrier front oil seal drift

AX

NT115

Adjusting bearing pre-load and gear height

(J34309) Differential shim selector

SU BR ST RS

NT134

Selecting pinion height adjusting washer

(J25269-4) Side bearing discs (2 Req’d)

BT NT136

HA Measuring carrier turning torque

(J8129) Spring gauge

SC EL

NT127

PD-41

IDX

REAR FINAL DRIVE

C200

Preparation (Cont’d) Tool number (Kent-Moore No.) Tool name KV381051S0 ( — ) Rear axle shaft dummy 1 KV38105110 ( — ) Torque wrench side 2 KV38105120 ( — ) Vise side

Description Checking differential torque on limited slip differential

NT142

Noise, Vibration and Harshness (NVH) Troubleshooting Refer

to

“NVH

PD-42

TROUBLESHOOTING

CHART”,

NGPD0053

PD-4.

REAR FINAL DRIVE

C200 On-vehicle Service

On-vehicle Service FRONT OIL SEAL REPLACEMENT 1. 2.

=NGPD0064

Remove propeller shaft. Refer to “Removal and Installation”, PD-8. Remove drive pinion nut. Tool number: KV38108300 (J44195)

GI MA EM LC

APD032

3. 4.

Remove companion flange. Remove ABS sensor and sensor rotor.

EC FE CL MT

SPD737

5.

Remove front oil seal.

AT TF

AX WPD013

6.

7. 8. 9.

Apply multi-purpose grease to cavity at sealing lips of oil seal. Press front oil seal into carrier. Tool number: KV38100500 (J25273) Install ABS sensor and sensor rotor. Install companion flange and drive pinion nut. Install rear propeller shaft.

SU BR ST RS

WPD014

REAR COVER GASKET REPLACEMENT (Rear final drive: Model C200) 1. Drain gear oil. 2. Remove rear cover and rear cover gasket. 3. Install new rear cover gasket and rear cover. 4. Fill final drive with recommended gear oil.

NGPD0054

BT HA SC EL

SPD740-A

PD-43

IDX

REAR FINAL DRIVE

C200

Components

Components

NGPD0055

WPD024

PD-44

REAR FINAL DRIVE

C200 Removal and Installation

Removal and Installation REMOVAL 쐌

NGPD0056 NGPD0056S01

Remove propeller shaft. Refer to “Removal and Installation”, PD-8. Plug end of transfer case. 쐌 Remove axle shaft. Refer to AX-32, “REAR AXLE”. CAUTION: 쐌 Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft. 쐌 Before removing the final drive assembly or rear axle assembly, disconnect the ABS sensor harness connector from the assembly and move it away from the final drive/ rear axle assembly area. Failure to do so may result in the sensor wires being damaged and the sensor becoming inoperative.

GI MA EM LC EC FE CL MT

INSTALLATION 쐌

NGPD0056S02

Fill final drive with recommended gear oil.

AT TF

AX SPD123

Disassembly PRE-INSPECTION

PD245

NGPD0057

Before disassembling final drive, perform the following inspection. 쐌 Total preload a) Turn drive pinion in both directions several times to set bearing rollers. b) Check total preload with Tool. Tool number: ST3127S000 (J25765-A) Total preload: 1.2 - 2.3 N·m (12 - 23 kg-cm, 10 - 20 in-lb) 쐌

SU

NGPD0057S01

Ring gear-to-drive pinion backlash. Check backlash of ring gear with a dial indicator at several points. Ring gear-to-drive pinion backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in)

BR ST RS BT HA SC EL

SPD196

PD-45

IDX

REAR FINAL DRIVE

C200

Disassembly (Cont’d)

쐌

Ring gear runout Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm (0.0020 in)

쐌

Tooth contact Check tooth contact. Refer to “TOOTH CONTACT”, PD-56. Side gear-to-pinion mate gear backlash Measure clearance between side gear thrust washer and differential case with a feeler gauge. Clearance between side gear thrust washer and differential case: Less than 0.15 mm (0.0059 in)

SPD702

쐌

SPD198

DIFFERENTIAL CARRIER 1. 2. 3.

NGPD0057S02

Drain gear oil. Remove rear cover and rear cover gasket. Put match marks on one side of side bearing cap with paint or punch to ensure that it is replaced in proper position during reassembly. Bearing caps are line-bored during manufacture and should be put back in their original places.

SPD714

4.

Remove side bearing caps.

5.

Remove differential case assembly with pry bar.

SPD202

SPD193

PD-46

REAR FINAL DRIVE

C200 Disassembly (Cont’d)

Keep the side bearing outer races together with their respective inner cones — do not mix them up.

GI MA EM LC

SPD745

6.

Remove pinion nut with Tool. Tool number: KV38108300 (J44195)

EC FE CL MT

APD032

7. 8.

Remove companion flange with puller. Remove ABS sensor and sensor rotor.

AT TF

AX SPD014

9. Remove drive pinion with soft hammer. 10. Remove front oil seal and pinion front bearing inner cone.

SU BR ST RS

SPD206

11. Remove pinion bearing outer races with a brass drift.

BT HA SC EL

PD349

PD-47

IDX

REAR FINAL DRIVE

C200

Disassembly (Cont’d)

12. Remove pinion rear bearing inner cone and pinion height adjusting washer. Tool number: ST30031000 (J22912-01)

PD179

DIFFERENTIAL CASE 1.

NGPD0057S03

Remove side bearing inner cones. To prevent damage to bearing, engage puller jaws in grooves. Tool numbers: A ST33051001 (J22888-20) B ST33061000 (J8107-2)

SPD529

Be careful not to confuse the right-hand and left-hand parts.

SPD022

2. Loosen ring gear bolts in a crisscross fashion. 3. Tap ring gear off the differential case with a soft hammer. Tap evenly all around to keep ring gear from binding.

SPD024

PD-48

REAR FINAL DRIVE

C200 Disassembly (Cont’d)

4. Punch off pinion mate shaft lock pin from ring gear side. Lock pin is caulked at pin hole mouth on differential case.

GI MA EM LC

SPD025

Inspection RING GEAR AND DRIVE PINION

NGPD0058 NGPD0058S01

EC

Check gear teeth for scoring, cracking or chipping. If any damaged part is evident, replace ring gear and drive pinion as a set (hypoid gear set).

FE CL MT

DIFFERENTIAL CASE ASSEMBLY

NGPD0058S02

Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft, thrust block and thrust washers.

AT TF

AX SPD584

BEARING 1. 2.

NGPD0058S03

Thoroughly clean bearing. Check bearings for wear, scratches, pitting or flaking. Check tapered roller bearing for smooth rotation. If damaged, replace outer race and inner cone as a set.

SU BR ST RS

SPD715

Adjustment

NGPD0059

For quiet and reliable final drive operation, the following five adjustments must be made correctly. 1. Side bearing preload. Refer to “Side Bearing Adjustment”, PD-62. 2. Pinion gear height. Refer to “Drive Pinion Height Adjustment”, PD-63. 3. Pinion bearing preload. Refer to “Drive Pinion Preload Adjustment”, PD-63. 4. Ring gear-to-pinion backlash. Refer to “Total Preload Adjustment”, PD-62.

PD-49

BT HA SC EL IDX

REAR FINAL DRIVE

C200

Adjustment (Cont’d)

5.

Ring and pinion gear tooth contact pattern. Refer to “TOOTH CONTACT”, PD-56.

SIDE BEARING PRELOAD

NGPD0059S01

A selection of carrier side bearing preload shims is required for successful completion of this procedure.

1.

2.

Make sure all parts are clean. Make sure, also, the bearings are well lubricated with light oil or “DEXRON姟” automatic transmission fluid. Place the differential carrier, with side bearings and bearing races installed, into the final drive housing.

SPD919

3. Put the side bearing spacer in place. CAUTION: Side bearing spacer is placed on either the right or left depending upon final drive gear ratio. Be sure to replace it on the correct side.

SPD894

4.

Use Tool to place original carrier side bearing preload shims on the carrier end, opposite the ring gear. Tool number: KV38100600 (J25267)

5.

Install the side bearing caps in their correct locations and torque the bearing cap retaining bolts. Specification: 88 - 98 N·m (9.0 - 10.0 kg-m, 65 - 72 ft-lb) Turn the carrier several times to seat the bearings.

SPD986

6.

SPD526

PD-50

REAR FINAL DRIVE

C200 Adjustment (Cont’d)

7.

Measure the turning torque of the carrier at the ring gear retaining bolts with a spring gauge, J8129. Specification: 34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) of pulling force at the ring gear bolt

GI MA EM LC

SPD194A

8. 쐌 쐌

9.

If the turning torque is not within the specifications, correct the torque as follows: If the turning torque is less than the specified range, install washers of greater thickness. If the turning torque is greater than the specification, install thinner washers to side bearing. Side bearing adjustment: Refer to “Side Bearing Adjustment”, PD-49. Record the total amount of washer thickness required for the correct carrier side bearing preload.

SPD772

10. Remove the carrier from the final drive housing. Save the selected preload washers for later use during the assembly of the final drive unit.

EC FE CL MT AT TF

AX PD344

PINION GEAR HEIGHT 1. 2.

NGPD0059S02

Make sure all parts are clean and that the bearings are well lubricated. Assemble the pinion gear bearings into the pinion preload shim selector Tool, J34309.

SU BR ST RS

SPD769

쐌

쐌

Front pinion bearing — make sure the J34309-3 front pinion bearing seat is secured tightly against the J34309-2 gauge anvil. Then turn the front pinion bearing pilot, J34309-5, to secure the bearing in its proper position. Rear pinion bearing — the rear pinion bearing pilot, J34309-8, is used to center the rear pinion bearing only. The rear pinion bearing locking seat, J34309-4, is used to lock the bearing to the assembly.

BT HA SC EL

SPD197A

PD-51

IDX

REAR FINAL DRIVE

C200

Adjustment (Cont’d)

3.

Install the pinion rear bearing inner cone into the final drive housing. Then place the pinion preload shim selector Tool, J34309-1, on gauge screw assembly.

4.

Assemble the front pinion bearing inner cone and the J34309-2 gauge anvil. Assemble them together with the J34309-1 gauge screw in the final drive housing. Make sure that the pinion height gauge plate, J34309-16, will turn a full 360 degrees. Tighten the two sections together by hand.

5.

Turn the assembly several times to seat the bearings.

6.

Measure the turning torque at the end of the J34309-2 gauge anvil using Tool. Tool number: ST3127S000 (J25765-A) Turning torque specification: 1.0 - 1.3 N·m (10 - 13 kg-cm, 8.7 - 11.3 in-lb)

SPD893

SPD199A

SPD770

SPD234A

7.

Place the J34309-11 pinion height adapter onto the gauge plate and tighten it by hand. CAUTION: Make sure all machined surfaces are clean.

SPD208A

PD-52

REAR FINAL DRIVE

C200 Adjustment (Cont’d)

PINION BEARING PRELOAD WASHER SELECTION 8. Place the solid pinion bearing spacer, small end first, over the J34309-2 gauge anvil and seat the small end squarely against the tip of the J34309-1 gauge screw in the tool recessed portion.

GI MA EM LC

SPD209A

EC FE CL MT

SPD773

9.

Select the correct thickness of pinion bearing preload adjusting washer using a standard gauge of 3.5 mm (0.138 in) and J34309-101 feeler gauge. The exact measure is the thickness of the adjusting washer required. Select the correct washer. Drive pinion bearing preload adjusting washer: Refer to “Drive Pinion Preload Adjustment”, PD-63. 10. Set the selected, correct pinion bearing preload adjusting washer aside for use when assembling the pinion gear and bearings into the final drive.

AT TF

AX SPD210A

SU BR ST RS SPD774

PINION HEIGHT ADJUSTING WASHER SELECTION 11. Now, position the side bearing discs, J25269-4, and arbor firmly into the side bearing bores. Install the side bearing caps and tighten the cap bolts to proper torque.

BT HA SC EL

SPD211A

PD-53

IDX

REAR FINAL DRIVE

C200

Adjustment (Cont’d)

12. Select the correct standard pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 in) and J34309-101 feeler gauge. Measure the distance between the J34309-11 pinion height adapter including the standard gauge and the arbor. 13. Write down the exact measurement (the value of feeler gauge).

SPD204A

14. Correct the pinion height washer size by referring to the “pinion head number”. There are two numbers painted on the pinion gear. The first one refers to the pinion and ring gear as a matched set. This number should be the same as the number on the ring gear. The second number is the “pinion head height number”. It refers to the ideal pinion height from standard for quietest operation. Use the following chart to determine the correct pinion height washer. SPD542

Use the following chart to determine the correct pinion height washer: Pinion head height number

Add or remove from the standard pinion height washer thickness measurement

−6

Add 0.06 mm (0.0024 in)

−5

Add 0.05 mm (0.0020 in)

−4

Add 0.04 mm (0.0016 in)

−3

Add 0.03 mm (0.0012 in)

−2

Add 0.02 mm (0.0008 in)

−1

Add 0.01 mm (0.0004 in)

0

Use the selected washer thickness

+1

Subtract 0.01 mm (0.0004 in)

+2

Subtract 0.02 mm (0.0008 in)

+3

Subtract 0.03 mm (0.0012 in)

+4

Subtract 0.04 mm (0.0016 in)

+5

Subtract 0.05 mm (0.0020 in)

+6

Subtract 0.06 mm (0.0024 in)

15. Select the correct pinion height washer. Drive pinion height adjusting washer: Refer to “Drive Pinion Height Adjustment”, PD-63.

PD-54

REAR FINAL DRIVE

C200 Adjustment (Cont’d)

16. Remove the J34309 pinion preload shim selector Tool from the final drive housing. Then disassemble to retrieve the pinion bearings.

GI MA EM LC

SPD205A

EC FE CL MT AT TF

AX SU BR ST RS BT HA SC EL

PD-55

IDX

REAR FINAL DRIVE

C200

Adjustment (Cont’d)

TOOTH CONTACT

=NGPD0059S03

Checking gear tooth contact pattern is necessary to verify correct relationship between ring gear and drive pinion. Hypoid gear set which is not positioned properly may be noisy, or have short life or both. With the checking or gear tooth contact pattern, the most desirable contact for low noise level and long life can be assured.

1. 2.

Thoroughly clean ring gear and drive pinion teeth. Sparingly apply a mixture of powdered ferric oxide and oil or equivalent to 3 or 4 teeth of ring gear drive side.

3.

Hold companion flange steady and rotate the ring gear in both directions.

SPD199

SPD200

SPD007-B

PD-56

REAR FINAL DRIVE

C200 Assembly

Assembly DIFFERENTIAL CASE 1.

2.

NGPD0060 NGPD0060S01

Measure clearance between side gear thrust washer and differential case. Clearance between side gear thrust washer and differential case (A – B): Less than 0.15 mm (0.0059 in) The clearance can be adjusted with side gear thrust washer. Refer to “Side Gear Adjustment”, PD-62. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see that they turn properly.

GI MA EM LC EC FE CL MT

SPD656

3.

Install differential case LH and RH.

AT TF

AX SPD643

4. 5.

Place differential case on ring gear. Apply locking agent [Loctite (stud lock) or equivalent] to ring gear bolts, and install them. Tighten bolts in a crisscross pattern.

SU BR ST RS

SPD746

6.

Press-fit side bearing inner cones on differential case with Tool. Tool numbers: A ST33230000 (J25805-01) B ST33061000 (J8107-2)

BT HA SC EL

PD353

PD-57

IDX

REAR FINAL DRIVE

C200

Assembly (Cont’d)

DIFFERENTIAL CARRIER

NGPD0060S02

1.

Press-fit front and rear bearing outer races with Tools. Tool numbers: A ST30611000 (J25742-1) B ST30621000 (J25742-5) C ST30613000 (J25742-3)

2. 3.

Select pinion height adjusting washer. Refer to “Drive Pinion Height Adjustment”, PD-51. Install pinion height adjusting washer in drive pinion, and press-fit rear bearing inner cone in it, with press and Tool. Tool number: ST30901000 (J26010-01)

4.

Place pinion front bearing inner cone in gear carrier.

5.

Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal. Tool number: KV38100500 (J25273)

SPD679

SPD377

SPD581

SPD557

PD-58

REAR FINAL DRIVE

C200 Assembly (Cont’d)

6.

Place drive pinion bearing spacer, drive pinion bearing adjusting washer and drive pinion in gear carrier.

GI MA EM LC

SPD222

7. 8.

Install ABS sensor and sensor rotor. Insert companion flange into drive pinion by tapping the companion flange with a soft hammer until fully seated.

EC FE CL MT

SPD708

9.

Tighten pinion nut 127 - 294 N·m (13 - 30 kg-m, 94 - 217 ftlb). The threaded portion of drive pinion and pinion nut should be free from oil or grease. Tool number: KV38108300 (J44195)

AT TF

AX APD032

SPD241

10. Tighten the pinion nut by very small degrees until the specified preload is achieved. When checking the preload, turn the drive pinion in both directions several times to set the bearing rollers. Tool number: ST3127S000 (J25765-A) Pinion bearing preload: 1.1 - 1.7 N·m (11 - 17 kg-cm, 9.5 - 14.8 in-lb) This procedure will have to be repeated if: 쐌 Maximum preload is achieved before the minimum pinion nut torque is reached. 쐌 Minimum preload is not achieved before maximum pinion nut torque is reached. 11. Select side bearing adjusting washer. Refer to “Side Bearing Adjustment”, PD-62. 12. Install differential case assembly with side bearing outer races into gear carrier.

SU BR ST RS BT HA SC EL

SPD203

PD-59

IDX

REAR FINAL DRIVE

C200

Assembly (Cont’d)

13. Insert left and right side bearing adjusting washers in place between side bearing and carrier.

SPD558

14. Drive in side bearing spacer with Tool. Tool number: KV38100600 (J25267)

SPD709

15. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.

SPD226

16. Measure ring gear-to-drive pinion backlash with a dial indicator. Ring gear-to-pinion backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in) 쐌 If backlash is too small, decrease thickness of right shim and increase thickness of left shim by the same amount. If backlash is too great, reverse the above procedure. Never change the total amount of shims as it will change the bearing preload. SPD196

17. Check total preload with Tool. When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly. Total preload: 1.2 - 2.3 N·m (12 - 23 kg-cm, 10 - 20 in-lb) Tool number: ST3127S000 (J25765-A)

SPD241

PD-60

REAR FINAL DRIVE

C200 Assembly (Cont’d)

쐌

If preload is too great, remove the same amount of shim from each side. 쐌 If preload is too small, add the same amount of shim to each side. Never add or remove a different number of shims for each side as it will change ring gear-to-pinion backlash. 18. Recheck ring gear-to-pinion backlash because increase or decrease in thickness of shims will cause change of ring gearto-pinion backlash.

MA EM LC

SPD561

SPD702

GI

19. Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm (0.0020 in) 쐌 If backlash varies excessively in different places, the variance may have resulted from foreign matter caught between the ring gear and the differential case. 쐌 If the backlash varies greatly when the runout of the ring gear is within a specified range, the hypoid gear set or differential case should be replaced. 20. Check tooth contact. Refer to “TOOTH CONTACT”, PD-56. 21. Install rear cover and gasket.

EC FE CL MT AT TF

AX SU BR ST RS BT HA SC EL

PD-61

IDX

REAR FINAL DRIVE

C200

Service Data and Specifications (SDS)

Service Data and Specifications (SDS) C200 General Specifications

=NGPD0061 NGPD0061S01

Engine

KA24DE

Vehicle grade

XE Standard

Rear final drive

C200 2-pinion

Gear ratio

4.625

Number of teeth (Ring gear/drive pinion)

37/8

Oil capacity (Approx.)


(US pt, lmp pt)

1.3 (2-3/4, 2-1/4)

Ring Gear Runout Ring gear runout limit

NGPD0061S02

mm (in)

0.05 (0.0020)

Side Gear Adjustment

NGPD0061S03

Side gear backlash (Clearance between side gear and differential case) (in)

mm

Thickness mm (in) 0.75 0.78 0.81 0.84 0.87 0.90 0.93

Available side gear thrust washers

Less than 0.15 (0.0059) Part number*

(0.0295) (0.0307) (0.0319) (0.0331) (0.0343) (0.0354) (0.0366)

38424-N3110 38424-N3111 38424-N3112 38424-N3113 38424-N3114 38424-N3115 38424-N3116

*Always check with the Parts Department for the latest parts information.

Side Bearing Adjustment

NGPD0061S04

Differential carrier assembly turning resistance

N (kg, lb)

34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8)

Thickness mm (in) 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60

Available side bearing adjusting washers

Part number*

(0.0787) (0.0807) (0.0827) (0.0846) (0.0866) (0.0886) (0.0906) (0.0925) (0.0945) (0.0965) (0.0984) (0.1004) (0.1024)

38453-N3100 38453-N3101 38453-N3102 38453-N3103 38453-N3104 38453-N3105 38453-N3106 38453-N3107 38453-N3108 38453-N3109 38453-N3110 38453-N3111 38453-N3112

*Always check with the Parts Department for the latest parts information.

Total Preload Adjustment Total preload

NGPD0061S05

N·m (kg-cm, in-lb)

Ring gear-to-pinion backlash

1.2 - 2.3 (12 - 23, 10 - 20)

mm (in)

0.13 - 0.18 (0.0051 - 0.0071)

PD-62

REAR FINAL DRIVE

C200

Service Data and Specifications (SDS) (Cont’d)

Drive Pinion Height Adjustment

NGPD0061S06

Thickness mm (in)

Part number*

3.09 (0.1217) 3.12 (0.1228) 3.15 (0.1240) 3.18 (0.1252) 3.21 (0.1264) 3.24 (0.1276) 3.27 (0.1287) 3.30 (0.1299) 3.33 (0.1311) 3.36 (0.1323) 3.39 (0.1335) 3.42 (0.1346) 3.45 (0.1358) 3.48 (0.1370) 3.51 (0.1382) 3.54 (0.1394) 3.57 (0.1406) 3.60 (0.1417) 3.63 (0.1429) 3.66 (0.1441)

38154-P6017 38154-P6018 38154-P6019 38154-P6020 38154-P6021 38154-P6022 38154-P6023 38154-P6024 38154-P6025 38154-P6026 38154-P6027 38154-P6028 38154-P6029 38154-P6030 38154-P6031 38154-P6032 38154-P6033 38154-P6034 38154-P6035 38154-P6036

Available pinion height adjusting washers

GI MA EM LC EC FE CL

*Always check with the Parts Department for the latest parts information.

Drive Pinion Preload Adjustment

NGPD0061S07

Drive pinion bearing preload adjusting method Drive pinion preload with front oil seal

N·m (kg-cm, in-lb)

Drive pinion preload without front oil seal

MT

Collapsible spacer 1.1 - 1.7 (11 - 17, 9.5 - 14.8)

N·m (kg-cm, in-lb)

AT

1.0 - 1.6 (10 - 16, 8.7 - 14)

TF

AX SU BR ST RS BT HA SC EL

PD-63

IDX

REAR FINAL DRIVE

H233B

Preparation

Preparation SPECIAL SERVICE TOOLS

NGPD0029

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name ST3127S000 (See J25765-A) Preload gauge 1 GG91030000 (J25765) Torque wrench 2 HT62940000 ( — ) Socket adapter 3 HT62900000 ( — ) Socket adapter

Description Measuring pinion bearing preload and total preload

NT124

Mounting final drive

ST06340000 (J24310, J34310) Differential attachment

NT140

Adjusting side bearing preload and backlash (ring gear-drive pinion)

ST32580000 (J34312) Differential side bearing adjusting nut wrench

NT141

Removing and installing propeller shaft lock nut, and drive pinion lock nut

KV38108300 (J44195) Companion flange wrench

NT771

ST3090S000 ( — ) Drive pinion rear inner race puller set 1 ST30031000 (J22912-01) Puller 2 ST30901000 (J26010-01) Base ST3306S001 Differential side bearing puller set 1 ST33051001 (J22888-20) Body 2 ST33061000 (J8107-2) Adapter

Removing and installing drive pinion rear inner cone a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35 mm (1.38 in) dia.

NT527

Removing and installing differential side bearing inner cone a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia.

NT072

PD-64

REAR FINAL DRIVE

H233B Preparation (Cont’d)

Tool number (Kent-Moore No.) Tool name

Description

GI

ST33190000 (J25523) Differential side bearing drift

Installing side bearing inner cone a: 52 mm (2.05 in) dia. b: 45.5 mm (1.791 in) dia. c: 34 mm (1.34 in) dia.

MA EM

NT085

Installing side bearing inner cone a: 43 mm (1.69 in) dia. b: 33.5 mm (1.319 in) dia.

ST33081000 ( — ) Side bearing puller adapter

LC EC FE

NT431

Installing pinion rear bearing outer race (Use with ST30621000 or ST30613000)

ST30611000 (J25742-1) Drift

CL MT

NT090

Installing pinion rear bearing outer race a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia.

ST30621000 (J25742-5) Drift

AT TF

NT073

Installing pinion front bearing outer race (Use with ST30611000) a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia.

ST30613000 (J25742-3) Drift

NT073

KV381025S0 ( — ) Oil seal fitting tool 1 ST30720000 (J25405) Drift bar 2 KV38102510 ( — ) Drift

AX SU

Installing front oil seal a: 77 mm (3.03 in) dia. b: 55 mm (2.17 in) dia. c: 71 mm (2.80 in) dia. d: 65 mm (2.56 in) dia.

BR ST

NT525

RS Adjusting bearing pre-load and gear height

(J34309) Differential shim selector

BT HA SC NT134

EL

PD-65

IDX

REAR FINAL DRIVE

H233B

Preparation (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

(J25269-18) Side bearing discs (2 Req’d)

Selecting pinion height adjusting washer

NT135

KV381052S0 ( — ) Rear axle shaft dummy 1 KV38105210 ( — ) Torque wrench side 2 KV38105220 ( — ) Vice side

Checking differential torque on limited slip differential

NT142

Installing front oil seal a: 85 mm (3.35 in) dia. b: 60 mm (2.36 in) dia.

KV38100500 (J25273) Gear carrier front oil seal drift

NT115

Noise, Vibration and Harshness (NVH) Troubleshooting

NGPD0051

Refer to “NVH TROUBLESHOOTING CHART”, PD-4.

On-vehicle Service FRONT OIL SEAL REPLACEMENT 1. 2.

SPD479A

3. 4.

NGPD0030

Remove propeller shaft. Refer to “Removal and Installation”, PD-8. Remove drive pinion nut. Tool number: KV38108300 (J44195)

Remove companion flange. Remove ABS sensor and sensor rotor (2WD models).

SPD737

PD-66

REAR FINAL DRIVE

H233B On-vehicle Service (Cont’d)

5.

Remove front oil seal.

GI MA EM LC

SPD738

6.

Apply multi-purpose grease to cavity at sealing lips of oil seal. Press front oil seal into carrier. Tool number: KV38100500 (J25273) NOTE: Always install a new sensor rotor. 7. Install ABS sensor and sensor rotor (2WD models). 8. Install companion flange and drive pinion nut. 9. Install propeller shaft. Refer to “Removal and Installation”, PD-8.

SPD739

EC FE CL MT AT TF

AX SU BR ST RS BT HA SC EL

PD-67

IDX

REAR FINAL DRIVE

H233B

Components

Components

NGPD0031

WPD025

PD-68

REAR FINAL DRIVE

H233B Removal and Installation

Removal and Installation REMOVAL 쐌

NGPD0032 NGPD0032S01

Remove propeller shaft. Plug end of transfer case. 쐌 Remove axle shaft. Refer to AX-32, “REMOVAL”. 쐌 Remove rear final drive mounting bolts. CAUTION: Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft. Before removing the final drive assembly or rear axle assembly, disconnect the ABS sensor harness connector from the assembly and move it away from the final drive/rear axle assembly area. Failure to do so may result in the sensor wires being damaged and the sensor becoming inoperative.

GI MA EM LC EC FE CL MT

INSTALLATION 쐌

NGPD0032S02

Fill final drive with recommended gear oil.

AT TF

AX SPD123

쐌

Pay attention to the direction of gasket.

SU BR ST RS

SPD767

Disassembly PRE-INSPECTION

SPD149

NGPD0033 NGPD0033S01

Before disassembling final drive, perform the following inspection. 쐌 Total preload a) Turn drive pinion in both directions several times to seat bearing rollers correctly. b) Check total preload with Tool. Tool number: ST3127S000 (J25765-A) Total preload: 1.7 - 2.5 N·m (17 - 25 kg-cm, 15 - 22 in-lb)

PD-69

BT HA SC EL IDX

REAR FINAL DRIVE

H233B

Disassembly (Cont’d)

쐌

Ring gear-to-pinion backlash Check backlash of ring gear with a dial indicator at several points. Ring gear-to-pinion backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in)

쐌

Ring gear runout Check runout of ring gear with a dial indicator. Runout limit: 0.08 mm (0.0031 in)

쐌

Tooth contact Check tooth contact. Refer to “TOOTH CONTACT”, PD-83. Side gear to pinion mate gear backlash Measure clearance between side gear thrust washer and differential case with a feeler gauge. Clearance between side gear thrust washer and differential case: 0.10 - 0.20 mm (0.0039 - 0.0079 in)

SPD246

SPD247

쐌

SPD004

DIFFERENTIAL CARRIER 1.

NGPD0033S02

Mount final drive assembly on Tool. Tool number: ST06340000 (J24310, J34310)

SPD683

2.

Put match marks on one side of side bearing cap with paint or punch to ensure that it is replaced in proper position during reassembly. Bearing caps are line-bored during manufacture and should be put back in their original places.

SPD249

PD-70

REAR FINAL DRIVE

H233B Disassembly (Cont’d)

3.

Remove side lock fingers and side bearing caps.

GI MA EM LC

SPD250

4.

Remove side bearing adjuster with Tool. Tool number: ST32580000 (J34312)

EC FE CL MT

SPD684

5.

Remove differential case assembly with a pry bar.

AT TF

AX SPD685

Keep the side bearing outer races together with their respective inner cones — do not mix them up.

SU BR ST RS

SPD011

6. 7. 8.

Remove drive pinion nut with Tool. Tool number: KV38108300 (J44195) Remove companion flange with puller. Remove ABS sensor and sensor rotor (2WD models).

BT HA SC EL

SPD480A

PD-71

IDX

REAR FINAL DRIVE

H233B

Disassembly (Cont’d)

9.

Take out drive pinion together with pinion rear bearing inner cone, drive pinion bearing spacer and pinion bearing adjusting shim.

SPD687

10. Remove front oil seal and pinion front bearing inner cone. 11. Remove pinion bearing outer races with a brass drift.

SPD563

12. Remove pinion rear bearing inner cone and drive pinion adjusting washer. Tool number: ST30031000 (J22912-01)

SPD018

DIFFERENTIAL CASE 1.

NGPD0033S03

Remove side bearing inner cones. To prevent damage to bearing, engage puller jaws in groove. Tool number: A ST33051001 (J22888-20) B ST33061000 (J8107-2)

SPD529

PD-72

REAR FINAL DRIVE

H233B Disassembly (Cont’d)

Be careful not to confuse the left-hand and right-hand parts. Keep bearing and bearing race for each side together. 2. Loosen ring gear bolts in a crisscross pattern.

GI MA EM LC

SPD022

3. Tap ring gear off differential case with a soft hammer. Tap evenly all around to keep ring gear from binding.

EC FE CL MT

SPD024

4.

Drive out pinion mate shaft lock pin, with punch from ring gear side. Lock pin is caulked at pin hole mouth on differential case.

AT TF

AX SPD025

Inspection RING GEAR AND DRIVE PINION

NGPD0034

SU

NGPD0034S01

Check gear teeth for scoring, cracking or chipping. If any damaged part is evident, replace ring gear and drive pinion as a set (hypoid gear set).

BR ST RS

DIFFERENTIAL CASE ASSEMBLY

NGPD0034S02

Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft, and thrust washers.

BT HA SC EL

SPD530-A

PD-73

IDX

REAR FINAL DRIVE

H233B

Inspection (Cont’d)

BEARING 1. 2.

NGPD0034S03

Thoroughly clean bearing. Check bearings for wear, scratches, pitting or flaking. Check tapered roller bearing for smooth rotation. If damaged, replace outer race and inner cone as a set.

SPD715

Limited Slip Differential PREPARATION FOR DISASSEMBLY

NGPD0035

CAUTION: Do not run engine when only one wheel (rear) is off the ground.

Checking Differential Torque

NGPD0035S01

Measure differential torque with Tool. If it is not within the specifications, inspect components of limited slip differential. Differential torque: 187 - 245 N·m (19 - 25 kg-m, 138 - 180 ft-lb) Tool number: A KV38105210 ( — ) Tool number: B KV38105220 ( — ) SPD415

DISASSEMBLY

NGPD0036

APD027

PD-74

REAR FINAL DRIVE

H233B Limited Slip Differential (Cont’d)

CAUTION: Do not run engine when one wheel (rear) is off the ground.

GI MA EM LC 1.

Remove side bearing inner cone with Tool. To prevent damage to bearing, engage puller jaws in groove. Tool number: A ST33051001 (J22888-20) B ST33061000 (J8107-2) 2. Loosen ring gear bolts in a crisscross pattern. Bend down lock straps before removing bolts.

EC FE CL MT AT TF

AX SPD529

3. Tap ring gear off gear case with a soft hammer. Tap evenly all around to keep ring gear from binding.

SU BR ST RS

SPD275

4.

Remove couple bolts from differential cases A and B. Use a press with tool and a vise to keep the differential from rotating. Tool number: ST33081000 ( — ) 5. Separate differential case A and B. Draw out component parts (discs and plates, etc.). Put marks on gears and pressure rings so that they can be reinstalled in their original positions from which they were removed.

BT HA SC EL

SPD363A

PD-75

IDX

REAR FINAL DRIVE

H233B

Limited Slip Differential (Cont’d)

INSPECTION Contact Surfaces 1. 2.

NGPD0037 NGPD0037S01

Clean the disassembled parts in suitable solvent and blow dry with compressed air. If following surfaces are found with burrs or scratches, smooth with oil stone. 1 Differential case B 2 Differential case A 3 Side gear 4 Pinion mate gear 5 Pinion mate shaft 6 Friction plate guide

SPD359A

Disc and Plate 1. 2.

3.

NGPD0037S02

Clean the discs and plates in suitable solvent and blow dry with compressed air. Inspect discs and plates for wear, nicks and burrs.

Check friction discs or plates for warpage. Allowable warpage: 0.08 mm (0.0031 in) If it exceeds limits, replace with a new plate to eliminate possibility of clutch slippage or sticking.

SPD279

PD-76

REAR FINAL DRIVE

H233B Limited Slip Differential (Cont’d)

4.

Measure frictional surfaces and projected portions of friction disc, friction plate, spring plate, and determine each part’s differences to see if the specified wear limit has been exceeded. If any part has worn beyond the wear limit, and deformed or fatigued, replace it with a new one that is the same thickness as the projected portion. Wear limit: 0.1 mm (0.004 in) or less A − B = Wear limit mm (in) 쐌 Measuring points A: Projected portion B: Frictional surface

GI MA EM LC EC FE CL MT

SPD381A

ADJUSTMENT Friction Disc and Friction Plate End Play

SPD383A

NGPD0038

AT

NGPD0038S01

End play of friction disc and friction plate can be calculated by using following equation and should be adjusted within following range. Adjustment can be made by selecting friction disc having two different thicknesses. End play E: 0.05 - 0.15 mm (0.0020 - 0.0059 in) E = A − (B + C) A: Length of differential case contact surface to differential case inner bottom. B: Total thickness of friction discs, friction plates, spring disc and spring plate in differential case on one side. C: Length of differential case contact surface to back side of side gear.

TF

AX SU BR ST RS

SPD417

1.

Measure values of “A”. Standard length A: 49.50 - 49.55 mm (1.9488 - 1.9508 in)

BT HA SC EL

SPD417

PD-77

IDX

REAR FINAL DRIVE

H233B

Limited Slip Differential (Cont’d)

2.

Measure thickness of each disc and plate. Total thickness “B”: 19.24 - 20.26 mm (0.7575 - 0.7976 in) No. of discs and plates (One side): Friction disc 5 Friction plate 6 Spring plate 2

3. a. b.

Measure values of “C”. Attach a dial indicator to the base plate. Place differential case B on the base plate, and install a master gauge on case B. Then adjust the dial indicator scale to zero with its tip on the master gauge.

SPD420

SPD418

c.

SPD419

Install pinion mate gears, side gears and pinion mate shaft in differential case B. d. Set dial indicator’s tip on the side gear, and read the indication. Example: E = A − D = A − (B + C) = 0.05 to 0.15 mm A = 49.52 mm B = 19.45 mm C = 29.7 mm D=B+C 49.15 (D) = 19.45 (B) + 29.7 (C) E=A−D 0.37 (E) = 49.52 (A) − 49.15 (D) From the above equation, end play of 0.37 mm exceeds the specified range of 0.05 to 0.15 mm. Select suitable discs and plates to adjust correctly.

ASSEMBLY

NGPD0039

Prior to assembling discs and plates, properly lubricate them by dipping them in limited slip differential oil. Refer to MA-13, “RECOMMENDED FLUIDS AND LUBRICANTS”. 1. Alternately position specified number of friction plates and friction discs on rear of side gear. Always position a friction plate first on rear of side gear.

SPD421

PD-78

REAR FINAL DRIVE

H233B Limited Slip Differential (Cont’d)

2.

Install spring plate.

GI MA EM LC

SPD384A

3. Install friction plate guides. Correctly align the raised portions of friction plates, and apply grease to inner surfaces of friction plate guides to prevent them from falling.

EC FE CL MT

SPD385A

4. 쐌 쐌

Install differential case B over side gear, discs, plates and friction plate guide assembly. Install differential case B while supporting friction plate guides with your finger inserted through oil hole in differential case. Be careful not to detach spring disc from the hexagonal part of the side gear.

AT TF

AX SPD386A

5.

Install pinion mate gears and pinion mate thrust washers on pinion mate shaft, then install pinion mate shaft in differential case B.

SU BR ST RS

SPD426

6. Install side gear to pinion mate gears. 7. Install each disc and plate. Use same procedures as outlined in steps 1 through 4 above.

BT HA SC EL

SPD387A

PD-79

IDX

REAR FINAL DRIVE

H233B

Limited Slip Differential (Cont’d)

8. Install differential case A. Position differential cases A and B by correctly aligning marks stamped on cases.

SPD388A

9. Tighten differential case couple bolts. 10. Place ring gear on differential case and tighten ring gear bolts. Tighten bolts in a crisscross pattern. Then bend up lock straps to lock the bolts in place. 11. Install side bearing inner cone. 12. Check differential torque.

SPD364A

Adjustment

NGPD0040

For quiet and reliable final drive operation, the following five adjustments must be made correctly: 1. Side bearing preload. Refer to “Total Preload Adjustment”, PD-90. 2. Pinion gear height. Refer to “Pinion Gear Height”, PD-80. 3. Pinion bearing preload. Refer to “Drive Pinion Preload Adjustment”, PD-91. 4. Ring gear-to-pinion backlash. Refer to “Total Preload Adjustment”, PD-90. 5. Ring and pinion gear tooth contact pattern. Refer to “TOOTH CONTACT”, PD-83.

PINION GEAR HEIGHT 1. 2.

NGPD0040S01

Make sure all parts are clean and that the bearings are well lubricated. Assemble the pinion gear bearings into the pinion pre-load shim selector tool, J34309.

SPD196A

PD-80

REAR FINAL DRIVE

H233B Adjustment (Cont’d)

쐌

쐌

Rear Pinion Bearing — the rear pinion bearing pilot, J34309-8, is used to center the rear pinion bearing only. The rear pinion bearing locking seat, J34309-4, is used to lock the bearing to the assembly. Front Pinion Bearing — make sure the J34309-3, front pinion bearing seat is secured tightly against the J34309-2 gauge anvil. Then turn the front pinion bearing pilot, J34309-5, to secure the bearing in its proper position.

GI MA EM LC

SPD197A

3.

Place the pinion preload shim selector tool gauge screw assembly, J34309-1, with the pinion rear bearing inner cone installed, into the final drive housing.

EC FE CL MT

SPD216A

4.

5.

Install the J34309-2 gauge anvil with the front pinion bearing into the final drive housing and assemble it to the J34309-1 gauge screw. Make sure that the J34309-16 gauge plate will turn a full 360 degrees, and tighten the two sections by hand to set bearing preload. Turn the assembly several times to seat the bearings.

AT TF

AX SPD217A

6.

Measure the turning torque at the end of the J34309-2 gauge anvil using torque wrench J25765. Turning torque specification: 0.4 - 0.9 N·m (4 - 9 kg-cm, 3.5 - 7.8 in-lb)

SU BR ST RS

SPD234A

7.

Place the J34309-12 “H233B” pinion height adapter onto the gauge plate and tighten it by hand. CAUTION: Make sure all machined surfaces are clean.

BT HA SC EL

SPD208A

PD-81

IDX

REAR FINAL DRIVE

H233B

Adjustment (Cont’d)

PINION HEIGHT ADJUSTING WASHER SELECTION 8. Position the J25269-18 side bearing discs and the arbor into the side bearing bores.

SPD286A

9.

Install the bearing caps and torque the bolts. Specification: 93 - 103 N·m (9.5 - 10.5 kg-m, 69 - 76 ft-lb)

SPD237A

10. Select the correct standard pinion height adjusting washer thickness using a standard gauge of 2.5, 3.0, or 3.5 mm (0.098, 0.118, or 0.138 in) and your J34309-101 feeler gauge. Measure the distance between the J34309-12 “H233B” pinion height adapter and the arbor. 11. Write down the exact total measurement.

SPD204A

12. Correct the pinion height washer size by referring to the “pinion head height number”. There are two numbers painted on the pinion gear. The first one refers to the pinion and ring gear as a matched set and should be the same as the number on the ring gear. The second number is the “pinion head height number”, and it refers to the ideal pinion height from standard for the quietest operation. Use the following chart to determine the correct pinion height washer. Refer to “Drive Pinion Height Adjustment”, PD-90. SPD542

PD-82

REAR FINAL DRIVE

H233B Adjustment (Cont’d)

Pinion Head Height Number

Add or Remove from the Selected Standard Pinion Height Washer Thickness Measurement

−6

Add 0.06 mm (0.0024 in)

−5

Add 0.05 mm (0.0020 in)

−4

Add 0.04 mm (0.0016 in)

−3

Add 0.03 mm (0.0012 in)

−2

Add 0.02 mm (0.0008 in)

−1

Add 0.01 mm (0.0004 in)

0

Use the selected washer thickness

+1

Subtract 0.01 mm (0.0004 in)

+2

Subtract 0.02 mm (0.0008 in)

+3

Subtract 0.03 mm (0.0012 in)

+4

Subtract 0.04 mm (0.0016 in)

+5

Subtract 0.05 mm (0.0020 in)

+6

Subtract 0.06 mm (0.0024 in)

GI MA EM LC EC FE CL MT

13. Select the correct pinion height washer. Drive pinion height adjustment: Refer to “Drive Pinion Height Adjustment”, PD-90.

AT TF

AX 14. Remove the J34309 pinion preload shim selector tool from the final drive housing and disassemble to retrieve the pinion bearings.

SU BR ST RS

SPD220A

TOOTH CONTACT

NGPD0040S02

Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion. Hypoid gear sets which are not positioned properly in relation to one another may be noisy, or have short life or both. With a pattern check, the most desirable contact for low noise level and long life can be assured.

BT HA SC EL

PD-83

IDX

REAR FINAL DRIVE

H233B

Adjustment (Cont’d)

1. 2.

Thoroughly clean ring gear and drive pinion teeth. Sparingly apply a mixture of powdered ferric oxide and oil or equivalent to 3 or 4 teeth of ring gear drive side.

3.

Hold companion flange steady by hand and rotate the ring gear in both directions.

SPD005

SPD695

SPD007-B

Assembly DIFFERENTIAL CASE 1.

NGPD0041 NGPD0041S01

Install side gears, pinion mate gears and thrust washers into differential case. The clearance can be adjusted with side gear thrust washer. Refer to “Side Gear Adjustment”, PD-89

SPD552

PD-84

REAR FINAL DRIVE

H233B Assembly (Cont’d)

2. 3.

Fit pinion mate shaft to differential case so that it meets lock pin holes. Adjust backlash between side gear and pinion mate gear by selecting side gear thrust washer. Backlash between side gear and pinion mate gear (Clearance between side gear thrust washer and differential case: 0.10 – 0.20 mm (0.0039 – 0.0079 in)

GI MA EM LC

SPD258

4.

Install pinion mate shaft lock pin with a punch. Make sure lock pin is flush with case.

EC FE CL MT

SPD030

5. 6.

Apply gear oil to gear tooth surfaces and thrust surfaces and check to see that they turn properly. Install differential case assembly on ring gear. Tighten bolts in a crisscross pattern.

AT TF

AX SPD322

7.

Press-fit side bearing inner cones on differential case with Tool. Tool number: A ST33190000 (J25523) B ST33081000 ( — )

SU BR ST RS

PD244

BT HA SC EL

PD-85

IDX

REAR FINAL DRIVE

H233B

Assembly (Cont’d)

DIFFERENTIAL CARRIER

NGPD0041S02

1.

Press-fit front and rear bearing outer races with Tools. Tool number: A ST30611000 (J25742-1) B ST30621000 (J25742-5) C ST30613000 (J25742-3)

2.

Select drive pinion height adjusting washer. Refer to “Drive Pinion Height Adjustment”, PD-90. Install drive pinion adjusting washer in drive pinion, and pressfit pinion rear bearing inner cone in it, with press and Tool. Tool number: ST30901000 (J26010-01)

SPD580

3.

SPD377

4.

Place pinion front bearing inner cone in gear carrier.

5.

Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal. Tool number: A ST30720000 (J25405) B KV38102510 ( — )

SPD581

SPD291A

PD-86

REAR FINAL DRIVE

H233B Assembly (Cont’d)

6.

Install drive pinion bearing spacer, pinion bearing adjusting shim and drive pinion in gear carrier.

GI MA EM LC

SPD935-A

7. 8.

Install ABS sensor and sensor rotor (2WD models). Insert companion flange into drive pinion by tapping the companion flange with a soft hammer until fully seated.

EC FE CL MT

SPD697

9.

Tighten pinion nut 127 - 249 N·m (13.0 - 30.0 kg-m, 94 - 217 ft-lb) until total preload of 1.2 - 2.2 N·m (12 - 22 kg-m, 10 - 19 ft-in) is obtained. The threaded portion of drive pinion and pinion nut should be free from oil or grease. Tool number: KV38108300 (J44195)

AT TF

AX SPD481A

SPD149

10. Turn drive pinion in both directions several times, and measure pinion bearing preload. Tool number: ST3127S000 (J25765-A) Pinion bearing preload (With front oil seal): 1.4 - 1.7 N·m (14 - 17 kg-cm, 12 - 15 in-lb) Pinion bearing preload (Without front oil seal): 1.2 - 1.5 N·m (12 - 15 kg-cm, 10 - 13 in-lb) If preload is out of specification, adjust the thickness of spacer and shim combination by replacing shim and spacer with thinner one. 쐌 Start from the combination of thickest spacer and shim. 쐌 Combine each spacer and shim thickness one by one until the correct specification are achieved. Drive pinion bearing preload adjusting spacer and shim: Refer to “Drive Pinion Preload Adjustment”, PD-91. 11. Install differential case assembly with side bearing outer races into gear carrier. 12. Position side bearing adjusters on gear carrier with threads properly engaged; screw in adjusters lightly at this stage of assembly. Tool number: ST32580000 (J34312)

SU BR ST RS BT HA SC EL

SPD684

PD-87

IDX

REAR FINAL DRIVE

H233B

Assembly (Cont’d)

13. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier. 쐌 Do not tighten at this point. This allows further tightening of side bearing adjusters.

SPD265

14. Tighten both right and left side bearing adjusters alternately and measure ring gear backlash and total preload at the same time. Adjust right and left side bearing adjusters by tightening them alternately so that proper ring gear backlash and total preload can be obtained. Ring gear-to-drive pinion backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in)

SPD246

쐌

When checking preload, turn drive pinion in both directions several times to set bearing rollers. Tool number: ST3127S000 (J25765-A) Total preload: 1.7 - 2.5 N·m (17 - 25 kg-cm, 15 - 22 in-lb)

SPD149

15. Tighten side bearing cap bolts. 16. Install side lock finger in place to prevent rotation during operation.

SPD698

17. Check runout of ring gear with a dial indicator. Runout limit: 0.08 mm (0.0031 in) 쐌 If backlash varies excessively in different places, the variance may have resulted from foreign matter caught between the ring gear and the differential case. 쐌 If the backlash varies greatly when the runout of the ring gear is within a specified range, the hypoid gear set or differential case should be replaced. 18. Check tooth contact. Refer to “TOOTH CONTACT”, PD-83. SPD247

PD-88

REAR FINAL DRIVE

H233B Service Data and Specifications (SDS)

Service Data and Specifications (SDS) H233B General Specifications

GI =NGPD0042

2WD Model

NGPD0042S02

Engine

VG33E

Vehicle grade

VG33ER

XE Standard

Optional*

Rear final drive

SE

XE, SE

Standard

Standard

EM

H233B 2-pinion

LSD

LSD

LSD

Gear ratio

4.636

4.900

4.900

4.636

Number of teeth (Ring gear/drive pinion)

51/11

49/10

49/10

51/11

Oil capacity (Approx.)
(US pt, lmp pt)

MA

LC EC

2.8 (5-7/8, 4-7/8)

FE

*: Standard on Canada models.

4WD Model

NGPD0042S03

Engine

VG33E

VG33ER

Vehicle grade

XE Standard

SE Optional

Rear final drive

Standard

MT

XE, SE Optional*

Standard

AT

H233B 2-pinion

LSD

2-pinion

2-pinion

LSD

LSD

Gear ratio

4.636

4.636

4.900

4.900

4.900

4.636

Number of teeth (Ring gear/drive pinion)

51/11

51/11

49/10

49/10

49/10

51/11

Oil capacity (Approx.)
(US pt, lmp pt)

TF

2.8 (5-7/8, 4-7/8)

AX

*: Standard on Canada models.

Ring Gear Runout Ring gear runout limit

NGPD0043

mm (in)

SU

0.08 (0.0031)

Side Gear Adjustment

NGPD0044

Side gear backlash (Clearance between side gear and differential case) (in) Available side gear thrust washers

CL

mm

0.10 - 0.20 (0.0039 - 0.0079)

Thickness mm (in)

Part number*

1.75 (0.0689) 1.80 (0.0709) 1.85 (0.0728)

38424-T5000 38424-T5001 38424-T5002

*Always check with the Parts Department for the latest parts information.

BR ST RS BT HA SC EL

PD-89

IDX

REAR FINAL DRIVE

H233B

Service Data and Specifications (SDS) (Cont’d)

Differential Torque Adjustment (LSD Models) Differential torque

N·m (kg-m, ft-lb)

187 - 245 (19 - 25, 138 - 180) Friction disc

5

Number of discs and plates (One side) Friction plate

6

Spring plate Wear limit of plate and disc

2

mm (in)

0.1 (0.004)

Allowable warpage of friction disc and plate

mm (in)

Plate name

Available discs and plates

NGPD0045

0.08 (0.0031) Thickness

mm (in)

Part number*

Friction disc

1.48 - 1.52 (0.0583 - 0.0598) 1.38 - 1.42 (0.0543 - 0.0559) 1.58 - 1.62 (0.0622 - 0.0638)

38433-C6002 (Standard type) 38433-C6004 (Adjusting type) 38433-C6003 (Adjusting type)

Friction plate

1.48 - 1.52 (0.0583 - 0.0598)

38432-C6001

Spring plate

1.48 - 1.52 (0.0583 - 0.0598)

38435-S9200

*Always check with the Parts Department for the latest parts information.

Total Preload Adjustment Total preload

NGPD0046

N·m (kg-cm, in-lb)

Ring gear-to-pinion backlash

1.7 - 2.5 (17 - 25, 15 - 22)

mm (in)

0.13 - 0.18 (0.0051 - 0.0071)

Side bearing adjusting method

Side adjuster

Drive Pinion Height Adjustment

Available pinion height adjust washers

NGPD0047

Thickness mm (in)

Part number*

2.58 (0.1016) 2.61 (0.1028) 2.64 (0.1039) 2.67 (0.1051) 2.70 (0.1063) 2.73 (0.1075) 2.76 (0.1087) 2.79 (0.1098) 2.82 (0.1110) 2.85 (0.1122) 2.88 (0.1134) 2.91 (0.1146) 2.94 (0.1157) 2.97 (0.1169) 3.00 (0.1181) 3.03 (0.1193) 3.06 (0.1205) 3.09 (0.1217) 3.12 (0.1228) 3.15 (0.1240) 3.18 (0.1252) 3.21 (0.1264) 3.24 (0.1276) 3.27 (0.1287) 3.30 (0.1299) 3.33 (0.1311) 3.36 (0.1323) 3.39 (0.1335) 3.42 (0.1346) 3.45 (0.1358) 3.48 (0.1370) 3.51 (0.1382) 3.54 (0.1394) 3.57 (0.1406) 3.60 (0.1417) 3.63 (0.1429) 3.66 (0.1441)

38151-01J00 38151-01J01 38151-01J02 38151-01J03 38151-01J04 38151-01J05 38151-01J06 38151-01J07 38151-01J08 38151-01J09 38151-01J10 38151-01J11 38151-01J12 38151-01J13 38151-01J14 38151-01J15 38151-01J16 38151-01J17 38151-01J18 38151-01J19 38151-01J60 38151-01J61 38151-01J62 38151-01J63 38151-01J64 38151-01J65 38151-01J66 38151-01J67 38151-01J68 38151-01J69 38151-01J70 38151-01J71 38151-01J72 38151-01J73 38151-01J74 38151-01J75 38151-01J76

PD-90

REAR FINAL DRIVE

H233B

Service Data and Specifications (SDS) (Cont’d) *Always check with the Parts Department for the latest parts information.

Drive Pinion Preload Adjustment

NGPD0048

Drive pinion bearing preload adjusting method

Adjusting shim and spacer

Drive pinion preload without front oil seal

1.4 - 1.7 (14 - 17, 12 - 15)

N·m (kg-cm, in-lb)

Thickness mm (in)

Available front drive pinion bearing adjusting shims

2.31 2.33 2.35 2.37 2.39 2.41 2.43 2.45 2.47 2.49 2.51 2.53 2.55 2.57 2.59

4.50 4.75 5.00 5.25 5.50

MA

Part number*

(0.0909) (0.0917) (0.0925) (0.0933) (0.0941) (0.0949) (0.0957) (0.0965) (0.0972) (0.0980) (0.0988) (0.0996) (0.1004) (0.1012) (0.1020)

38125-82100 38126-82100 38127-82100 38128-82100 38129-82100 38130-82100 38131-82100 38132-82100 38133-82100 38134-82100 38135-82100 38136-82100 38137-82100 38138-82100 38139-82100

Thickness mm (in) Available drive pinion bearing adjusting spacers

GI

EM LC EC FE CL

Part number*

(0.1772) (0.1870) (0.1969) (0.2067) (0.2165)

38165-76000 38166-76000 38167-76000 38166-01J00 38166-01J10

MT AT

*Always check with the Parts Department for the latest parts information.

TF

AX SU BR ST RS BT HA SC EL

PD-91

IDX

NOTES

FRONT & REAR AXLE SECTION

AX

GI MA EM LC EC

CONTENTS FRONT AXLE ..................................................................2 Precautions ..................................................................2 PRECAUTIONS .........................................................2 Preparation ..................................................................2 SPECIAL SERVICE TOOLS ........................................2 COMMERCIAL SERVICE TOOLS ................................3 Noise, Vibration and Harshness (NVH) Troubleshooting ...........................................................4 NVH TROUBLESHOOTING CHART ............................4 On-vehicle Service.......................................................4 FRONT AXLE PARTS ................................................4 FRONT WHEEL BEARING .........................................5 DRIVE SHAFT ...........................................................7 Components.................................................................8 Manual-lock Free-running Hub ..................................10 DESCRIPTION ........................................................10 REMOVAL AND INSTALLATION ...............................10 INSPECTION ...........................................................11 Auto-lock Free-running Hub ......................................11 DESCRIPTION ........................................................11 REMOVAL AND INSTALLATION ...............................12 INSPECTION ...........................................................13 TROUBLE DIAGNOSIS FOR NOISE .........................13 Wheel Hub and Rotor Disc........................................14 REMOVAL AND INSTALLATION ...............................14 DISASSEMBLY ........................................................15 INSPECTION ...........................................................15 ASSEMBLY .............................................................15 Knuckle Spindle .........................................................16 REMOVAL ...............................................................16 INSPECTION ...........................................................17 INSTALLATION........................................................18 Drive Shaft .................................................................18

COMPONENTS .......................................................18 REMOVAL ...............................................................19 DISASSEMBLY ........................................................20 INSPECTION ...........................................................21 ASSEMBLY .............................................................21 INSTALLATION........................................................23

Service Data and Specifications (SDS).....................25 WHEEL BEARING (FRONT) .....................................25 DRIVE SHAFT (4WD MODELS) ................................25 REAR AXLE...................................................................27 Precautions ................................................................27 PRECAUTIONS .......................................................27 Preparation ................................................................27 SPECIAL SERVICE TOOLS ......................................27 COMMERCIAL SERVICE TOOLS ..............................27 Noise, Vibration and Harshness (NVH) Troubleshooting .........................................................29 On-vehicle Service.....................................................29 REAR AXLE PARTS.................................................29 REAR WHEEL BEARING .........................................30 Components...............................................................31 Removal.....................................................................32 Inspection...................................................................34 AXLE SHAFT...........................................................34 WHEEL BEARING ...................................................34 AXLE CASE ............................................................34 Installation..................................................................34 2WD MODELS.........................................................34 4WD MODELS.........................................................36 Service Data and Specifications (SDS).....................38 WHEEL BEARING (REAR) .......................................38

FE CL MT AT TF PD

SU BR ST RS BT HA SC EL IDX

FRONT AXLE Precautions

Precautions PRECAUTIONS

NGAX0001

쐌

SBR686C

When installing rubber parts, 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. 쐌 Use flare nut wrench when removing and installing brake tubes. 쐌 After installing removed suspension parts, check wheel alignment and adjust if necessary. 쐌 Always torque brake lines when installing. CAUTION: 쐌 The ZF100 (wheel side) type joint assembly has two types of boot material; one is made of rubber and the other is made of plastic. 쐌 Do not disassemble the joint assembly with the plastic boot. If the boot or joint is damaged, replace the drive shaft assembly.

Preparation SPECIAL SERVICE TOOLS

NGAX0002

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description

ST29020001 (J24319-01) Gear arm puller

Removing ball joint for knuckle spindle a: 34 mm (1.34 in) b: 6.5 mm (0.256 in) c: 61.5 mm (2.421 in)

NT694

Removing tie-rod outer end and lower ball joint a: 33 mm (1.30 in) b: 50 mm (1.97 in) r: R11.5 mm (0.453 in)

HT72520000 (J25730-B) Ball joint remover

NT546

Installing wheel bearing outer race

KV401021S0 ( — ) Bearing race drift

NT153

AX-2

FRONT AXLE Preparation (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

GI

KV40105400 (J36001) Wheel bearing lock nut wrench

Removing and installing wheel bearing lock nut (4WD models only)

MA EM

NT154

COMMERCIAL SERVICE TOOLS Tool name

NGAX0003

LC

Description

1 Flare nut crowfoot 2 Torque wrench

Removing and installing each brake piping a: 10 mm (0.39 in)

EC FE CL

NT360

MT AT TF PD

SU BR ST RS BT HA SC EL

AX-3

IDX

FRONT AXLE Noise, Vibration and Harshness (NVH) Troubleshooting

Noise, Vibration and Harshness (NVH) Troubleshooting

=NGAX0004

NVH TROUBLESHOOTING CHART

NGAX0004S01

Symptom AXLE

NVH, SU-3

NVH, SU-3

NVH, SU-3

NVH, BR-5

NVH, ST-5

TIRES

ROAD WHEEL

BRAKES

STEERING

Refer to DRIVE SHAFT in this chart. DRIVE SHAFT

×

SUSPENSION

NVH, PD-4 DIFFERENTIAL ×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

Noise

×

×

×

Shake

×

×

×

×

×

×

Vibration

×

×

×

×

×

×

Shimmy

×

×

×

×

×

×

×

Judder

×

×

×

×

×

×

Poor quality ride or handling

×

×

×

×

×

×

×

Refer to AXLE in this chart.

NVH, PD-4 PROPELLER SHAFT ×

AXLE

AX-5, 30 Wheel bearing damage

—

×

Parts interference

Shake

AX-8, 31

×

DRIVE SHAFT

Improper installation, looseness

×

Possible cause and SUSPECTED PARTS

—

AX-21 Joint sliding resistance

Noise, Vibration

Reference page

Imbalance

— Excessive joint angle

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×

×: Applicable

On-vehicle Service FRONT AXLE PARTS

SMA525A

NGAX0005

Check front axle parts for excessive play, cracks, wear and other damage. 쐌 Shake each front wheel to check for excessive play. If looseness is noted, adjust wheel bearing end play, then check ball joint end play. 쐌 Make sure that the cotter pin is inserted. 쐌 Retighten all nuts and bolts to the specified torque. : Refer to SU-11, “Components”.

AX-4

FRONT AXLE On-vehicle Service (Cont’d)

FRONT WHEEL BEARING 쐌 쐌 쐌

NGAX0006

Check that wheel bearings operate smoothly. Check axial end play. Axial end play: 0 mm (0 in) Adjust wheel bearing preload if there is any axial end play or wheel bearing does not turn smoothly.

GI MA EM LC

SMA571A

Preload Adjustment (2WD models)

SFA847BA

NGAX0006S01

Adjust wheel bearing preload after wheel bearing has been replaced or front axle has been reassembled. 1. Before adjustment, thoroughly clean all parts to prevent dirt entry. 2. Apply multi-purpose grease sparingly to the following parts: 쐌 Threaded area of spindle 쐌 Contact surface between lock washer and outer wheel bearing 쐌 Hub cap (as shown at left) 18 - 22 g (0.63 - 0.78 oz) 쐌 Grease seal lip 3. 4. 5.

Tighten wheel bearing lock nut to the specified torque. : 34 - 39 N·m (3.5 - 4.0 kg-m, 25 - 29 ft-lb) Turn wheel hub several times in both directions to seat wheel bearing correctly. Again tighten wheel bearing lock nut to the specified torque. : 34 - 39 N·m (3.5 - 4.0 kg-m, 25 - 29 ft-lb)

EC FE CL MT AT TF PD

SFA890

6. 7.

Turn wheel bearing lock nut back 45 degrees. Fit adjusting cap and new cotter pin. Align cotter pin slot by loosening nut 15 degrees or less.

SU BR ST RS

SFA452B

8.

Measure wheel bearing preload and axial end play. Axial end play: 0 mm (0 in) Wheel bearing preload (As measured at wheel hub bolt): New grease seal 9.8 - 28.4 N (1.0 - 2.9 kg, 2.2 - 6.4 lb) Used grease seal 9.8 - 23.5 N (1.0 - 2.4 kg, 2.2 - 5.3 lb) Repeat above procedures until correct bearing preload is obtained.

BT HA SC EL

SMA574A

AX-5

IDX

FRONT AXLE On-vehicle Service (Cont’d)

9. Spread cotter pin. 10. Install hub cap.

Preload Adjustment (4WD models)

NGAX0006S02

Adjust wheel bearing preload after wheel bearing has been replaced or front axle has been reassembled. Adjust wheel bearing preload as follows: 1. Before adjustment, thoroughly clean all parts to prevent dirt entry. SRA417

2. 쐌 쐌 쐌 쐌

Apply multi-purpose grease sparingly to the following parts: Threaded portion of spindle Contact surface between wheel bearing washer and outer wheel bearing Grease seal lip Wheel hub (as shown at left) 18 - 23 g (0.63 - 0.81 oz)

SFA891-C

3. 4. 5. 6.

Tighten wheel bearing lock nut with Tool. : 78 - 98 N·m (8 - 10 kg-m, 58 - 72 ft-lb) Turn wheel hub several times in both directions. Loosen wheel bearing lock nut so that torque becomes 0 N·m (0 kg-m, 0 ft-lb). Retighten wheel bearing lock nut with Tool. : 0.5 - 1.5 N·m (0.05 - 0.15 kg-m, 4.3 - 13.0 in-lb)

AFA148

7. 8. 9.

Turn wheel hub several times in both directions. Retighten wheel bearing lock nut with Tool. : 0.5 - 1.5 N·m (0.05 - 0.15 kg-m, 4.3 - 13.0 in-lb) Measure wheel bearing axial end play. Axial end play: 0 mm (0 in)

SFA845B

10. Measure starting force “A” at wheel hub bolt.

SMA580A

AX-6

FRONT AXLE On-vehicle Service (Cont’d)

SFA830

11. Install lock washer by tightening the lock nut within 15 to 30 degrees to align screw holes. 12. Turn wheel hub several times in both directions to seat wheel bearing correctly. 13. Measure starting force “B” at wheel hub bolt. Refer to step 10. 14. Wheel bearing preload “C” can be calculated as shown below. C=B−A Wheel bearing preload “C”: 7.06 - 20.99 N (0.72 - 2.14 kg, 1.59 - 4.72 lb) 15. If wheel bearing preload “C” is outside specifications, remove lock washer. Tighten or loosen lock nut within ±15 degrees (Refer to step 11 above). Install lock washer, then repeat steps 12, 13 and 14. 16. Repeat above procedures until correct axial end play and wheel bearing preload are obtained. 17. Tighten screws. : 1.2 - 1.8 N·m (0.12 - 0.18 kg-m, 10.4 - 15.6 in-lb) 18. Install free-running hub. 19. Tighten bolts. : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

GI MA EM LC EC FE CL MT

DRIVE SHAFT

NGAX0007

쐌 Check for grease leakage and damage. CAUTION: 쐌 The ZF100 (wheel side) type joint assembly has two types of boot material; one is made of rubber and the other is made of plastic. 쐌 Do not disassemble the joint assembly with the plastic boot. If the boot or joint is damaged, replace the drive shaft assembly.

AT TF PD

SFA901

SU BR ST RS BT HA SC EL

AX-7

IDX

FRONT AXLE Components

Components

NGAX0008

WAX029

AX-8

FRONT AXLE Components (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD

SU BR ST RS BT HA SC WAX026

EL

AX-9

IDX

FRONT AXLE Manual-lock Free-running Hub

Manual-lock Free-running Hub DESCRIPTION

SFA936

NGAX0041

Manual-lock free-running hubs are locked by rotating the operation knob to the LOCK position. The drive shaft and hub are now locked. If the teeth are not meshed, the operation is possible and the connection can be made simultaneously with the rotation of the hub. When the operation knob is rotated to the FREE position, the lock between the drive shaft and the hub is released. In most cases, the “ratcheting” noise sometimes heard in manuallock free-running hubs occurs when one hub is locked and the opposite hub is unlocked. The noise is heard in the side opposite to the locked hub. For example, if the noise is heard at the left front wheel, the right front hub is still locked and is not unlocking. This condition may be caused by a mechanical condition in one of the hubs or by incorrect operation on the part of the vehicle driver. The ratcheting noise does not necessarily cause damage to the good hub. If the noise is caused by incorrect operation, counsel the driver of the vehicle. If replacement is necessary, replace only the defective parts. It is not necessary to replace manual-lock freerunning hubs in pairs.

REMOVAL AND INSTALLATION

NGAX0042

AAX007

1. 2.

Set knob of manual-lock free-running hub in the FREE position. Remove manual-lock free-running hub.

WAX030

AX-10

FRONT AXLE Manual-lock Free-running Hub (Cont’d)

3. 4. 5.

AFA143

Remove snap ring. Remove spindle washer and thrust washer. When installing manual-lock free-running hub, make sure the hub is in the FREE position. 6. Place the thrust washer, spindle washer and then the snap ring over the axle shaft and position them between the two locking grooves. 7. While supporting the axle shaft behind the knuckle, use an appropriate sized deep socket to securely seat the snap ring into the inner locking groove. CAUTION: Visually verify that the snap ring is fully seated into the locking groove. 8. After installing manual-lock free-running hub, check operation. During installation, apply recommended grease to the parts shown in the above illustration.

INSPECTION

GI MA EM LC EC FE

NGAX0043

1. 2.

Check axle axial end play. Refer to “INSTALLATION”, AX-23. Inspect thrust washer assembly. If this part shows evidence of galling or heat damage—usually caused by too little axle axial end play—replace as necessary. Check axle axial end play if this part is replaced. Refer to “INSTALLATION”, AX-23. 3. Inspect hub assembly. Hold inner splines on a finger and spin the outer body. If the hub shows signs of damage, or if there is excessive metallic clicking when the hub is spun, replace with a new one. 4. Check that the knob moves smoothly and freely. 5. Check that the clutch moves smoothly in the body. NOTE: New hubs are greased during manufacture. No additional grease is required. CAUTION: Any hub, the original or a new one, should go onto the axle freely by hand and fit flush against its seat. If it does not fit flush, do not pull the hub into place by tightening the bolts. The hub is possibly misaligned inside and tightening the bolts will cause damage. Remove the hub and turn to align correctly before continuing. 6. Once repair is complete, test drive to check for correct operation and the absence of noise.

CL MT AT TF PD

SU BR ST RS

Auto-lock Free-running Hub DESCRIPTION

BT NGAX0039

Auto-lock free-running hubs are locked by placing the transfer case into the 4WD mode and moving the vehicle. They are unlocked by placing the transfer case into 2WD mode and moving the vehicle in reverse gear in a straight line for at least 2–3 meters (7–10 feet). In most cases, the “ratcheting” noise sometimes heard in auto-lock free-running hubs occurs when one hub is locked and the opposite hub is unlocked. The noise is heard in the side opposite to the locked hub. For example, if the noise is heard at the left front wheel,

AX-11

HA SC EL IDX

FRONT AXLE Auto-lock Free-running Hub (Cont’d)

the right front hub is still locked and is not unlocking. This condition may be caused by a mechanical condition in one of the hubs or by incorrect operation on the part of the vehicle driver, for example by not backing up in a straight line to unlock the hubs, by not backing up enough, or by shifting into 4WD at too high a vehicle speed, etc. The ratcheting noise does not necessarily cause damage to the good hub. If the noise is caused by incorrect operation, counsel the driver of the vehicle. If replacement is necessary, replace only the defective parts. It is not necessary to replace auto-lock free-running hubs in pairs. Use the trouble diagnosis chart to isolate the cause of the noise. Refer to “TROUBLE DIAGNOSIS FOR NOISE”, AX-13.

REMOVAL AND INSTALLATION

NGAX0011

AAX008

1.

Remove auto-lock free-running hub assembly.

2. 3. 4.

Remove snap ring. Remove spindle washer and fixed cam assembly. Install fixed cam assembly. Be sure to align the tabs of the fixed cam assembly to the notches of the knuckle. Place the spindle washer and then the snap ring over the axle shaft and position them between the 2 locking grooves. While supporting the axle shaft behind the knuckle, use an appropriate sized deep socket to securely seat the snap ring into the inner locking groove.

SFA828B

5. 6.

AFA143

AX-12

FRONT AXLE Auto-lock Free-running Hub (Cont’d)

CAUTION: Visually verify that the snap ring is fully seated into the locking groove. 7. After installing auto-lock free-running hub, check operation. During installation, apply recommended grease to the parts shown in the above illustration.

INSPECTION

NGAX0038

1. 2.

Check axle axial end play. Refer to “INSTALLATION”, AX-23. Inspect fixed cam (thrust washer) assembly. If this part shows evidence of galling or heat damage—usually caused by too little axle axial end play—replace as necessary. Check axle axial end play if this part is replaced. Refer to “INSTALLATION”, AX-23. 3. Inspect hub assembly. Hold inner splines on a finger and spin the outer body. If the hub shows signs of damage, or if there is excessive metallic clicking when the hub is spun, replace with a new one. NOTE: New hubs are greased during manufacture. No additional grease is required. New hubs are supplied with fixed cam assemblies. CAUTION: Any hub, the original or a new one, should go onto the axle freely by hand and fit flush against its seat. If it does not fit flush, do not pull the hub into place by tightening the bolts. The hub is possibly misaligned inside and tightening the bolts will cause damage. Remove the hub and turn to align correctly before continuing. 4. Once repair is complete, test drive to check for correct operation and the absence of noise.

TROUBLE DIAGNOSIS FOR NOISE Symptom

Possible cause

GI MA EM LC EC FE CL MT AT TF PD

NGAX0040

Repair order

Ratchet noise in hub after shifting the transfer case into 4WD at speeds higher than 40 km/h (25 mph).

1. Shifting into 4WD at higher speeds is difficult and may cause damage to transfer case

1. Stop the vehicle or decrease speed to less than 40 km/h (25 mph). Return the transfer case lever to the 2H position once, then re-shift to the 4H position. Move forward until the hubs lock.

Ratchet noise in hub after shifting or attempting to shift the transfer case into 4WD at speeds less than 40 km/h (25 mph).

1. Transfer case was not fully 1. Make sure the 4WD lamp on the dash engaged or shifting was stopped is ″ON″ when shifting into 4WD. Slow halfway so that only one hub or stop the vehicle. Shift into 2H, then locked back to 4H. Move forward until the hubs lock.

Ratchet noise in hub after shifting the transfer case into 4WD on snowy or muddy roads or on slopes.

1. If the rear wheels slip during the 1. Reduce engine speed and drive forward slowly. The hubs will lock evenly hub locking operation, noise can occur in the hubs and the noise will stop.

Ratchet noise in hub after shifting the transfer case into 2WD and backing up to unlock the hubs.

1. The hubs may not be fully released

1. Stop the vehicle, make sure the transfer case lever is fully in the 2H position, then back up slowly in a straight line at least 2-3 meters (7-10 feet).

SU BR ST RS BT HA SC EL

AX-13

IDX

FRONT AXLE Auto-lock Free-running Hub (Cont’d) Symptom

Possible cause

Ratchet noise in hub when driving in extremely cold weather.

1. The viscosity of differential oil grows higher in extreme cold, increasing the possibility that one hub may lock. A lower viscosity differential fluid may be required for extreme cold temperatures. See owner’s manual

Continual ratchet noise in one wheel when mov- 1. A hub may be mechanically ing forward. locked either by damage or misinstallation

Repair order 1. Shift the transfer case into 4H and drive the vehicle for 10 minutes or more to warm the differential oil. Then shift to 2WD and back up in a straight line for at least 2-3 meters (7-10 feet) to disengage the hubs. 1. Remove hubs and inspect. Refer to “INSPECTION”, AX-13. Pay special attention to the hub opposite the noisy side. The ratcheting does not necessarily cause damage to the good hub.

Wheel Hub and Rotor Disc REMOVAL AND INSTALLATION

NGAX0012

CAUTION: If equipped with ABS, disconnect the ABS wheel sensor from the assembly before removing the front axle assembly. Then move it away from the front axle assembly area. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative.

1.

Remove free-running hub assembly (4WD models). Refer to “REMOVAL AND INSTALLATION”, AX-12. 2. Remove brake caliper assembly without disconnecting hydraulic line. 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.

SFA825B

3.

Remove lock washer (4WD models).

SFA364BB

AX-14

FRONT AXLE Wheel Hub and Rotor Disc (Cont’d)

4.

Remove wheel bearing lock nut. 2WD Models: With suitable tool 4WD Models: With Tool

GI MA EM LC

AFA141

5. Remove wheel hub and wheel bearing. Be careful not to drop outer bearing. 6. After installing wheel hub and wheel bearing, adjust wheel bearing preload. Refer to “Preload Adjustment (2WD models)”, AX-5; or “Preload Adjustment (4WD models)”, AX-6.

EC FE CL MT

SFA827B

DISASSEMBLY 쐌

NGAX0013

Remove grease seal and bearing outer races with suitable brass bar.

AT TF PD

FA858

INSPECTION

NGAX0014

SU

NGAX0014S01

BR

Thoroughly clean wheel bearings and wheel hub.

Wheel Bearings 쐌

Make sure wheel bearings roll freely and are free from noise, cracks, pitting and wear.

Wheel Hub 쐌

ASSEMBLY 1.

NGAX0014S02

Check wheel hub for cracks by using a magnetic exploration or dyeing test.

NGAX0015

ST RS BT

Install bearing outer race with Tool until it is fully seated in hub.

HA SC EL WAX028

AX-15

IDX

FRONT AXLE Wheel Hub and Rotor Disc (Cont’d)

2.

Install the sensor rotor using suitable drift and press. Always replace sensor rotor with new one. Pay attention to the direction of front sensor rotor as shown in figure.

3.

Pack multi-purpose grease in wheel hub and hub cap (2WD models).

4. 5.

Apply multi-purpose grease to each bearing cone. Pack grease seal lip with multi-purpose grease, then install it into wheel hub with suitable drift.

SBR400DA

AFA122

SFA459B

Knuckle Spindle REMOVAL 1. 2.

NGAX0016

Remove free-running hub assembly (4WD models). Refer to “REMOVAL AND INSTALLATION”, AX-12. Remove wheel hub and rotor disc. Refer to “REMOVAL AND INSTALLATION”, AX-14.

SFA828B

3.

Separate drive shaft from knuckle spindle by slightly tapping drive shaft end (4WD models).

SFA844-A

AX-16

FRONT AXLE Knuckle Spindle (Cont’d)

4. Separate tie-rod from knuckle spindle with Tool. Install stud nut conversely on stud bolt so as not to damage stud bolt.

GI MA EM LC

AFA139

5. a.

Separate knuckle spindle from ball joints. Loosen (do not remove) upper and lower ball joint tightening nuts.

EC FE CL MT

SFA829B

b.

Separate knuckle spindle from upper and lower ball joint studs with Tool. During above operation, never remove ball joint nuts which are loosened in step (a) above. Tool: 2WD Models ST29020001 (J24319-01) 4WD Models HT72520000 (J25730-B)

AT TF PD

SFA079

c. d.

Remove ball joint tightening nuts. Support lower link with jack. Remove knuckle spindle from upper and lower links.

INSPECTION Knuckle Spindle 쐌

SU BR NGAX0017 NGAX0017S01

Check knuckle spindle for deformation, cracks and other damage by using a magnetic exploration or dyeing test.

ST RS

SFA830B

Bearing Spacer (2WD models) 쐌

Needle Bearing (4WD models) 쐌

NGAX0017S02

BT

NGAX0017S03

HA

Check bearing spacer for damage. Check needle bearing for wear, scratches, pitting, flaking and burn marks.

SC EL

AX-17

IDX

FRONT AXLE Knuckle Spindle (Cont’d)

INSTALLATION

NGAX0018

1. Install needle bearing into knuckle spindle (4WD models). Make sure that needle bearing is facing in the proper direction. Apply multi-purpose grease.

SFA962-C

2.

Install knuckle spindle to upper and lower ball joints with lower link jacked up. CAUTION: Make sure that oil and grease do not come into contact with tapered areas of ball joint, knuckle spindle and threads of ball joint. 3. Connect tie-rod to knuckle spindle. 4. Install wheel hub and rotor disc. Refer to “REMOVAL AND INSTALLATION”, AX-14. SFA831B

5.

6.

7.

After installing knuckle spindle, adjust wheel bearing preload. Refer to “Preload Adjustment (2WD models)”, AX-5; or “Preload Adjustment (4WD models)”, AX-6. After installing drive shaft, check drive shaft axial end play. Do not reuse snap ring once it has been removed. Refer to “INSTALLATION”, AX-23. Install free-running hub assembly (4WD models). Refer to “REMOVAL AND INSTALLATION”, AX-12.

SFA369BC

Drive Shaft COMPONENTS

NGAX0019

CAUTION: 쐌 The ZF100 (wheel side) type joint assembly has two types of boot material; one is made of rubber and the other is made of plastic. 쐌 Do not disassemble the joint assembly with the plastic boot. If the boot or joint is damaged, replace the drive shaft assembly.

AX-18

FRONT AXLE Drive Shaft (Cont’d)

GI MA EM LC EC FE SFA874-B

CL MT

REMOVAL

NGAX0020

1.

Remove free-running hub or drive flange and snap ring. Refer to “REMOVAL AND INSTALLATION”, AX-12. 2. Remove torsion bar spring. Refer to SU-12, “REMOVAL”. 3. Remove shock absorber lower bolt. 4. Remove lower link bolts. Support lower link with jack.

AT TF PD

SFA832B

5.

Remove drive shaft to final drive bolts.

SU BR ST RS

SFA236

6.

Separate drive shaft from knuckle spindle by slightly tapping end of drive shaft.

BT HA SC EL

SFA833B

AX-19

IDX

FRONT AXLE Drive Shaft (Cont’d)

DISASSEMBLY Final Drive Side (TS82F) 1. 2.

NGAX0021 NGAX0021S01

Remove plug seal from slide joint housing by lightly tapping around slide joint housing. Remove boot bands.

SFA880

3.

Move boot and slide joint housing toward wheel side, and apply matching marks.

4.

Remove snap ring.

5.

Detach spider assembly with press.

SFA963

SFA964

SFA392

6. Draw out boot. Cover drive shaft serration with tape to prevent damaging the boot.

SFA799

AX-20

FRONT AXLE Drive Shaft (Cont’d)

Wheel Side (ZF100)

SFA455

NGAX0021S02

CAUTION: 쐌 The ZF100 (wheel side) type joint assembly has two types of boot material; one is made of rubber and the other is made of plastic. 쐌 Do not disassemble the joint assembly with the plastic boot. If the boot or joint is damaged, replace the drive shaft assembly. The procedures for the joint with the rubber boot are as follows: 쐌 Before separating joint assembly, put matching marks on drive shaft and joint assembly. 쐌 Separate joint assembly with suitable tool. Be careful not to damage threads on drive shaft. 쐌 Remove boot bands.

GI MA EM LC EC FE CL MT

INSPECTION

NGAX0022

Thoroughly clean all parts in cleaning solvent, and dry with compressed air. Check parts for evidence of deformation and other damage.

Drive Shaft

AT TF

NGAX0022S01

Replace drive shaft if it is twisted, cracked or bent.

PD

Boot

NGAX0022S02

Check boot for fatigue, cracks and wear. Replace boot and boot bands with new.

Joint Assembly (Final drive side) 쐌 쐌 쐌

NGAX0022S03

Replace any parts of double offset joint which show signs of scorching, rust, wear or excessive play. Check serration for deformation. Replace if necessary. Check slide joint housing for any damage. Replace if necessary.

Joint Assembly (Wheel side)

NGAX0022S04

CAUTION: 쐌 The ZF100 (wheel side) type joint assembly has two types of boot material; one is made of rubber and the other is made of plastic. 쐌 Do not disassemble the joint assembly with the plastic boot. If the boot or joint is damaged, replace the drive shaft assembly. Replace joint assembly if it is deformed or damaged.

ASSEMBLY 쐌 쐌

BR ST RS BT HA

NGAX0023

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.

AX-21

SU

SC EL IDX

FRONT AXLE Drive Shaft (Cont’d)

Final Drive Side (TS82F)

NGAX0023S01

1.

Install new small boot band, boot and side joint housing to drive shaft. Cover drive shaft serration with tape to prevent damaging boot during installation.

SFA800

2. 쐌 3.

Install spider assembly securely, making sure marks are properly aligned. Press-fit with spider assembly serration chamfer facing shaft. Install new snap ring.

SFA397

4.

5.

Pack with grease. Specified amount of grease: 95 - 105 g (3.35 - 3.70 oz) Make sure that the boot is properly installed on the drive shaft groove. Set the boot so that it does not swell or deform when its length is “L1”. Length “L1”: 95 - 97 mm (3.74 - 3.82 in)

SFA460BA

6.

Lock new large boot band securely with a suitable tool, then lock new small boot band. 7. Install new plug seal to slide joint housing by lightly tapping it. Apply suitable sealant to mating surface of plug seal.

SFA443B

Wheel Side (ZF100)

NGAX0023S02

CAUTION: 쐌 The ZF100 (wheel side) type joint assembly has two types of boot material; one is made of rubber and the other is made of plastic. 쐌 Do not disassemble the joint assembly with the plastic boot. If the boot or joint is damaged, replace the drive shaft assembly. The procedures for the joint with the rubber boot are as follows:

AX-22

FRONT AXLE Drive Shaft (Cont’d)

1. Install new small boot band and boot on drive shaft. Cover drive shaft serration with tape to prevent damaging boot during installation.

GI MA EM LC

SFA800

2.

Set joint assembly onto drive shaft by lightly tapping it. Install joint assembly securely, ensuring that marks which were made during disassembly are properly aligned.

EC FE CL MT

SFA884

3.

4.

Pack drive shaft with specified amount of grease. Specified amount of grease: 115 - 125 g (4.06 - 4.41 oz) Make sure that the boot is properly installed on the drive shaft groove. Set the boot so that it does not swell or deform when its length is “L2”. Length “L2”: 96 - 98 mm (3.78 - 3.86 in)

AT TF PD

SFA473BA

5.

Lock new large boot band securely with a suitable tool, then lock new small boot band.

SU BR ST RS

SFA443B

INSTALLATION 1.

NGAX0024

BT

Apply multi-purpose grease.

HA SC EL SFA887

AX-23

IDX

FRONT AXLE Drive Shaft (Cont’d)

2. Install bearing spacer onto drive shaft. Make sure that the bearing spacer is facing in the proper direction. 3. After installing wheel hub and wheel bearing, adjust wheel bearing preload. Refer to “Preload Adjustment (2WD models)”, AX-5; or “Preload Adjustment (4WD models)”, AX-6.

SFA846

4. a.

When installing drive shaft, adjust drive shaft axial end play by selecting a suitable snap ring. Temporarily install new snap ring on drive shaft in the same thickness as the one that was removed.

SFA940

b. c.

d.

Set dial gauge on drive shaft end. Measure axial end play of drive shaft. Axial end play: 0.10 – 0.45 mm (0.004 – 0.0177 in) If axial end play is not within the specified limit, select another snap ring. 1.1 1.3 1.5 1.7

mm mm mm mm

SFA847

AX-24

(0.043 (0.051 (0.059 (0.067

in) in) in) in)

1.9 mm (0.075 in) 2.1 mm (0.083 in) 2.3 mm (0.091 in)

FRONT AXLE Service Data and Specifications (SDS)

Service Data and Specifications (SDS) WHEEL BEARING (FRONT) 2WD Models Wheel bearing axial end play

=NGAX0025

GI

NGAX0025S01

mm (in)

0 (0) Tightening torque

N·m(kg-m, ft-lb)

MA

34 - 39 (3.5 - 4.0, 25 - 29)

Wheel bearing lock nut Return angle

degree

At wheel hub bolt With new grease seal

Wheel bearing starting torque

45° - 60°

N (kg, lb)

With used grease seal

EM

9.8 - 28.4 (1.0 - 2.9, 2.2 - 6.4)

N (kg, lb)

LC

9.8 - 23.5 (1.0 - 2.4, 2.2 - 5.3)

4WD Models

NGAX0025S02

Tightening torque

N·m(kg-m, ft-lb)

Retightening torque after loosening wheel bearing lock nut N·m(kg-m, ft-lb) Axial end play

Wheel bearing lock nut

mm (in) N (kg, lb)

degree

CL

A

N (kg, lb)

B−A

MT

B 7.06 - 20.99 (0.72 - 2.14, 1.59 - 4.72)

DRIVE SHAFT (4WD MODELS)

Drive shaft joint type

NGAX0026

Final drive side

TS82F

Wheel side

ZF100*

Fixed joint axial end play limit Diameter

mm (in)

mm (in)

Wheel side (D1)

TF PD

1 (0.04)

NISSAN genuine grease or equivalent

Grease

Boot length

AT

29.0 (1.142)

Quality

Capacity

FE

0.5 - 1.5 (0.05 - 0.15, 0.4 - 1.1)

15° - 30°

Starting force at wheel hub bolt Wheel bearing preload at wheel hub bolt N (kg, lb)

78 - 98 (8 - 10, 58 - 72)

0 (0)

Starting force at wheel hub bolt Turning angle

EC

Final drive side

95 - 105 (3.35 - 3.70)

Wheel side

115 - 125 (4.06 - 4.41)

SU

g (oz)

Final drive side (L1)

95 - 97 (3.74 - 3.82)

Wheel side (L2)

96 - 98 (3.78 - 3.86)

BR

mm (in)

ST RS BT HA SC SFA877A

EL *: The ZF100 (wheel side) type joint assembly has two types of boot material; one is made of rubber and the other is made of plastic. Do not disassemble the joint assembly with the plastic boot. If the boot or joint is damaged, replace the drive shaft assembly.

AX-25

IDX

FRONT AXLE Service Data and Specifications (SDS) (Cont’d)

Drive Shaft Axial End Play Drive shaft axial end play

NGAX0026S01

mm (in)

0.10 – 0.45 (0.004 – 0.0177)

Drive Shaft End Snap Ring

NGAX0026S02

Thickness mm (in) 1.1 1.3 1.5 1.7 1.9 2.1 2.3

Part No.*

(0.043) (0.051) (0.059) (0.067) (0.075) (0.083) (0.091)

39253-88G10 39253-88G11 39253-88G12 39253-88G13 39253-88G14 39253-88G15 39253-88G16

*: Always check with the Parts Department for the latest parts information.

AX-26

REAR AXLE Precautions

Precautions PRECAUTIONS 쐌

쐌 쐌 SBR686C

쐌

NGAX0027

When installing rubber parts, 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 and installing brake tubes. After installing removed suspension parts, check wheel alignment and adjust if necessary. Always torque brake lines when installing.

GI MA EM LC

Preparation SPECIAL SERVICE TOOLS

NGAX0028

EC

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

FE

Description

CL

Removing rear axle shaft

KV40101000 (J25604-01) Axle stand

MT NT159

AT

Removing rear axle shaft

ST36230000 (J25840-A) Sliding hammer

TF NT126

PD Removing wheel bearing, wheel bearing lock nut and ABS sensor rotor

KV40106500 (J-45073) Rear axle shaft bearing puller

SU LPD022

BR

Installing rear axle shaft

ST37840000 ( — ) Rear axle shaft guide

ST NT162

RS

COMMERCIAL SERVICE TOOLS Tool name

NGAX0029

Description

BT

1 Flare nut crowfoot 2 Torque wrench

Removing and installing each brake piping a: 10 mm (0.39 in)

HA SC

NT360

EL

AX-27

IDX

REAR AXLE Preparation (Cont’d) Tool name

Description

Bearing cage oil seal drift

Installing oil seal a: 74 mm (2.91 in) dia. b: 68 mm (2.68 in) dia.

NT115

Installing oil seal a: 54.5 mm (2.15 in.) b: 34.5 mm (1.36 in.)

Rear axle oil seal drift

NT115

AX-28

REAR AXLE Noise, Vibration and Harshness (NVH) Troubleshooting

Noise, Vibration and Harshness (NVH) Troubleshooting

=NGAX0030

Refer to “Noise, Vibration and Harshness (NVH) Troubleshooting”, AX-4.

GI MA EM LC

On-vehicle Service REAR AXLE PARTS Check rear axle parts for excessive play, wear and damage. 쐌 Shake each rear wheel to check for excessive play.

NGAX0031

EC FE CL MT

SMA525A

쐌

Retighten all nuts and bolts to the specified torque. : Refer to SU-21, “Components”.

AT TF PD

SRA839

SU BR ST RS BT HA SC EL

AX-29

IDX

REAR AXLE On-vehicle Service (Cont’d)

쐌 쐌

Check shock absorber for oil leakage and other damage. Check shock absorber bushing for excessive wear and other damage.

SRA734

REAR WHEEL BEARING 쐌 쐌

Check that wheel bearings operate smoothly. Check axial end play. Axial end play: Refer to “WHEEL BEARING (REAR)”, AX-38.

SRA006-A

AX-30

NGAX0032

REAR AXLE Components

Components

NGAX0033

GI MA EM LC EC FE CL MT AT TF PD

SU WAX032

BR ST RS BT HA SC EL

AX-31

IDX

REAR AXLE Components (Cont’d)

WAX033

Removal 쐌

쐌 쐌 쐌

1. 2.

NGAX0034

Before removing the rear axle, disconnect the ABS wheel sensor from the assembly. Then move it away from the axle. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative. Wheel bearing does not require maintenance. If growling noise is emitted from wheel bearing during operation, replace wheel bearing assembly. If the wheel bearing assembly is removed, it must be replaced. The old assembly must not be re-used. Disconnect parking brake cable and brake tube. Remove nuts securing wheel bearing cage with baffle plate.

SRA002

3. Draw out axle shaft with Tool. When drawing out axle shaft, be careful not to damage oil seal. 4. Remove case shim and case seal (2WD models). 5. Remove O-ring (4WD models). 6. Remove oil seal. Do not reuse oil seal once it is removed. Always install new one.

ARA096

AX-32

REAR AXLE Removal (Cont’d)

7.

Remove ABS sensor rotor with tool (4WD models). Always replace sensor rotor with a new one.

GI MA EM LC

ARA097

8.

Unbend lock washer with suitable Tool.

EC FE CL MT

SRA104

9.

Remove bearing lock nut with Tool.

AT TF PD

ARA095

10. Remove wheel bearing together with bearing cage and baffle plate from axle shaft with Tool.

SU BR ST RS

ARA098

11. Remove grease seal in bearing cage with suitable bar. 12. Remove wheel bearing outer race with a brass drift (2WD models).

BT HA SC EL

SRA106

AX-33

IDX

REAR AXLE Removal (Cont’d)

13. Remove wheel bearing assembly (4WD models).

ARA094

Inspection AXLE SHAFT 쐌

NGAX0035S02

Make sure wheel bearing rolls freely and is free from noise, cracks, pitting and wear.

AXLE CASE 쐌

NGAX0035S01

Check axle shaft for straightness, cracks, damage, wear and distortion. Replace if necessary.

WHEEL BEARING 쐌

NGAX0035

NGAX0035S03

Check axle case for yield, deformation and cracks. Replace if necessary.

Installation 2WD MODELS

NGAX0036 NGAX0036S01

1. Install wheel bearing outer race with a brass drift. 2. Install a new grease seal in bearing cage. After installing new grease seal, coat sealing lip with multipurpose grease.

SRA010

3.

Install bearing spacer with chamfer side facing axle shaft flange.

4. 5.

Install wheel bearing inner race with a brass drift. Coat each bearing cone with multi-purpose grease. Specified amount of grease: 8 - 12 g (0.28 - 0.42 oz)

SRA510

SRA011

AX-34

REAR AXLE Installation (Cont’d)

6. Install plain washer and a new wheel bearing lock washer. 7. Tighten wheel bearing lock nut. Fit wheel bearing lock washer lip in wheel bearing lock nut groove correctly by tightening lock nut. Be sure to bend it up.

GI MA EM LC

SRA730

8. Install a new oil seal with suitable tool. After installing new oil seal, coat sealing lip with multi-purpose grease.

EC FE CL MT

SRA731

9. Apply recess of axle case end with multi-purpose grease. 10. Apply gear oil to the spline of axle shaft. Coat seal surface of axle shaft with multi-purpose grease (as shown left).

AT TF PD

SRA652A

11. Adjust axial end play. a. Select end shims. Standard thickness including seal: 1.5 mm (0.059 in) Axle case end shim: Refer to “WHEEL BEARING (REAR)”, AX-38. Do not insert end shims between case seal and bearing cage.

SU BR ST RS

SRA653A

b.

c.

ARA088

Insert axle shaft with Tool as a guide. When inserting axle shaft, be careful not to damage oil seal. Measure end play of axle shaft. Axial end play: Servicing only one side of axle shaft 0.02 - 0.15 mm (0.0008 - 0.0059 in) Servicing both side axle shafts On first axle shaft (right or left) adjust axial end play 0.30 - 0.90 mm (0.0118 - 0.0354 in) After servicing second axle shaft, total end play

AX-35

BT HA SC EL IDX

REAR AXLE Installation (Cont’d)

0.02 - 0.15 mm (0.0008 - 0.0059 in)

d.

If axial end play is not within the specified limit, reselect axle case end shims. While adjusting axial end play, be careful not to damage oil seal.

SRA006-A

4WD MODELS

NGAX0036S02

1.

Press new wheel bearing until it bottoms end face of bearing cage. Maximum load P: 78 kN (8 ton, 8.8 US ton, 7.9 Imp ton) Always press outer race of wheel bearing during installation.

SRA288A

2.

Press new grease seal until it bottoms end face of bearing cage. After installing new grease seal, coat sealing lip with multipurpose grease.

SRA289A

3.

Press axle shaft into inner race of wheel bearing. Maximum load P: 47.1 kN (4.8 ton, 5.3 US ton, 4.72 Imp ton) Be careful not to damage or deform grease seal.

SRA761A

AX-36

REAR AXLE Installation (Cont’d)

4. 5.

Install plain washer and a new wheel bearing lock washer. Tighten wheel bearing lock nut to specified torque. : 147 - 196 N·m (15 - 20 kg-m, 108 - 145 ft-lb) Fit wheel bearing lock washer lip in wheel bearing lock nut groove correctly by tightening lock nut. Be sure to bend it up.

GI MA EM LC

SRA762A

6. a. b.

Check wheel bearing preload. Turn bearing cage (with respect to axle shaft) two or three times. It must turn smoothly. Attach spring gauge to bearing cage bolt (as shown at left) and pull it at a speed of 10 rpm to measure preload. Spring gauge indication: 6.9 - 48.1 N (0.7 - 4.9 kg, 1.5 - 10.8 lb)

EC FE CL MT

SRA763A

7. Install new oil seal to rear axle housing using a suitable tool. After installing new oil seal, coat sealing lip with multi-purpose grease. 8. Install new O-ring to rear axle housing.

AT TF PD

SRA803A

9.

Press ABS sensor rotor onto axle shaft until it contacts wheel bearing lock nut. Always replace sensor rotor with new one.

SU BR ST RS

SRA802A

10. Position axle shafts in rear axle housing with Tool as a guide. Be careful not to damage oil seal.

BT HA SC EL

ARA088

AX-37

IDX

REAR AXLE Installation (Cont’d)

11. Check axial end play. a. Check that wheel bearings operate smoothly. b. Check axial end play. Axial end play: 0 mm (0 in)

SRA006-A

Service Data and Specifications (SDS) WHEEL BEARING (REAR) 2WD Models Total end play

NGAX0037 NGAX0037S01

mm (in)

0.02 - 0.15 (0.0008 - 0.0059) Thickness mm (in) 0.05 0.07 0.10 0.15 0.20 0.50 1.00

Available rear axle case end shims

Part number*

(0.0020) (0.0028) (0.0039) (0.0059) (0.0079) (0.0197) (0.0394)

43086-P0110 43087-P0110 43088-P0110 43086-B9500 43089-P0110 43090-P0110 43036-01G00

*: Always check with the Parts Department for the latest parts information.

4WD Models Total end play

NGAX0037S02

mm (in)

Wheel bearing preload at bearing cage bolt

0 (0) N (kg, lb)

6.9 - 48.1 (0.7 - 4.9, 1.5 - 10.8)

AX-38

FRONT & REAR SUSPENSION SECTION

SU

GI MA EM LC EC

CONTENTS FRONT SUSPENSION ....................................................2 Precautions ..................................................................2 PRECAUTIONS .........................................................2 Preparation ..................................................................2 SPECIAL SERVICE TOOLS ........................................2 COMMERCIAL SERVICE TOOLS ................................2 Noise, Vibration and Harshness (NVH) Troubleshooting ...........................................................3 NVH TROUBLESHOOTING CHART ............................3 Components.................................................................4 2WD MODEL .............................................................4 4WD MODEL .............................................................5 On-vehicle Service.......................................................6 FRONT SUSPENSION PARTS ...................................6 FRONT WHEEL ALIGNMENT .....................................6 Components...............................................................11 Shock Absorber .........................................................12 REMOVAL AND INSTALLATION ...............................12 INSPECTION ...........................................................12 Torsion Bar Spring .....................................................12 REMOVAL ...............................................................12 INSPECTION ...........................................................13 INSTALLATION AND ADJUSTMENT .........................13 Stabilizer Bar .............................................................14 REMOVAL ...............................................................14 INSPECTION ...........................................................14 INSTALLATION........................................................14 Upper Link .................................................................15 REMOVAL ...............................................................15 INSTALLATION........................................................15 DISASSEMBLY ........................................................15 INSPECTION ...........................................................15 ASSEMBLY .............................................................16 Lower Link .................................................................16 REMOVAL AND INSTALLATION ...............................16 INSPECTION ...........................................................16 Upper Ball Joint and Lower Ball Joint .......................17

REMOVAL AND INSTALLATION ...............................17 INSPECTION ...........................................................17

Service Data and Specifications (SDS).....................17 GENERAL SPECIFICATIONS (FRONT) .....................17 WHEEL RUNOUT AVERAGE ....................................17 UPPER BALL JOINT ................................................17 LOWER BALL JOINT ...............................................17 WHEEL ALIGNMENT (UNLADEN*1) ..........................18 REAR SUSPENSION.....................................................20 Precautions ................................................................20 PRECAUTIONS .......................................................20 Preparation ................................................................20 COMMERCIAL SERVICE TOOLS ..............................20 Noise, Vibration and Harshness (NVH) Troubleshooting .........................................................21 Components...............................................................21 2WD KA24DE MODEL .............................................21 2WD VG33E AND VG33ER MODELS .......................22 4WD VG33E AND VG33ER MODELS .......................23 On-vehicle Service.....................................................23 REAR SUSPENSION PARTS ...................................23 Removal and Installation ...........................................24 Shock Absorber .........................................................24 REMOVAL AND INSTALLATION ...............................24 INSPECTION ...........................................................25 Leaf Spring ................................................................25 REMOVAL ...............................................................25 INSPECTION ...........................................................25 INSTALLATION........................................................26 Stabilizer Bar .............................................................26 REMOVAL ...............................................................26 INSPECTION ...........................................................26 INSTALLATION........................................................26 Service Data and Specifications (SDS).....................27 GENERAL SPECIFICATIONS (REAR) .......................27

FE CL MT AT TF PD AX

BR ST RS BT HA SC EL IDX

FRONT SUSPENSION Precautions

Precautions PRECAUTIONS 쐌

쐌 쐌 SBR686C

쐌

NGSU0001

When installing rubber parts, 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 and installing brake tubes. After installing removed suspension parts, check wheel alignment and adjust if necessary. Always torque brake lines when installing.

Preparation SPECIAL SERVICE TOOLS

NGSU0002

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description Removing ball joint for knuckle spindle a: 34 mm (1.34 in) b: 6.5 mm (0.256 in) c: 61.5 mm (2.421 in)

ST29020001 (J24319-01) Gear arm puller

NT694

Removing tie-rod outer end a: 33 mm (1.30 in) b: 50 mm (1.97 in) r: 11.5 mm (0.453 in)

HT72520000 (J25730-B) Ball joint remover

NT546

To replace the lower control arm frame bushing

(j-45813) Front lower control arm frame bushing removal/ installation tool

LSU029

COMMERCIAL SERVICE TOOLS Tool name

NGSU0003

Description

1 Flare nut crowfoot 2 Torque wrench

Removing and installing each brake piping a: 10 mm (0.39 in)

NT360

SU-2

FRONT SUSPENSION Noise, Vibration and Harshness (NVH) Troubleshooting

Noise, Vibration and Harshness (NVH) Troubleshooting

=NGSU0004

NVH TROUBLESHOOTING CHART

GI

NGSU0004S01

ST-5, NVH

BR-5, NVH

Refer to ROAD WHEEL in this chart.

Refer to TIRES in this chart.

Refer to SUSPENSION in this chart.

AX-4, NVH

AX-4, NVH

PD-4, NVH

PD-16, PD-66, PD-42, NVH

—

—

—

—

—

—

SU-6

SU-14

SU-6

SU-11, 24

SU-11, 24

—

×

×

×

×

Shake

×

×

×

×

Vibration

×

×

×

×

Shimmy

×

×

×

×

Judder

×

×

×

Poor quality ride or handling

×

×

×

Noise

×

×

×

×

×

×

Shake

×

×

×

×

×

×

EM LC

TIRES

ROAD WHEEL

BRAKES

STEERING

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

× ×

×

Vibration

×

AT TF PD AX

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

Judder

×

×

×

×

×

×

×

×

×

×

Poor quality ride or handling

×

×

×

×

×

×

×

×

×

×

Noise

×

×

×

×

×

×

×

×

×

×

×

Shake

×

×

×

×

×

×

×

×

×

×

×

Shimmy, Judder

×

×

×

×

×

×

×

×

×

Poor quality ride or handling

×

×

×

×

×

×

×

×

MT

×

Shimmy

x: Applicable

×

×

SUSPENSION

AXLE

×

CL DRIVE SHAFT

PROPELLER SHAFT

Incorrect tire size

Non-uniformity

Uneven tire wear

×

Incorrect air pressure

×

Imbalance

×

Out-of-round

Suspension looseness

×

Stabilizer bar fatigue

Spring fatigue

Deformation or damage

FE

DIFFERENTIAL

×

Incorrect wheel alignment

Parts interference

SU-11, 24 Bushing or mounting deterioration

SUSPENSION TIRES ROAD WHEEL

Symptom

SU-12, 24 Shock absorber deformation, damage or deflection

Noise

Possible Cause and SUSPECTED PARTS

MA

EC

Improper installation, looseness

Reference page

SU-4, 21

Use the chart below to help you find the cause of the symptom. Repair or replace parts as necessary.

BR ST RS BT HA SC EL

SU-3

IDX

FRONT SUSPENSION Components

Components 2WD MODEL

NGSU0005 NGSU0005S01

WSU013

SU-4

FRONT SUSPENSION Components (Cont’d)

4WD MODEL

NGSU0005S02

GI MA EM LC EC FE CL MT AT TF PD AX

BR ST RS BT HA SC WSU014

SU-5

EL IDX

FRONT SUSPENSION On-vehicle Service

On-vehicle Service FRONT SUSPENSION PARTS

SMA525A

NGSU0006

Check front suspension parts for excessive play, cracks, wear and other damage. 쐌 Shake each front wheel to check for excessive play. If looseness is noted, adjust wheel bearing end play, then check ball joint end play. Refer to “INSPECTION”, SU-17. 쐌 Make sure that the cotter pin is inserted. 쐌 Retighten all nuts and bolts to the specified torque. : Refer to “FRONT SUSPENSION”, SU-11. 쐌 쐌

Check shock absorber for oil leakage and other damage. Check suspension ball joint for grease leakage and ball joint dust cover for cracks and other damage.

ASU018

FRONT WHEEL ALIGNMENT

NGSU0007

Before checking front wheel alignment, make a preliminary inspection (Unladen*). *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

Preliminary Inspection 1. 2. 1) 2)

SFA975B

3. 4. 5. 6.

NGSU0007S01

Check tires for wear and proper inflation. Check wheels for deformation, cracks and other damage. If deformed, remove wheel and check wheel runout. Remove tire from aluminum wheel and mount wheel on a tire balance machine. Set dial indicator as shown in the illustration. Wheel runout (Dial indicator value): Refer to “WHEEL RUNOUT AVERAGE”, SU-17. Check front wheel bearings for looseness. Check front suspension for looseness. Check steering linkage for looseness. Check that front shock absorbers work properly by using the standard bounce test.

SU-6

FRONT SUSPENSION On-vehicle Service (Cont’d)

7. a.

b. c. d. ASU019

Check vehicle posture (Unladen): H = A − B mm (in) Refer to “2WD Model”, SU-18 or “4WD Model”, SU-19. Exercise the front suspension by bouncing the front of the vehicle 4 or 5 times to ensure that the vehicle is in a neutral height attitude. Measure wheel alignment. Refer to “2WD Model”, SU-18 or “4WD Model”, SU-19. If wheel alignment is not as specified, adjust vehicle posture. Refer to “2WD Model”, SU-18 or “4WD Model”, SU-19. Adjust wheel alignment. Refer to “2WD Model”, SU-18 or “4WD Model”, SU-19.

GI MA EM LC EC FE CL MT

Camber, Caster and Kingpin Inclination

NGSU0007S02

Before checking camber, caster or kingpin inclination, move vehicle up and down on turning radius gauge to minimize friction. Ensure that the vehicle is in correct posture. 쐌 Measure camber, caster and kingpin inclination of both right and left wheels with a suitable alignment gauge and adjust in accordance with the following procedures. Camber, Caster and Kingpin inclination: Refer to “2WD Model”, SU-18 or “4WD Model”, SU-19.

AT TF PD AX

SFA894

쐌

a) b) 쐌

In the following two cases, temporarily tighten the adjusting bolts while aligning the matching marks with the slits as shown in the figure at the left and measure the camber, caster and kingpin inclination: When replacing the upper link or other suspension parts with new ones When matching marks were not painted on adjusting bolts before suspension disassembly procedures If matching marks were already painted during suspension disassembly, align the matching marks with the slits, then temporarily tighten the adjusting bolts. Measure the camber, caster and kingpin inclination.

BR ST RS BT HA SC EL

SFA817B

SU-7

IDX

FRONT SUSPENSION On-vehicle Service (Cont’d)

Adjustment 1. 쐌 2. a.

b.

3.

a.

SFA817B

b. c.

NGSU0007S03

Both camber and caster angles are adjusted by adjusting bolts. If the kingpin inclination is outside specifications, check the front suspension parts for wear or damage. Replace faulty parts with new ones. From the measured value, read the coordinate (or: graduation) at the intersecting point in the graph. If the coordinate (or: graduation) at the intersecting point is positive, move the pin outward by turning the corresponding adjusting bolt by the indicated graduation. If the coordinate (or: graduation) at the intersecting point is negative, move the pin inward by turning the corresponding adjusting bolt by the indicated graduation. After properly moving the pin(s), tighten the front and rear adjusting bolts to specifications. Re-measure to ensure that the camber and caster are within specified tolerances. [Example] Measured values corresponding with the two values indicated below: (See chart for 4WD model.) Camber angle: −0°06′ (−0.10°) Caster angle: 2°10′ (2.17°) Apply the above two values to the graph and determine point “A”. The coordinate (or: graduation) indicates that both the front and rear adjusting bolts must be turned outward by 3 graduations. Turn the adjusting bolts by the amount corresponding with the 3 graduations.

AFA147

SU-8

FRONT SUSPENSION On-vehicle Service (Cont’d)

Toe-in

SFA614B

NGSU0007S04

Measure toe-in using the following procedure. WARNING: 쐌 Always perform the following procedure on a flat surface. 쐌 Make sure that no one is in front of the vehicle before pushing it. 1. Bounce front of vehicle up and down to stabilize the posture. 2. Push the vehicle straight ahead about 5 m (16 ft). 3. Put a mark on base line of 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). 쐌 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 “2WD Model”, SU-18 or “4WD Model”, SU-19.

GI MA EM LC EC FE CL MT

SFA234AC

7. a. b.

Adjust toe-in by varying the length of both steering tie-rods. Loosen lock nuts. Adjust toe-in by turning both the left and right tie-rod tubes equal amounts.

AT TF PD AX

ASU020

c.

Make sure that the tie-rod bars are screwed into the tie-rod tube more than 35 mm (1.38 in). Make sure that the tie-rods are the same length before aligning the front end. Standard length (A = B): 297.6 mm (11.72 in) Tighten clamp bolts or lock nuts, then torque them.

BR ST RS

ASU021

BT HA SC EL

SU-9

IDX

FRONT SUSPENSION On-vehicle Service (Cont’d)

Front Wheel Turning Angle 1. 2. 쐌 쐌 SFA439BA

3.

=NGSU0007S05

Set wheels in straight-ahead position. Then move vehicle forward until front wheels rest properly on turning radius gauge. 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 “2WD Model”, SU-18 or “4WD Model”, SU-19.

Adjust stopper bolt if necessary. Standard length “L2 Except P265/70R15 tire: 26.5 mm (1.043 in) (Length before cap is mounted) P265/70R15 tire: 30.0 mm (1.2 in) (Length before cap is mounted)

ASU022

SU-10

FRONT SUSPENSION Components

Components

NGSU0008

GI MA EM LC EC FE CL MT AT TF PD AX

BR ST RS BT HA SC WSU030

SU-11

EL IDX

FRONT SUSPENSION Shock Absorber

Shock Absorber REMOVAL AND INSTALLATION 1. 2. 3.

INSPECTION

SFA836B

NGSU0009

Support lower link with jack. Remove bolt and nut that hold shock absorber. Tighten upper nut and lower bolt to specification. Refer to “Components”, SU-11. NGSU0010

Except for nonmetallic parts, clean all parts with suitable solvent and dry with compressed air. Use compressed air to blow dirt and dust off nonmetallic parts. 쐌 Check for oil leakage and cracks. Replace if necessary. 쐌 Check piston rod for cracks, deformation and other damage. Replace if necessary. 쐌 Check rubber parts for wear, cracks, damage and deformation. Replace if necessary.

Torsion Bar Spring REMOVAL 1.

NGSU0011

Move dust cover.

AFA140

2.

Paint matching marks on the torsion bar spring and the corresponding arm. Always use paint to place the matching mark; do not scribe the affected parts.

ASU023

3.

Measure anchor bolt protrusion “L” and remove the lock nut and adjusting nut. Standard length “L” = 68 mm (2.68 in) Before removing the nuts, ensure that twisting force is eliminated from the torsion bar springs.

ASU024

SU-12

FRONT SUSPENSION Torsion Bar Spring (Cont’d)

4. 쐌

Remove torsion bar spring. Remove torque arm fixing nuts, then withdraw torsion bar spring forward with torque arm.

GI MA EM LC

ASU025

INSPECTION 쐌 쐌 쐌

NGSU0012

Check torsion bar spring for wear, twist, bend and other damage. Check serrations of each part for cracks, wear, twist and other damage. Check dust cover for cracks.

EC FE CL MT

INSTALLATION AND ADJUSTMENT

NGSU0013

Adjustment of anchor arm adjusting nut is in tightening direction only. Do not adjust by loosening anchor arm adjusting nut. 1. Coat multi-purpose grease on the serration of torsion bar spring. 2. Place lower link in the position where bound bumper clearance “C” is 0. Clearance “C”: 0 mm (0 in)

AT TF PD AX

SFA549

3. Install torsion bar spring with torque arm. Be sure to install right and left torsion bar springs correctly.

BR ST RS SFA854

4.

While aligning the anchor arm with the matching mark, install the anchor arm to the torsion bar spring. If a new torsion bar spring or anchor arm is installed, adjust anchor arm length to the dimension indicated in the figure at the left. Standard length “G”: 25 - 39 mm (0.98 - 1.54 in)

BT HA SC EL

ASU026

SU-13

IDX

FRONT SUSPENSION Torsion Bar Spring (Cont’d)

5.

Tighten the adjusting nut so the torsion bar length corresponds with dimension “L” previously measured during torsion bar removal. Tighten the lock nut to specifications. If a new torsion bar spring or anchor arm is installed, tighten the adjusting nut to the dimension indicated in the figure at the left, then tighten the lock nut to specifications. Standard length “L”: 68 mm (2.68 in)

6.

Bounce vehicle with tires on ground (Unladen) to eliminate friction of suspension. Measure vehicle posture “H”. Exercise the front suspension by bouncing the front of the vehicle 4 or 5 times to ensure that the vehicle is in a neutral height attitude. Measure vehicle posture ... Dimension “H”. Refer to “2WD MODEL”, SU-18; or “4WD MODEL”, SU-19. H = A − B mm (in) “Unladen” If height of the vehicle is not within allowable limit, adjust vehicle posture. Refer to “2WD MODEL”, SU-18; or “4WD MODEL”, SU-19. Check wheel alignment if necessary. Refer to “2WD MODEL”, SU-18; or “4WD MODEL”, SU-19.

ASU024

7. a.

b.

8. ASU019

9.

Stabilizer Bar REMOVAL

NGSU0014

Remove stabilizer bar connecting bolts and clamp bolts.

INSPECTION 쐌 쐌

ASU027

NGSU0015

Check stabilizer bar for twist and deformation. Replace if necessary. Check rubber bushing for cracks, wear and deterioration. Replace if necessary.

INSTALLATION

NGSU0016

Install in the reverse order of removal. Refer to “Components”, SU-11.

SU-14

FRONT SUSPENSION Upper Link

Upper Link REMOVAL 1. 2.

NGSU0017

Remove shock absorber. Refer to “Shock Absorber”, SU-12. Separate upper ball joint stud from knuckle spindle. Support lower link with jack. Refer to AX-16, “Knuckle Spindle”.

GI MA EM LC

SFA836B

3.

Put matching marks on adjusting bolts and remove adjusting bolts.

EC FE CL MT

SFA842B

INSTALLATION 1.

2. 3.

4.

NGSU0018

While aligning the adjusting bolts with the matching marks, install the upper link. If a new upper link or any other suspension part is installed, align the matching mark with the slit as indicated in the figure at the left, then install the upper link. Refer to “FRONT WHEEL ALIGNMENT”, SU-6. Install shock absorber. Tighten adjusting bolts under unladen condition (fuel, radiator coolant, and engine oil full; spare tire, jack, hand tools, and mats in designated positions) with tires on ground. Refer to “Components”, SU-11 After installing, check wheel alignment. Adjust if necessary. Refer to “FRONT WHEEL ALIGNMENT”, SU-6.

AT TF PD AX

BR ST RS SFA817B

DISASSEMBLY 쐌

INSPECTION 쐌 쐌

NGSU0019

BT

NGSU0020

HA

Press out upper link bushings. Check adjusting bolts and rubber bushings for damage. Replace if necessary. Check upper link for deformation and cracks. Replace if necessary.

SC EL

SFA843B

SU-15

IDX

FRONT SUSPENSION Upper Link (Cont’d)

ASSEMBLY

NGSU0021

1. Apply soapsuds to rubber bushing. 2. Press upper link bushing. Press bushing so that the flange of bushing securely contacts the end surface of the upper link collar.

SFA102

Lower Link REMOVAL AND INSTALLATION

ASU023

NGSU0024

1. Remove torsion bar spring. Refer to “REMOVAL”, SU-12. Make matching marks and measure dimension “L” when loosening adjusting nut until there is no tension on torsion bar spring. Standard length “L”: 68 mm (2.68 in) 2. Remove shock absorber lower fixing bolt. 3. Remove stabilizer bar connecting bolt. 4. Separate drive shaft from front final drive (4WD model). Refer to AX-19, “Drive Shaft”. 5. Separate lower link ball joint from knuckle spindle. Refer to AX-16, “Knuckle Spindle”.

ASU024

6.

Remove front lower link fixing bolts.

7. 8.

Remove bushing of lower link spindle from frame with Tool. After installing lower link, adjust wheel alignment and vehicle height. Refer to “FRONT WHEEL ALIGNMENT”, SU-6.

ASU028

INSPECTION Lower Link and Lower Link Spindle 쐌

NGSU0025S01

Check for deformation and cracks. Replace if necessary.

Lower Link Bushing 쐌

NGSU0025

NGSU0025S02

Check for distortion and damage. Replace if necessary.

WSU031

SU-16

FRONT SUSPENSION Upper Ball Joint and Lower Ball Joint

Upper Ball Joint and Lower Ball Joint REMOVAL AND INSTALLATION

NGSU0026

Separate knuckle spindle from upper and lower links. Refer to AX-16, “Knuckle Spindle”.

MA

INSPECTION 쐌

AFA136

쐌

GI

NGSU0027

Check joints for play. If ball is worn and play in axial direction is excessive or joint is hard to swing, replace as an upper link or lower link. Axial end play “C”: Upper link 0 mm (0 in) Lower link 0.2 mm (0.008 in) or less Check dust cover for damage. Replace dust cover and dust cover clamp if necessary.

EM LC EC FE CL MT

Service Data and Specifications (SDS) GENERAL SPECIFICATIONS (FRONT)

AT NGSU0028

Suspension type

Independent double wishbone torsion bar spring

Shock absorber type

TF

Double-acting hydraulic

Stabilizer

Standard equipment

PD

WHEEL RUNOUT AVERAGE

NGSU0029

AX

Steel Wheel type

Aluminum Inside

Outside

Radial runout limit

mm (in)

0.8 (0.031) or less

0.4 (0.016) or less

0.3 (0.012)

Lateral runout limit

mm (in)

1.0 (0.039) or less

0.9 (0.035) or less

0.3 (0.012)

BR

UPPER BALL JOINT Axial end play “C”

NGSU0030

mm (in)

0 (0)

LOWER BALL JOINT Axial end play “C”

ST NGSU0031

mm (in)

0.2 (0.008) or less

RS BT HA SC EL

SU-17

IDX

FRONT SUSPENSION Service Data and Specifications (SDS) (Cont’d)

WHEEL ALIGNMENT (UNLADEN*1) 2WD Model

Camber Degree minute (Decimal degree)

=NGSU0032 NGSU0032S01

Minimum

0°03′ (0.05°)

Nominal

0°33′ (0.55°)

Maximum

1°03′ (1.05°)

Left and right difference

Caster Degree minute (Decimal degree)

Minimum

2°04′ (2.07°)

Nominal

2°34′ (2.57°)

Maximum

3°04′ (3.07°)

Left and right difference

Kingpin inclination Degree minute (Decimal degree)

Distance (A − B) mm (in)

45′ (0.75°) or less

45′ (0.75°) or less

Minimum

10°23′ (10.38°)

Nominal

10°53′ (10.88°)

Maximum

11°23′ (11.38°)

Radial tire

Minimum

3 (0.12)

Nominal

4 (0.16)

Maximum

5 (0.20)

Minimum

15′ (0.25°)

Nominal

20′ (0.33°)

Maximum

25′ (0.42°)

Total toe-in Angle (left plus right) Degree minute (Decimal degree)

Inside Degree minute (Decimal degree) Wheel turning angle

Full turn*2 Outside Degree minute (Decimal degree)

Vehicle posture Lower arm pivot height (H)

Radial tire

Except P265/70R15

P265/70R15

Minimum

32°48′ (32.80°)

30°48′ (30.80°)

Nominal

34°48′ (34.80°)

32°48′ (32.80°)

Maximum

34°48′ (34.80°)

32°48′ (32.80°)

Minimum

31°00′ (31.00°)

28°42′ (28.70°)

Nominal

33°00′ (33.00°)

30°42′ (30.70°)

Maximum

33°00′ (33.00°)

30°42′ (30.70°)

mm (in)

37.7 - 41.7 (1.484 - 1.642)

ASU019

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.

SU-18

FRONT SUSPENSION Service Data and Specifications (SDS) (Cont’d)

4WD Model

=NGSU0032S02

Camber Degree minute (Decimal degree)

Minimum

0°06′ (0.10°)

Nominal

0°36′ (0.60°)

Maximum

1°06′ (1.10°)

Left and right difference

Caster Degree minute (Decimal degree)

Kingpin inclination Degree minute (Decimal degree)

Distance (A − B) mm (in)

MA

45′ (0.75°) or less

Minimum

1°40′ (1.67°)

Nominal

2°10′ (2.17°)

Maximum

2°40′ (2.67°)

Left and right difference

GI

EM LC

45′ (0.75°) or less

Minimum

10°18′ (10.30°)

Nominal

10°48′ (10.80°)

Maximum

11°18′ (11.30°)

Radial tire

Minimum

3 (0.12)

Nominal

4 (0.16)

Maximum

5 (0.20)

Minimum

15′ (0.25°)

Nominal

20′ (0.33°)

Maximum

25′ (0.42°)

EC FE CL

Total toe-in Angle (left plus right) Degree minute (Decimal degree)

Inside Degree minute (Decimal degree) Wheel turning angle

Full turn*2 Outside Degree minute (Decimal degree)

Vehicle posture Lower arm pivot height (H)

Radial tire

MT AT

Except P265/70R15

P265/70R15

Minimum

33°06′ (33.10°)

31°00′ (31.00°)

Nominal

35°06′ (35.10°)

33°00′ (33.00°)

Maximum

35°06′ (35.10°)

33°00′ (33.00°)

Minimum

31°12′ (31.20°)

29°00′ (29.00°)

Nominal

33°12′ (33.20°)

31°00′ (31.00°)

Maximum

33°12′ (33.20°)

31°00′ (31.00°)

mm (in)

TF PD AX

45.5 - 49.5 (1.791 - 1.949)

BR ST RS ASU019

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.

BT HA SC EL

SU-19

IDX

REAR SUSPENSION Precautions

Precautions PRECAUTIONS 쐌

쐌 쐌 SBR686C

쐌

NGSU0033

When installing rubber parts, 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 and installing brake tubes. After installing removed suspension parts, check wheel alignment and adjust if necessary. Always torque brake lines when installing.

Preparation COMMERCIAL SERVICE TOOLS Tool name

NGSU0035

Description

1 Flare nut crowfoot 2 Torque wrench

Removing and installing each brake piping a: 10 mm (0.39 in)

NT360

SU-20

REAR SUSPENSION Noise, Vibration and Harshness (NVH) Troubleshooting

Noise, Vibration and Harshness (NVH) Troubleshooting

=NGSU0036

Refer to “Noise, Vibration and Harshness (NVH) Troubleshooting”, SU-3.

Components 2WD KA24DE MODEL

NGSU0037

GI MA

NGSU0037S03

EM LC EC FE CL MT AT TF PD ASU030

AX

BR ST RS BT HA SC EL

SU-21

IDX

REAR SUSPENSION Components (Cont’d)

2WD VG33E AND VG33ER MODELS

NGSU0037S04

ASU038

SU-22

REAR SUSPENSION Components (Cont’d)

4WD VG33E AND VG33ER MODELS

NGSU0037S05

GI MA EM LC EC FE CL MT AT ARA109

TF PD AX

On-vehicle Service REAR SUSPENSION PARTS

NGSU0038

Check rear suspension parts for excessive play, wear and damage. 쐌 Shake each rear wheel to check for excessive play.

BR ST RS

SMA525A

쐌

Retighten all nuts and bolts to the specified torque. : Refer to “REMOVAL AND INSTALLATION”, SU-24.

BT HA SC EL

ASU031

SU-23

IDX

REAR SUSPENSION On-vehicle Service (Cont’d)

쐌 쐌

Check shock absorber for oil leakage and other damage. Check shock absorber bushing for excessive wear and other damage.

SRA734

Removal and Installation

NGSU0039

WSU028

Shock Absorber REMOVAL AND INSTALLATION 1. 2.

NGSU0040

Remove shock absorber by disconnecting upper and lower end. Install in reverse order of removal.

ASU033

SU-24

REAR SUSPENSION Shock Absorber (Cont’d)

INSPECTION 쐌 쐌

NGSU0041

If oil leakage, cracks and deformation occurs, replace shock absorber assembly. If rubber bushings are cracked and deformed, replace rubber bushings.

GI MA EM LC

Leaf Spring REMOVAL 1.

NGSU0042

EC

Disconnect shock absorber lower end, and remove U-bolts.

FE CL MT

SRA702

2.

Remove the spring shackle.

AT TF PD AX SRA704

3. 4.

Remove the front pin. Remove leaf spring.

BR ST RS ASU034

INSPECTION 쐌 쐌 쐌

NGSU0043

Check leaf spring for cracks. Replace if necessary. Check front bracket and pin, shackle, U-bolts and spring pad for wear, cracks, straightness and damaged threads. Replace if necessary. Check all bushings for deformation and cracks. Replace if necessary. (4WD models: Rear spring front bushing) Make sure that front bushing is properly installed.

BT HA SC EL

ASU035

SU-25

IDX

REAR SUSPENSION Leaf Spring (Cont’d)

INSTALLATION

NGSU0044

1. 2. 3. 4.

Apply soapsuds to rubber bushing. Install spring shackle and front pin, and finger tighten the nuts. Install spring pad and nuts under leaf spring or axle case. Tighten U-bolt mounting nuts diagonally. Refer to “Removal and Installation” SU-24. Tighten U-bolts so that the lengths of all U-bolts under spring pad are the same. 5. Install shock absorber, and finger tighten the nuts.

SRA727

6.

Remove stands and bounce the vehicle to stabilize suspension. (Unladen)

ASU036

7.

Tighten spring shackle nuts, front pin nuts and shock absorber nuts. Refer to “Removal and Installation” SU-24. When installing rubber parts, final tightening must be carried out under unladen condition* with tires on the ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

ASU037

Stabilizer Bar REMOVAL

NGSU0046

Remove stabilizer bar connecting bolts and clamp bolts.

INSPECTION 쐌 쐌

INSTALLATION ASU029

NGSU0047

Check stabilizer bar for twist and deformation. Check rubber bushing for cracks, wear and deterioration. Replace if necessary. NGSU0048

Install in the reverse order of removal. Refer to “Components”, SU-21.

SU-26

REAR SUSPENSION Service Data and Specifications (SDS)

Service Data and Specifications (SDS) GENERAL SPECIFICATIONS (REAR)

NGSU0045

Suspension type

GI

Rigid axle with semi-elliptic leaf spring

Shock absorber type

Double-acting hydraulic

MA EM LC EC FE CL MT AT TF PD AX

BR ST RS BT HA SC EL

SU-27

IDX

NOTES

BRAKE SYSTEM SECTION

BR

GI MA EM LC EC

CONTENTS PRECAUTIONS ...............................................................3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............3 Precautions for Brake System.....................................3 Wiring Diagrams and Trouble Diagnosis.....................3 PREPARATION ...............................................................4 Special Service Tools ..................................................4 Commercial Service Tools ...........................................4 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................5 NVH Troubleshooting Chart.........................................5 ON-VEHICLE SERVICE ..................................................6 Checking Brake Fluid Level.........................................6 Checking Brake Line ...................................................6 Changing Brake Fluid ..................................................6 Brake Burnishing Procedure........................................7 Bleeding Brake System ...............................................8 BRAKE HYDRAULIC LINE .............................................9 Hydraulic Circuit...........................................................9 Removal.......................................................................9 Inspection...................................................................10 Installation..................................................................10 BRAKE PEDAL AND BRACKET..................................11 Removal and Installation ...........................................11 Inspection...................................................................11 Adjustment .................................................................12 MASTER CYLINDER.....................................................13 Removal.....................................................................13 Disassembly...............................................................13 Inspection...................................................................14 Assembly ...................................................................14 Installation..................................................................15 BRAKE BOOSTER........................................................16 On-vehicle Service.....................................................16 OPERATING CHECK ...............................................16 AIRTIGHT CHECK ...................................................16 Removal.....................................................................16 Inspection...................................................................16 OUTPUT ROD LENGTH CHECK ..............................16

FE

Installation..................................................................17 VACUUM PIPING...........................................................18 Removal and Installation ...........................................18 Inspection...................................................................18 HOSES AND CONNECTORS ...................................18 CHECK VALVE ........................................................18 FRONT DISC BRAKE ...................................................19 Pad Replacement ......................................................19 Removal.....................................................................20 Disassembly...............................................................21 Inspection...................................................................21 CALIPER .................................................................21 ROTOR ...................................................................21 Assembly ...................................................................22 Installation..................................................................22 Brake Burnishing Procedure......................................22 REAR DRUM BRAKE ...................................................23 Components...............................................................23 Removal.....................................................................23 Inspection...................................................................24 WHEEL CYLINDER ..................................................24 Wheel Cylinder Overhaul...........................................24 Inspection...................................................................25 DRUM .....................................................................25 LINING ....................................................................25 Installation..................................................................25 PARKING BRAKE CONTROL ......................................27 Components...............................................................27 Removal and Installation ...........................................27 Inspection...................................................................27 Adjustment .................................................................28 ABS DESCRIPTION ...............................................................29 Purpose......................................................................29 Operation ...................................................................29 ABS Hydraulic Circuit ................................................29 System Components .................................................30 System Description....................................................30

CL MT AT TF PD AX SU

ST RS BT HA SC EL IDX

CONTENTS WHEEL SENSOR ....................................................30 CONTROL UNIT (BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT) .....................................................30 ABS ACTUATOR AND ELECTRIC UNIT ....................31 G SENSOR (4WD MODELS) ....................................31

TROUBLE DIAGNOSIS - INTRODUCTION..................32 How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................32 INTRODUCTION ......................................................32 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........33 Preliminary Check......................................................33 Ground Circuit Check ................................................36 ABS ACTUATOR AND ELECTRIC UNIT GROUND.....36 Component Parts and Harness Connector Location .....................................................................37 Schematic ..................................................................38 2–WHEEL DRIVE ....................................................38 4–WHEEL DRIVE ....................................................39 Wiring Diagram - ABS - 2WD - .................................40 Wiring Diagram - ABS - 4WD - .................................43 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................46 Self-diagnosis (Without CONSULT-II) .......................46 FUNCTION ..............................................................46 SELF-DIAGNOSIS PROCEDURE ..............................46 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) ........................................47 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) ........................................47

TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................48 Malfunction Code Chart (Without CONSULT-II)........48 Symptom Chart..........................................................48 CONSULT-II ...............................................................49 CONSULT-II APPLICATION TO ABS..........................49 ECU (ABS CONTROL UNIT) PART NUMBER MODE .....................................................................49

CONSULT-II Inspection Procedure............................50 SELF-DIAGNOSIS PROCEDURE ..............................50 SELF-DIAGNOSTIC RESULTS MODE.......................51 DATA MONITOR PROCEDURE ................................52 ACTIVE TEST PROCEDURE ....................................53 DATA MONITOR MODE ...........................................54 ACTIVE TEST MODE ...............................................54 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS.............................................................................55

(Cont’d)

Wheel Sensor or Rotor..............................................55 DIAGNOSTIC PROCEDURE .....................................55 ABS Actuator Solenoid Valve or Solenoid Valve Relay..........................................................................58 DIAGNOSTIC PROCEDURE .....................................58 Motor Relay or Motor.................................................60 DIAGNOSTIC PROCEDURE .....................................60 Low Voltage ...............................................................62 DIAGNOSTIC PROCEDURE .....................................62 G Sensor and Circuit .................................................64 DIAGNOSTIC PROCEDURE .....................................64 Control Unit................................................................66 DIAGNOSTIC PROCEDURE .....................................66 TROUBLE DIAGNOSES FOR SYMPTOMS .................67 1. ABS Works Frequently ..........................................67 2. Unexpected Pedal Action ......................................67 3. Long Stopping Distance ........................................69 4. ABS Does Not Work..............................................69 5. Pedal Vibration and Noise.....................................69 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On .....................................70 7. Warning Lamp Stays On When Ignition Switch Is Turned On..............................................................71 REMOVAL AND INSTALLATION .................................75 Front Wheel Sensor...................................................75 Rear Wheel Sensor ...................................................75 4WD MODELS.........................................................75 2WD MODELS.........................................................76 Front Sensor Rotor ....................................................76 REMOVAL ...............................................................76 INSTALLATION........................................................76 Rear Sensor Rotor (4WD) .........................................77 REMOVAL ...............................................................77 INSTALLATION........................................................77 G Sensor....................................................................77 ABS Actuator and Electric Unit..................................78 REMOVAL ...............................................................78 INSTALLATION........................................................78 SERVICE DATA AND SPECIFICATIONS (SDS) .........79 General Specifications...............................................79 Disc Brake .................................................................79 Drum Brake................................................................79 Brake Pedal ...............................................................79 Parking Brake Control ...............................................80

BR-2

PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGBR0001

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 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), 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 this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

GI MA EM LC EC FE CL MT

Precautions for Brake System 쐌 쐌 쐌

SBR686C

NGBR0002

Use brake fluid “DOT 3”. 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. 쐌 To clean master cylinder parts, disc brake caliper parts or wheel cylinder parts, use clean brake fluid. 쐌 Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of hydraulic system. 쐌 Use flare nut wrench when removing and installing brake tubes. 쐌 Always torque brake lines when installing. WARNING: 쐌 Clean brakes with a vacuum dust collector to minimize risk of health hazard from powder caused by friction.

AT TF PD AX SU

ST RS

Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the followings: 쐌 GI-10,“HOW TO READ WIRING DIAGRAMS”. 쐌 EL-10, “POWER SUPPLY ROUTING” for power distribution circuit. When you perform trouble diagnosis, refer to the followings: 쐌 GI-33, “How To Follow Test Group In Trouble Diagnoses”. 쐌 GI-22, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.

NGBR0003

BT HA SC EL

BR-3

IDX

PREPARATION Special Service Tools

Special Service Tools

NGBR0004

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description Removing rear wheel sensor rotor

KV40106500 (JS25852-B) Wheel bearing puller

NT724

Commercial Service Tools Tool name

Description

1 Flare nut crowfoot 2 Torque wrench

Removing and installing each brake piping a: 10 mm (0.39 in)

NT360

Measuring brake fluid pressure

Brake fluid pressure gauge

NT151

Installing rear wheel sensor rotor a: 75 mm (2.95 in) dia. b: 63 mm (2.48 in) dia.

Rear wheel sensor rotor drift

NT509

BR-4

NGBR0005

Symptom BRAKE × × × ×

Shake ×

Shimmy, Judder × × ×

BR-5 × × × × ×

PROPELLER SHAFT DIFFERENTIAL DRIVE SHAFT AXLE SUSPENSION TIRES ROAD WHEEL STEERING

Drum out of round

Rotor thickness variation

Rotor or drum rust

Rotor or drum deflection

Rotor or drum deformation

Rotor or drum runout

Rotor or drum damage

Rotor or drum imbalance

Shims damaged

Noise Return spring damaged

Possible cause and SUSPECTED PARTS Linings or pads - uneven wear

×

NVH, ST-5.

NVH Troubleshooting Chart

NVH, SU-3.

NVH, SU-3.

NVH, SU-3.

NVH, AX-4.

NVH, AX-4.

NVH, PD-16, PD-42 PD-66.

NVH, PD-4.

BR-25

BR-21

—

—

—

BR-21, 25

—

—

BR-19

BR-23

BR-19, 25

BR-25

Reference page

Linings or pads - damaged

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NGBR0085

NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. NGBR0085S01

× × × × × × × ×

× × × × × ×

× × × × ×

GI

MA

EM

LC

EC

FE

CL

MT

×: Applicable

AT

TF

PD

AX

SU

ST

RS

BT

HA

SC

EL

IDX

ON-VEHICLE SERVICE Checking Brake Fluid Level

Checking Brake Fluid Level 쐌 쐌 쐌

NGBR0006

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. If the brake warning lamp comes on, check brake fluid level switch and parking brake switch.

SBR451D

Checking Brake Line

NGBR0007

CAUTION: If leakage occurs around joints, retighten or, if necessary, replace damaged parts. 1. Check brake lines (tubes and hoses) for cracks, deterioration and other damage. Replace any damaged parts. 2. Check for oil leakage by fully depressing brake pedal while engine is running.

SBR389C

Changing Brake Fluid

SBR419C

NGBR0008

CAUTION: 쐌 Refill with new brake fluid “DOT 3”. 쐌 Always keep fluid level higher than minimum line on reservoir tank. 쐌 Never reuse drained brake fluid. 쐌 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. 4. Refill until 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.

BR-6

ON-VEHICLE SERVICE Brake Burnishing Procedure

Brake Burnishing Procedure

=NGBR0120

Burnish the brake contact surfaces according to the following procedure after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. CAUTION: Only perform this procedure under safe road and traffic conditions. Use extreme caution. 1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH). 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 to 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.

GI MA EM LC EC FE CL MT AT TF PD AX SU

ST RS BT HA SC EL

BR-7

IDX

ON-VEHICLE SERVICE Bleeding Brake System

Bleeding Brake System

SBR995

=NGBR0009

CAUTION: 쐌 Carefully monitor brake fluid level at master cylinder during bleeding operation. 쐌 If master cylinder is suspected to have air inside, bleed air from master cylinder first. Refer to “Installation”, BR-15. 쐌 Fill reservoir with new brake fluid “DOT 3”. Make sure it is full at all times while bleeding air out of system. 쐌 Place a container under master cylinder to avoid spillage of brake fluid. 쐌 Turn ignition switch OFF and disconnect ABS actuator connectors or battery ground cable. 쐌 Bleed air in the following order. 1. Left rear brake 2. Right rear brake 3. Left front brake 4. Right front brake

1. 2. 3. 4. 5. 6. 7.

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 to specified torque. : 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb)

SBR419C

BR-8

BRAKE HYDRAULIC LINE Hydraulic Circuit

Hydraulic Circuit

NGBR0010

GI MA EM LC EC FE CL MT AT

LBR138

TF PD AX

Removal

SBR992

NGBR0011

CAUTION: 쐌 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. 쐌 All hoses must be free from excessive bending, twisting and pulling. 1. Connect vinyl tube to air bleeder valve. 2. Drain brake fluid from each air bleeder valve by depressing brake pedal. 3. Remove flare nut connecting brake tube and hose, then withdraw lock spring. 4. Cover openings to prevent entrance of dirt whenever disconnecting brake line.

SU

ST RS BT HA SC EL

BR-9

IDX

BRAKE HYDRAULIC LINE Inspection

Inspection

NGBR0012

Check brake lines (tubes and hoses) for cracks, deterioration and other damage. Replace any damaged parts.

Installation

SBR686C

NGBR0013

CAUTION: 쐌 Refill with new brake fluid “DOT 3”. 쐌 Never reuse drained brake fluid. 1. Tighten all flare nuts and connecting bolts. Flare nut: : 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) Connecting bolt: : 17 - 19 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

BRAKE PEDAL AND BRACKET Removal and Installation

Removal and Installation

NGBR0016

GI MA EM LC EC FE CL MT AT TF PD ABR824

AX

Inspection Check brake pedal for following items. 쐌 Brake pedal bend 쐌 Clevis pin deformation 쐌 Crack of any welded portion 쐌 Crack or deformation of clevis pin stopper

NGBR0017

SU

ST RS

SBR997

BT HA SC EL

BR-11

IDX

BRAKE PEDAL AND BRACKET Adjustment

Adjustment

NGBR0018

Check brake pedal free height from metal floor. H: Free height Refer to “Brake Pedal”, BR-79. D: Depressed height Refer to “Brake Pedal” BR-79. Under force of 490 N (50 kg, 110 lb) with engine running C1, C2: Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch 0.3 - 1.0 mm (0.012 - 0.039 in) A: Pedal free play 1 - 3 mm (0.04 - 0.12 in) If necessary, adjust brake pedal free height.

SBR278AB

1.

SBR930

Loosen lock nut and adjust pedal free height by turning brake booster input rod. Then tighten lock nut. Make sure that tip of input rod stays inside. 2. Adjust clearance “C1” and “C2” with stop lamp switch and ASCD switch respectively. Then tighten lock nuts. 3. Check pedal free play. Make sure that stop lamp is off when pedal is released. 4. 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.

BR-12

MASTER CYLINDER Removal

Removal

NGBR0019

CAUTION: 쐌 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. 쐌 In the case of brake fluid leakage from the master cylinder, disassemble the cylinder. Then check piston cups for deformation and scratches and replace necessary parts. 1. Connect a vinyl tube to air bleeder valve. 2. Drain brake fluid from each air bleeder valve, depressing brake pedal to empty fluid from master cylinder. 3. Remove brake pipe flare nuts. 4. Remove master cylinder mounting nuts.

GI MA EM LC EC FE CL MT AT TF PD AX SU

ST ABR873

Disassembly 1.

NGBR0020

RS BT

Bend claws of stopper cap outward.

HA SC EL SBR938A

BR-13

IDX

MASTER CYLINDER Disassembly (Cont’d)

2. Remove piston stopper while piston is pushed into cylinder. 3. Remove piston assemblies. If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet. 4. Draw out reservoir tank.

SBR939A

Inspection

NGBR0021

Check master cylinder inner wall for pin holes and scratches. Replace if damaged.

Assembly 1. 쐌

NGBR0022

Insert secondary piston assembly. Then insert primary piston assembly. Pay attention to direction of piston cups in figure at left. Also, insert pistons squarely to avoid scratches on cylinder bore.

ABR767

2. Install stopper cap. Before installing stopper cap, ensure that claws are bent inward. 3. Push reservoir tank seals into cylinder body. 4. Push reservoir tank into cylinder body.

SBR940A

BR-14

MASTER CYLINDER Installation

Installation

ABR190

=NGBR0023

CAUTION: 쐌 Refill with new brake fluid “DOT 3”. 쐌 Never reuse drained brake fluid. 1. Place master cylinder onto brake booster and secure mounting nuts lightly. 2. Torque mounting nuts. : 12 - 15 N·m (1.2 - 1.5 kg-m, 9 - 11 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 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) 8. Bleed air. Refer to “Bleeding Brake System”, BR-8.

GI MA EM LC EC FE CL MT AT TF PD AX SU

ST RS BT HA SC EL

BR-15

IDX

BRAKE BOOSTER On-vehicle Service

On-vehicle Service OPERATING CHECK 1.

2.

SBR002A

2.

NGBR0024S01

Depress brake pedal several times with engine off. After exhausting vacuum, make sure there is no change in pedal stroke. Depress brake pedal, then start engine. If pedal goes down slightly, operation is normal.

AIRTIGHT CHECK 1.

NGBR0024

NGBR0024S02

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. 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.

SBR365AA

Removal

NGBR0025

CAUTION: 쐌 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. 쐌 Be careful not to deform or bend brake pipes, during removal of booster.

ABR909

Inspection OUTPUT ROD LENGTH CHECK 1. 2. 3.

NGBR0026 NGBR0026S01

Apply vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg) to brake booster with a hand vacuum pump. Add preload of 19.6 N (2.0 kg, 4.4 lb) to output rod length. Check output rod length. Specified length: 10.275 - 10.525 mm (0.4045 - 0.4144 in)

ABR908

BR-16

BRAKE BOOSTER Installation

Installation

SBR116BE

=NGBR0027

CAUTION: 쐌 Be careful not to deform or bend brake pipes during installation of booster. 쐌 Replace clevis pin if damaged. 쐌 Refill with new brake fluid “DOT 3”. 쐌 Never reuse drained brake fluid. 쐌 Take care not to damage brake booster mounting bolt thread when installing. Due to the narrow angle of installation, the threads can be damaged by the dash panel. A: 138.5 mm (5.45 in) 1. Before fitting booster, temporarily adjust clevis to dimension shown. 2. Fit booster, then secure mounting nuts (brake pedal bracket to brake booster) lightly. 3. Connect brake pedal and booster input rod with clevis pin. 4. Secure mounting nuts. Specification: 13 - 16 N·m (1.3 - 1.6 kg-m, 9 - 12 ft-lb) 5. Install master cylinder. Refer to “Installation”, BR-15. 6. Adjust brake pedal height and free play. Refer to “Adjustment”, BR-12. 7. Secure lock nut for clevis. : 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb) 8. Bleed air. Refer to “Bleeding Brake System”, BR-8.

GI MA EM LC EC FE CL MT AT TF PD AX SU

ST RS BT HA SC EL

BR-17

IDX

VACUUM PIPING Removal and Installation

Removal and Installation

NGBR0029

CAUTION: When installing vacuum hoses, pay attention to the following points. 쐌 Do not apply any oil or lubricants to vacuum hose and check valve. 쐌 Insert vacuum tube into vacuum hose as shown. 쐌 Install check valve, paying attention to its direction. SBR225B

Inspection

NGBR0030

HOSES AND CONNECTORS

NGBR0030S01

Check vacuum lines, connections and check valve for airtightness, improper attachment chafing and deterioration.

CHECK VALVE

NGBR0030S02

Check vacuum with a vacuum pump. Connect to booster side

Vacuum should exist.

Connect to engine side

Vacuum should not exist.

SBR844B

BR-18

FRONT DISC BRAKE Pad Replacement

Pad Replacement

NGBR0032

WARNING: Clean brakes with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: 쐌 When cylinder body is open, do not depress brake pedal, or piston will pop out. 쐌 Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads. 쐌 If shims are rusted or show peeling of the rubber coat, replace them with new shims. 쐌 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. 쐌 Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.

GI MA EM LC EC FE CL MT

1. 2.

Remove master cylinder reservoir cap. Remove lower pin bolt.

AT TF PD AX

SBR081A

3.

Open cylinder body upward. Then remove pad retainers, inner and outer shims, and shim cover (if equipped). 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.

SU

ST RS BT HA SC EL

SBR010B

BR-19

IDX

FRONT DISC BRAKE Pad Replacement (Cont’d)

ABR918

1. 2. 3. 4. 5. 6.

Main pin Pin boot Torque member fixing bolt Torque member Shim cover (if equipped) Inner shim

7. 8. 9. 10. 11. 12.

Inner pad Pad retainer Outer pad Outer shim Connecting bolt Copper washer

Removal

13. 14. 15. 16. 17. 18.

Main pin bolt Bleed valve Cylinder body Piston seal Piston Piston boot

NGBR0033

WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: 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. In this case, suspend caliper assembly with wire so as not to stretch brake hose.

SBR083A

BR-20

FRONT DISC BRAKE Disassembly

Disassembly

NGBR0034

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.

GI MA EM LC

SBR085A

Inspection CALIPER Cylinder Body 쐌

NGBR0035 NGBR0035S01 NGBR0035S0101

Check inside surface of cylinder for score, rust, wear, damage and presence of foreign objects. If any of the above conditions are observed, replace cylinder body. 쐌 Minor damage from rust or foreign objects 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

NGBR0035S0102

CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign objects are stuck to sliding surface. Check pistons for uneven surface, chips or cracks. Replace if any of these conditions are observed.

Slide Pin, Pin Bolt and Pin Boot

NGBR0035S0103

Check for wear, cracks, rust and other damage. Replace if any of the above conditions are observed.

ROTOR Runout

SBR089A

EC

NGBR0035S02

FE CL MT AT TF PD AX SU

NGBR0035S0201

1. Check runout using a dial indicator. Make sure that wheel bearing axial end play is within the specifications before measuring. Refer to AX-5, “Front Wheel Bearing”. Maximum runout: 0.07 mm (0.0028 in) 2. If the runout is out of specification, machine rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or equivalent).

ST

Thickness

BT

NGBR0035S0202

Thickness variation (At least 8 positions): Maximum 0.02 mm (0.0008 in) If thickness variation exceeds the specification, turn rotor with oncar brake lathe. Rotor repair limit: 26.0 mm (1.024 in)

RS

HA SC EL

SBR090A

BR-21

IDX

FRONT DISC BRAKE Assembly

Assembly

NGBR0036

1. 2.

Insert piston seal into groove on cylinder body. With piston boot fitted to piston, insert piston boot into groove on cylinder body and install piston. 3. Properly secure piston boot CAUTION: 쐌 Secure dust seal property. 쐌 Lubricate with new brake fluid before installing plastic pistons into cylinder body. SBR178C

SBR179CA

Installation

NGBR0037

CAUTION: 쐌 Refill with new brake fluid “DOT 3”. 쐌 Never reuse drained brake fluid. 1. Install caliper assembly. 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. SBR084A

Brake Burnishing Procedure

NGBR0088

When experiencing soft brake pedal feel at very low mileage, or after replacing the rotor, burnish the brake pad contact surfaces according to the following procedures. 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). 2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds. 3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping. 4. Repeat steps 1 to 3 10 times or more to complete the burnishing procedure.

BR-22

REAR DRUM BRAKE Components

Components

NGBR0038

GI MA EM LC EC FE CL LBR384

1. 2. 3. 4. 5. 6. 7. 8. 9.

Shoe hold pin Plug Back plate Shoe (leading side) Air bleeder Spring Piston cup Piston Boot

10. 11. 12. 13. 14. 15. 16. 17.

Retainer ring Toggle lever Wave washer Shoe (trailing side) Adjuster Boot Piston Piston cup

18. 19. 20. 21. 22. 23. 24. 25.

MT

Wheel cylinder Adjuster lever Spring seat Shoe hold spring Retainer Adjuster spring Return spring (upper) Return spring (lower)

AT TF PD AX

Removal

NGBR0039

WARNING: Clean brake lining with a vacuum dust collector to minimize the hazard of airborne asbestos or other materials. CAUTION: Make sure parking brake lever is released completely.

SU

ST RS

1. 쐌 a.

Release parking brake pedal fully, then remove drum. If drum is hard to remove, the following procedures should be carried out. Remove plug. Shorten adjuster to make clearance between brake shoe and drum as shown

BT HA SC EL

SBR264CA

BR-23

IDX

REAR DRUM BRAKE Removal (Cont’d)

b.

Install two bolts as shown. Tighten the two bolts gradually.

SBR093A

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.

ABR369

5.

Remove retainer ring with a suitable tool. Then separate toggle lever and brake shoe.

ABR408

Inspection WHEEL CYLINDER 쐌 쐌

NGBR0040 NGBR0040S01

Check wheel cylinder for leakage. Check for wear, damage and loose conditions. Replace if any such condition exists.

ABR370

Wheel Cylinder Overhaul 쐌 쐌

NGBR0041

Check all internal parts for wear, rust and damage. Replace if necessary. Pay attention so as not to scratch cylinder when installing pistons.

SBR215B

BR-24

REAR DRUM BRAKE Inspection

Inspection

NGBR0042

DRUM 쐌 쐌 쐌 SBR095A

NGBR0042S01

Maximum inner diameter (Repair limit): 296.5 mm (11.67 in) Contact surface should be fine finished with No. 120 to 150 emery paper. Using a drum lathe, lathe 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.

LINING

GI MA EM LC

NGBR0042S02

Check lining thickness. Standard lining thickness: 5.8 mm (0.228 in) Lining wear limit (A): 1.5 mm (0.059 in)

EC FE CL MT

SBR021A

Installation

NGBR0043

Always perform shoe clearance adjustment. Refer to BR-28. 쐌 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”, BR-22. 1. Fit toggle lever to brake shoe with retainer clip.

AT TF PD AX

2. 쐌

Shorten adjuster by rotating it. Pay attention to direction of adjuster. Wheel

Left Right

ABR396

SU

Screw

Depression

Left-hand thread

Yes

Right-hand thread

No

3. Connect parking brake cable to toggle lever. 4. Install all parts. Be careful not to damage wheel cylinder piston boots. 5. 쐌

Check all parts are installed properly. After installation is completed, adjust shoe-to-drum clearance. Pay attention to direction of adjuster assembly. 6. Install brake drum. 7. When installing new wheel cylinder or overhauling wheel cylinder, bleed air. Refer to “Bleeding Brake System”, BR-8. 8. Adjust parking brake. Refer to “Adjustment”, BR-28. 쐌 Install all the parts by referring to the following figure.

ST RS BT HA SC EL

ABR372

BR-25

IDX

REAR DRUM BRAKE Installation (Cont’d)

LBR395

BR-26

PARKING BRAKE CONTROL Components

Components

NGBR0044

GI MA EM LC EC FE CL MT AT

LBR393

TF PD AX

Removal and Installation 1. 2. 3. 4.

NGBR0045

To remove parking brake pedal, remove lower instrument panel on driver side. Disconnect parking brake switch electrical connector. Remove nuts, slacken off and remove adjusting nut. Remove pedal assembly from vehicle and remove front cable from pedal assembly.

SU

ST RS

LBR394

Inspection 1. 2. 3. 4.

NGBR0046

Check parking brake pedal assembly for wear or other damage. Replace if necessary. Check cables for discontinuity or deterioration. Replace if necessary. Check warning lamp and switch. Replace if necessary. Check parts at each connection portion and, if found deformed or damaged, replace.

BT HA SC EL

BR-27

IDX

PARKING BRAKE CONTROL Adjustment

Adjustment

WBR348

NGBR0047

Pay attention to the following point after adjustment. 1) Ensure there is no drag when pedal is released. 1. Loosen parking brake cable. 2. Depress parking brake pedal fully more than five times. 3. Operate parking brake pedal 10 times or more with a full stroke [169 mm (6.6 in)]. 4. Adjust cable by turning adjusting nut. 5. Depress pedal with specified amount of force. Check pedal stroke and ensure smooth operation. Force: 196 N (20 kg, 44 lb) Number of notches: KA24DE models: 6–8 VG33E and VG33ER models: 7–9 6. Bend warning lamp switch plate. Warning lamp should come on when pedal is depressed “A” notches. It should go off when the pedal is fully released. Number of “A” notches for warning lamp actuation: 1

BR-28

DESCRIPTION

ABS Purpose

Purpose

NGBR0089

The Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for control of braking force so locking of the wheels can be avoided. 1) Improves proper tracking performance through steering wheel operation. 2) Eases obstacle avoidance through steering wheel operation. 3) Improves vehicle stability.

Operation 쐌 쐌

쐌

NGBR0090

When the vehicle speed is less than 10 km/h (6 MPH) this system does not work. The Anti-Lock Brake System (ABS) has a self-test function. The system turns on the ABS warning lamp for 1 second each time the ignition switch is turned ON. After the engine is started, the ABS warning lamp turns off. The system performs a test the first time the vehicle reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs this self-test. This is a normal part of the self-test feature. If a malfunction is found during this check, the ABS warning lamp will stay on. While driving, a mechanical noise may be heard during ABS operation. This is a normal condition.

GI MA EM LC EC FE

ABS Hydraulic Circuit

NGBR0091

CL MT AT TF PD AX SU

ST SBR859D

1. 2. 3.

Inlet solenoid valve Outlet solenoid valve Reservoir

4. 5. 6.

Pump Motor Inlet valve

7. 8. 9.

Outlet valve Bypass check valve Damper

RS BT HA SC EL

BR-29

IDX

DESCRIPTION

ABS

System Components

System Components

NGBR0092

ABR857

System Description WHEEL SENSOR

NGBR0093 NGBR0093S01

The sensor units consist of a gear-shaped sensor rotor and a sensor element. The front sensors are installed on the back of the front brake rotors. For 2-wheel drive systems a single sensor is installed at the companion flange of the rear axle housing and for 4-wheel drive systems there is a sensor installed at each rear brake drum. As the wheel rotates, the sensor generates a square-wave pattern. The frequency increases as the rotating speed increases. LBR333

CONTROL UNIT (BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT)

LBR380

NGBR0093S02

The control unit computes the wheel rotating speed by the signal current sent from the sensor. Then it supplies a DC current to the actuator solenoid valve. It 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. For control unit layout, refer to “ABS ACTUATOR AND ELECTRIC UNIT”, BR-31.

BR-30

DESCRIPTION

ABS System Description (Cont’d)

ABS ACTUATOR AND ELECTRIC UNIT

ABR858

ABS Actuator Operation Inlet solenoid valve Normal brake operation

ABS operation

OFF (Open)

NGBR0093S03

The ABS actuator and electric unit contains: 쐌 An electric motor and pump 쐌 Two relays 쐌 Six solenoid valves. An inlet and outlet each for — LH front — RH front — Rear 쐌 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 is serviced as an assembly. NGBR0093S0301

Outlet solenoid valve

GI MA EM LC EC FE

OFF (Closed)

Master cylinder brake fluid pressure is directly transmitted to caliper via the inlet solenoid valve.

Pressure hold

ON (Closed)

OFF (Closed)

Hydraulic circuit is shut off to hold the caliper brake fluid pressure.

Pressure decrease

ON (Closed)

ON (Open)

Caliper 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 caliper.

G SENSOR (4WD MODELS)

CL MT AT TF

NGBR0093S05

The G sensor senses deceleration during braking to determine whether the vehicle is being driven on a high µ road (asphalt road, etc.) or a low µ road (snow-covered road, etc.). It then sends a signal to the ABS control unit.

PD AX

This signal is received by the ABS control unit as a variable voltage signal. The input voltage varies from 1.3V ±0.125V during a hard deceleration condition, to 2.5V ±0.125V with the vehicle stopped and to 3.7V ±0.125V during a hard deceleration in reverse.

SU

ST RS ABR859

BT HA SC EL

BR-31

IDX

TROUBLE DIAGNOSIS — INTRODUCTION

ABS

How to Perform Trouble Diagnoses for Quick and Accurate Repair

How to Perform Trouble Diagnoses for Quick and Accurate Repair

NGBR0100

INTRODUCTION

SEF233G

SEF234G

NGBR0100S01

The ABS system has an electronic control unit to control major functions. The control unit accepts input signals from sensors and instantly drives the actuators. It is essential that both kinds of signals are proper 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 continuously. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems, so a road test should be performed. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with an ABS complaint. The customer is a very good source of information on such problems; especially intermittent ones. By talking to 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. Also check related Service bulletins for information.

BR-32

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS Preliminary Check

Preliminary Check 1

NGBR0101

CHECK BRAKE FLUID

GI

Check brake fluid for contamination. Has brake fluid been contaminated? Yes

䊳

Replace. GO TO 2.

No

䊳

GO TO 2.

2

MA EM

CHECK BRAKE FLUID LEVEL

LC

Check brake fluid level in reservoir tank. Low fluid level may indicate brake pad wear or leakage from brake line.

EC FE CL MT SBR451D

AT

Is brake fluid filled between MAX and MIN lines on reservoir tank ? Yes

䊳

GO TO 3.

No

䊳

Fill up brake fluid. GO TO 3.

3

TF PD

CHECK BRAKE LINE

Check brake line for leakage.

AX SU

SBR389C

ST

Is leakage present at or around brake lines, tubes or hoses or are any of these parts cracked or damaged? Yes

䊳

Repair. GO TO 4.

No

䊳

GO TO 4.

RS BT HA SC EL

BR-33

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Preliminary Check (Cont’d)

4

CHECK BRAKE BOOSTER OPERATION

Check brake booster for operation and air tightness. Refer to “BRAKE BOOSTER”, BR-16.

SBR058C

Is brake booster airtight and functioning properly? Yes

䊳

GO TO 5.

No

䊳

Replace. GO TO 5.

5

CHECK BRAKE PAD AND ROTOR

Check brake pad and rotor. Refer to BR-19, 21.

SBR059C

Are brake pads and rotors functioning properly? Yes

䊳

GO TO 6.

No

䊳

Replace.

BR-34

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Preliminary Check (Cont’d)

6

RECHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank again.

GI MA EM LC SBR451D

EC

Is brake fluid filled between MAX and MIN lines on reservoir tank ? Yes

䊳

GO TO 7.

No

䊳

Fill up brake fluid.

FE CL

7

CHECK WARNING LAMP ACTIVATION

Check warning lamp activation.

MT AT TF PD LBR380

AX

Does warning lamp turn on when ignition switch is turned ON? Yes

䊳

GO TO 8.

No

䊳

Check fuse, warning lamp bulb and warning lamp circuit.

8

SU

CHECK WARNING LAMP DEACTIVATION

Check warning lamp for deactivation after engine is started. Does warning lamp turn off when engine is started? Yes

䊳

GO TO 9.

No

䊳

Go to “Self-diagnosis”, BR-46.

9

ST RS BT

DRIVE VEHICLE

Drive vehicle at speeds over 30 km/h (19 MPH) for at least one minute. Does warning lamp remain off after vehicle has been driven at 30 km/h (19 MPH) for at least one minute? Yes

䊳

INSPECTION END

No

䊳

Go to “Self-diagnosis”, BR-46.

HA SC EL

BR-35

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Ground Circuit Check

Ground Circuit Check ABS ACTUATOR AND ELECTRIC UNIT GROUND 쐌

=NGBR0102 NGBR0102S01

Check continuity between ABS actuator and electric unit connector terminals and ground. Continuity should exist.

ABR882

BR-36

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Component Parts and Harness Connector Location

Component Parts and Harness Connector Location

NGBR0094

GI MA EM LC EC FE CL MT AT TF PD AX SU

ST RS BT HA SC EL LBR381

BR-37

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Schematic

Schematic 2–WHEEL DRIVE

NGBR0095 NGBR0095S01

WBR339

BR-38

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS Schematic (Cont’d)

4–WHEEL DRIVE

NGBR0095S02

GI MA EM LC EC FE CL MT AT TF PD AX SU

ST RS BT HA SC WBR190

BR-39

EL IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Wiring Diagram — ABS — 2WD —

Wiring Diagram — ABS — 2WD —

NGBR0096

LBR090

BR-40

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Wiring Diagram — ABS — 2WD — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU

ST RS BT HA SC WBR193

EL

BR-41

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Wiring Diagram — ABS — 2WD — (Cont’d)

LBR382

BR-42

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Wiring Diagram — ABS — 4WD —

Wiring Diagram — ABS — 4WD —

NGBR0122

GI MA EM LC EC FE CL MT AT TF PD AX SU

ST RS BT HA SC WBR340

BR-43

EL IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Wiring Diagram — ABS — 4WD — (Cont’d)

WBR195

BR-44

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Wiring Diagram — ABS — 4WD — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU

ST RS BT HA SC WBR196

EL

BR-45

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS

Self-diagnosis (Without CONSULT-II)

Self-diagnosis (Without CONSULT-II) FUNCTION 쐌

NGBR0097 NGBR0097S01

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 9 located on the “Data link connector”. The location of the malfunction is indicated by the warning lamp flashing]

SELF-DIAGNOSIS PROCEDURE

NGBR0097S02

1. 2.

Drive vehicle over 30 km/h (19 MPH) for at least one minute. Turn ignition switch OFF.

3.

Ground terminal 9 of data link connector with a suitable harness. Turn ignition switch ON while grounding terminal 9. Do not depress brake pedal.

4.

LEC104A

5. 6.

7.

LBR380

8.

After 3.0 seconds, the warning lamp starts flashing to indicate the malfunction code No. (See NOTE.) Verify the location of the malfunction with the malfunction code chart. Refer to “Malfunction Code/Symptom Chart”, BR-48. Then make the necessary repairs following the diagnostic procedures. After the malfunctions are repaired, erase the malfunction codes stored in the control unit. Refer to “HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)”, BR-47. Rerun the self-diagnostic results mode to verify that the malfunction codes have been erased.

9.

Disconnect the data link connector terminal from the ground. The self-diagnostic results mode is now complete. 10. Check warning lamp for deactivation after driving vehicle over 30 km/h (19 MPH) for at least one minute. 11. After making certain that warning lamp does not come on, test the ABS in a safe area to verify that it functions properly. NOTE: The indication terminates after 5 minutes. However, when the ignition switch is turned from OFF to ON, the indication starts flashing again. LEC104A

BR-46

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS

Self-diagnosis (Without CONSULT-II) (Cont’d)

HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) 1. 2.

3.

4.

=NGBR0097S03

Determine 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 lowest to highest. The indication then returns to the start code 12 to repeat (the indication will stay on for five minutes at the most). Refer to “Malfunction Code/Symptom Chart”, BR-48.

GI MA EM LC EC FE CL MT

SBR457D

AT TF PD AX HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) 1. 2.

3.

SU NGBR0097S04

Disconnect the check terminal from ground (ABS warning lamp will stay lit). Within 12.5 seconds, ground the check terminal three times. Each terminal ground must last more than 1 second. The ABS warning lamp goes out after the erase operation has been completed. Perform self-diagnosis again. Refer to “Self-diagnosis”, BR-46. Only the startcode should appear, no malfunction codes.

ST RS

ABR256

BT HA SC EL

BR-47

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ABS

Malfunction Code Chart (Without CONSULT-II)

Malfunction Code Chart (Without CONSULT-II)

NGBR0103

Code No. (No. of warning lamp flashes) 12

Malfunctioning part Self-diagnosis could not detect any malfunctions.

Reference Page —

17 ★1

G sensor and circuit (4WD)

BR-64

18 ★1

Sensor rotor or abnormal tire size

BR-55

21 ★1

Front right sensor

BR-55

25 ★1

Front left sensor

BR-55

31 ★1

Rear right sensor (4WD)

BR-55

35 ★1

Rear left sensor (4WD) Rear sensor (2WD)

BR-55

57 ★2

Abnormal battery voltage (High or low voltage)

BR-62

61 ★3

Actuator motor or motor relay

BR-60

63

Solenoid valve relay

BR-58

71

Control unit or Actuator solenoid valve

BR-58, 66

★1: 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 (Code Nos. 25, 21, 31 and 35), 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-46. Check to ensure that the ABS warning lamp goes out while the vehicle is being driven. ★2: The trouble code “57”, which refers to a low power supply voltage, does not indicate that the ABS control unit is malfunctioning. Do not replace the ABS control unit with a new one. ★3: The trouble code “61” can sometimes appear when the ABS motor is not properly grounded. If it appears, be sure to check the condition of the ABS motor ground circuit connection.

Symptom Chart

NGBR0125

Symptom

Malfunctioning part

Reference Page

ABS works frequently

—

BR-67

Unexpected pedal action

—

BR-67

Long stopping distance

—

BR-69

ABS does not work

—

BR-69

Pedal vibration and noise

—

BR-69

Warning lamp does not come on when ignition switch is turned ON.

Warning lamp stays on when ignition switch is turned ON.

Fuse, warning lamp bulb or warning lamp circuit Control unit

BR-70

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-71

BR-48

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ABS CONSULT-II

CONSULT-II

=NGBR0123

CONSULT-II APPLICATION TO ABS

NGBR0123S01

SELF-DIAGNOSTIC RESULTS

DATA MONITOR

ACTIVE TEST

Front right wheel sensor

×

×

—

Front left wheel sensor

×

×

—

Rear right wheel sensor★1

×

×

—

Rear left wheel sensor★1

×

×

—

Rear wheel sensor★2

×

×

—

G switch (G sensor)★1

×

×

×

ABS sensor

×

—

—

Stop lamp switch

—

×

—

Front right inlet solenoid valve

×

×

×

Front right outlet solenoid valve

×

×

×

Front left inlet solenoid valve

×

×

×

Front left outlet solenoid valve

×

×

×

Rear inlet solenoid valve

×

×

×

Rear outlet solenoid valve

×

×

×

Actuator solenoid valve relay

×

×

—

Actuator motor relay (MOTOR RELAY is shown on the Data Monitor screen.)

×

×

×

ABS warning lamp

—

×

—

Battery voltage

×

×

—

Control unit

×

—

—

ABS operating signal

—

×

×

ITEM

GI MA EM LC EC FE CL MT AT TF PD AX SU

×: Applicable —: Not applicable ★1: 4WD models only ★2: 2WD models only

ECU (ABS CONTROL UNIT) PART NUMBER MODE

NGBR0123S02

ST

Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order the ECU.

RS BT HA SC EL

BR-49

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ABS

CONSULT-II Inspection Procedure

CONSULT-II Inspection Procedure SELF-DIAGNOSIS PROCEDURE

=NGBR0124 NGBR0124S01

1. 2. 3. 4.

Turn ignition switch OFF. Connect CONSULT-II to data link connector. Start engine. Drive vehicle over 30 km/h (19 MPH) for at least one minute.

5.

Stop vehicle with engine running and touch “START” on CONSULT-II screen.

6.

Touch “ABS”.

7. 쐌

Touch “SELF-DIAG RESULTS”. The screen shows the detected malfunction and how many times the ignition switch has been turned ON since the malfunction. Make the necessary repairs following the diagnostic procedures.

LEC104A

PBR455D

WBR110

8.

SBR636E

9.

After the malfunctions are repaired, erase the self-diagnostic results stored in the control unit by touching “ERASE”. 10. Check warning lamp for deactivation after driving vehicle over 30 km/h (19 MPH) for at least one minute. 11. Test the ABS in a safe area to verify that it functions properly.

LBR378

BR-50

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ABS

CONSULT-II Inspection Procedure (Cont’d)

SELF-DIAGNOSTIC RESULTS MODE Diagnostic item

Diagnosed condition

Diagnostic item is detected when ...

=NGBR0124S02

Reference Page

GI

FR RH SENSOR-2★1 [C1107]

Open

쐌 Circuit for front right wheel sensor is open. (An abnormally high input voltage is entered.)

BR-55

FR LH SENSOR-2★1 [C1108]

Open

쐌 Circuit for front left wheel sensor is open. (An abnormally high input voltage is entered.)

BR-55

Open

쐌 Circuit for rear right sensor is open. (An abnormally high input voltage is entered.)

BR-55

RR LH SENSOR-2★1 [C1106]

Open

쐌 Circuit for rear left sensor (4WD) or rear sensor (2WD) is open. (An abnormally high input voltage is entered.)

BR-55

FR RH SENSOR-1★1 [C1103]

Short

쐌 Circuit for front right wheel sensor is shorted. (An abnormally low input voltage is entered.)

BR-55

FR LH SENSOR-1★1 [C1104]

Short

쐌 Circuit for front left wheel sensor is shorted. (An abnormally low input voltage is entered.)

BR-55

RR RH SENSOR-1★1 [C1101]

Short

쐌 Circuit for rear right sensor is shorted. (An abnormally low input voltage is entered.)

BR-55

RR LH SENSOR-1★1 [C1102]

Short

쐌 Circuit for rear left sensor (4WD) or rear sensor (2WD) is shorted. (An abnormally low input voltage is entered.)

BR-55

ABS SENSOR★1 [C1115]

Abnormal signal

쐌 Teeth damage on sensor rotor or improper installation of wheel sensor. (Abnormal wheel sensor signal is entered.)

BR-55

MAIN RELAY [C1114]

Abnormal

쐌 Actuator solenoid valve relay is ON, even if control unit sends off signal. 쐌 Actuator solenoid valve relay is OFF, even if control unit sends on signal.

BR-58

PUMP MOTOR [C1111]

Abnormal

쐌 Circuit for ABS motor relay is open or shorted. 쐌 Circuit for actuator motor is open or shorted. 쐌 Actuator motor relay is stuck.

BR-60

AX

BATTERY VOLTAGE [ABNORMAL] [C1109]

High or low

쐌 Power source voltage supplied to ABS control unit is abnormally high or low.

BR-62

SU

Control unit

쐌 Function of calculation in ABS control unit has failed.

BR-66

Solenoid valve open/ short

쐌 Circuit for solenoid valve is open or shorted. (An abnormally high or low output voltage is entered.)

BR-58

Abnormal signal

쐌 G sensor circuit is open or shorted.

RR RH SENSOR-2★1 [C1105]

CONTROLLER FAILURE [C1110] G SENSOR [C1113]★2 ABNORMAL TIRE SIZE [C1112]

EM LC EC FE CL MT AT TF PD

ST BR-64

RS

쐌 Sensor rotor damaged or incorrect tire size. Abnormal

MA

BR-55

BT

★1: 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 (Code Nos. C1101, C1102, C1103 and C1104), 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-46. Check to ensure that the ABS warning lamp goes out while the vehicle is being driven. ★2: 4WD models only

HA SC EL

BR-51

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ABS

CONSULT-II Inspection Procedure (Cont’d)

DATA MONITOR PROCEDURE

=NGBR0124S03

1. 2. 3. 4.

Turn ignition switch OFF. Connect CONSULT-II to data link connector. Turn ignition switch ON. Touch “START” on CONSULT-II screen.

5.

Touch “ABS”.

6.

Touch “DATA MONITOR”.

7.

Touch “SETTING” on “SELECT MONITOR ITEM” screen.

PBR455D

WBR110

SBR636E

SBR637E

BR-52

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ABS

CONSULT-II Inspection Procedure (Cont’d)

ACTIVE TEST PROCEDURE

=NGBR0124S04

쐌 쐌 1. 2. 3. 4.

When conducting Active test, vehicle must be stationary. When ABS warning lamp stays on, never conduct Active test. Turn ignition switch OFF. Connect CONSULT-II to data link connector. Start engine. Touch “START” on CONSULT-II screen.

5.

Touch “ABS”.

GI MA EM LC

PBR455D

EC FE CL MT

WBR110

6.

Touch “ACTIVE TEST”.

AT TF PD AX SBR636E

7.

Select active test item by touching screen.

SU

ST RS LBR379

8. 9.

Touch “START”. Carry out the active test by touching screen key.

BT HA SC EL

SBR639E

BR-53

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ABS

CONSULT-II Inspection Procedure (Cont’d)

DATA MONITOR MODE

=NGBR0124S05

MONITOR ITEM

CONDITION

SPECIFICATION

FR RH SENSOR FR LH SENSOR RR RH SENSOR★2 RR LH SENSOR★2 REAR SENSOR★1

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

DECEL G-SEN★2

Vehicle is driven. Vehicle is stopped. Brake is applied.

During sudden braking while driving on high µ roads (asphalt roads, etc.): OFF While vehicle is stopped or during constant-speed driving: ON

FR RH IN SOL FR RH OUT SOL FR LH IN SOL FR LH OUT SOL REAR IN SOL REAR OUT SOL

Operating conditions for each solenoid valve are indicated. ABS is 1. Drive vehicle at speeds over 30 km/h (19 MPH) for at not operating: OFF least 1 minute. 2. Engine is running. ABS is not operating: OFF ABS is operating: ON

MOTOR RELAY WARNING LAMP

Ignition switch is ON or engine is running.

BATTERY VOLT

ABS warning lamp is turned on: ON ABS warning lamp is turned off: OFF Power supply voltage for control unit

★1: 2WD models only ★2: 4WD models only

ACTIVE TEST MODE TEST ITEM

CONDITION

NGBR0124S06

JUDGEMENT Brake fluid pressure control operation

FR RH SOL FR LH SOL REAR SOL Engine is running.

ABS MOTOR

IN SOL

OUT SOL

UP (Increase):

OFF

OFF

KEEP (Hold):

ON

OFF

DOWN (Decrease):

ON

ON

ABS actuator motor ON: Motor runs (ABS motor relay ON) OFF: Motor stops (ABS motor relay OFF)

NOTE: Active test will automatically stop ten seconds after the test starts. (TEST IS STOPPED is displayed.)

BR-54

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Wheel Sensor or Rotor

Wheel Sensor or Rotor DIAGNOSTIC PROCEDURE

NGBR0104

With CONSULT-II: Malfunction code No. C1101, C1102, C1103, C1104, C1105, C1106, C1107, C1108, C1112, or C1115 Without CONSULT-II: Malfunction code No. 21, 25, 31, 35, or 18 NOTE: Wheel position should be distinguished by code No. except code No. 18 (sensor rotor). 1

INSPECTION START

GI MA EM LC

Wheel sensor inspection

EC FE CL MT AT TF PD WBR351

䊳

2

GO TO 2.

AX

CHECK CONNECTOR

1. Disconnect connectors from ABS actuator and electric unit and wheel sensor of malfunction code No. Check terminals for damage or loose connection. Then reconnect connectors. 2. Carry out “Self-diagnosis” again. Refer to BR-46.

SU

Does warning lamp activate again? Yes

䊳

GO TO 3.

No

䊳

INSPECTION END

3

ST RS

CHECK TIRE

Check for inflation pressure, wear and size of each tire. (See NOTE) Are tire pressure and size correct and is tire wear within specifications? Yes

䊳

GO TO 4.

No

䊳

Adjust tire pressure or replace tire(s). (See NOTE)

BT HA SC EL

BR-55

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Wheel Sensor or Rotor (Cont’d)

4

CHECK WHEEL BEARING

Check wheel bearing axial end play. (See NOTE) Is wheel bearing axial end play within specifications? Refer to AX-5, “FRONT AXLE” and AX-30, “REAR AXLE”. Yes

䊳

GO TO 5.

No

䊳

Check wheel bearing. Refer to AX-15, “FRONT AXLE” and AX-34, “REAR AXLE”.

5

CHECK WIRING HARNESS FOR SHORT

1. Disconnect ABS actuator and electric unit connector E39 and ABS sensor connectors E2, E16, and C102. 2. Check resistance between indicated wiring harness connector/terminal and ground Front RH wheel Connector E2, terminals 4 and 5 Front LH wheel Connector E16, terminals 6 and 7 Rear RH wheel (4WD) Connector C102, terminals 1 and 2 4WD: Rear LH wheel, 2WD: Rear wheels Connector C102, terminals 8 and 9

WBR353

0Ω:NG ∞Ω:OK Are resistance values OK? Yes

䊳

GO TO 6.

No

䊳

Repair/replace harness or connectors.

BR-56

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Wheel Sensor or Rotor (Cont’d)

6

CHECK WIRING HARNESS FOR OPEN

1. Disconnect ABS actuator and electric unit connector E39 and ABS sensor connectors E2, E16, and C102. 2. Check resistance of wiring harness between indicated connectors and terminals. Front RH wheel Connector E39, terminal 19 and connector E2, terminal 4 Connector E39, terminal 20 and connector E2, terminal 5 Front LH wheel Connector E39, terminal 1 and connector E16, terminal 6 Connector E39, terminal 3 and connector E16, terminal 7 Rear RH wheel (4WD) Connector E39, terminal 23 and connector C102, terminal 1 Connector E39, terminal 22 and connector C102, terminal 2 4WD: Rear LH wheel, 2WD: Rear wheels Connector E39, terminal 5 and connector C102, terminal 8 Connector E39, terminal 6 and connector C102, terminal 9

GI MA EM LC EC FE CL MT LBR342

0Ω:OK ∞Ω:NG

AT TF

Are resistance values OK? Yes

䊳

GO TO 7.

No

䊳

Repair/replace harness or connectors.

7

PD AX

CHECK SENSOR ROTOR

Check sensor rotor for teeth damage. (See NOTE) Is sensor rotor free from damage? Yes

䊳

1. 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. 2. If retest is NG, replace wheel speed sensor.

No

䊳

Replace sensor rotor. (See NOTE)

SU

ST RS BT HA SC EL

BR-57

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

ABS Actuator Solenoid Valve or Solenoid Valve Relay

ABS Actuator Solenoid Valve or Solenoid Valve Relay DIAGNOSTIC PROCEDURE

=NGBR0105

With CONSULT-II: Malfunction code No. C1110 or C1114 Without CONSULT-II: Malfunction code No. 63 or 71 1

INSPECTION START

Solenoid valve relay inspection

WBR338

䊳

2

GO TO 2.

CHECK FUSIBLE LINK

Check 40A fusible link c. For fusible link layout, refer to EL-10, “POWER SUPPLY ROUTING”. Is fusible link OK? Yes

䊳

GO TO 3.

No

䊳

GO TO 6.

3

CHECK CONNECTOR

1. Disconnect connector from ABS actuator and electric unit. Check terminals for damage or loose connection. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again? Yes

䊳

GO TO 4.

No

䊳

INSPECTION END

4

CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to “Ground Circuit Check”, BR-36. Is ground circuit OK? Yes

䊳

GO TO 5.

No

䊳

Repair harness or connector.

BR-58

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

ABS Actuator Solenoid Valve or Solenoid Valve Relay (Cont’d)

5

CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E39 terminal 9 and ground.

GI MA EM LC ABR887

EC

Does battery voltage exist? Yes

䊳

Replace ABS actuator and electric unit.

FE

No

䊳

Check the following. If NG, repair harness or connectors. 쐌 Harness connector E39 쐌 Harness for open or short between ABS actuator and electric unit and fusible link

CL MT

6

REPLACE FUSIBLE LINK

Replace fusible link.

AT Does the fuse blow out when ignition switch is turned ON?

Yes

䊳

GO TO 7.

No

䊳

INSPECTION END

7

TF PD

CHECK SOLENOID VALVE RELAY POWER SUPPLY CIRCUIT FOR SHORT

1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector E39 terminal 9 and ground.

AX SU

ST ABR888

Continuity should not exist.

RS

Does continuity exist? Yes

No

䊳

䊳

Check the following. If NG, repair harness or connector. 쐌 Harness connector E39 쐌 Harness for open or short between ABS actuator and electric unit and fusible link

BT HA

Replace ABS actuator and electric unit.

SC EL

BR-59

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Motor Relay or Motor

Motor Relay or Motor DIAGNOSTIC PROCEDURE

=NGBR0106

With CONSULT-II: Malfunction code No. C1111 Without CONSULT-II: Malfunction code No. 61 1

INSPECTION START

ABS motor relay inspection

ABR889

䊳

2

GO TO 2.

CHECK FUSIBLE LINK

Check 40A fusible link d. For fusible link layout, refer to EL-10, “POWER SUPPLY ROUTING”. Is fusible link OK? Yes

䊳

GO TO 3.

No

䊳

GO TO 6.

3

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? Yes

䊳

GO TO 4.

No

䊳

INSPECTION END

4

CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to “Ground Circuit Check”, BR-36. Is ground circuit OK? Yes

䊳

GO TO 5.

No

䊳

Repair harness or connector.

BR-60

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Motor Relay or Motor (Cont’d)

5

CHECK MOTOR RELAY POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E39 terminal 25 and ground.

GI MA EM LC ABR890

EC

Does battery voltage exist? Yes

䊳

Replace ABS actuator and electric unit.

FE

No

䊳

Check the following. If NG, repair harness or connector. 쐌 Harness connector E39 쐌 Harness for open or short between ABS actuator and electric unit and fusible link

CL MT

6

REPLACE FUSIBLE LINK

Replace fusible link.

AT Does the fusible link blow out when ignition switch is turned ON?

Yes

䊳

GO TO 7.

No

䊳

INSPECTION END

7

TF PD

CHECK ABS ACTUATOR MOTOR POWER SUPPLY CIRCUIT FOR SHORT

1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector E39 terminal 25 and ground.

AX SU

ST ABR891

Continuity should not exist.

RS

Does continuity exist? Yes

No

䊳

䊳

Check the following. If NG, repair harness or connector. 쐌 Harness connector E39 쐌 Harness for open or short between ABS actuator and electric unit and fusible link

BT HA

Replace ABS actuator and electric unit.

SC EL

BR-61

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Low Voltage

Low Voltage DIAGNOSTIC PROCEDURE

NGBR0107

With CONSULT-II: Malfunction code No. C1109 Without CONSULT-II: Malfunction code No. 57 1

INSPECTION START

ABS actuator and electric unit power supply and ground circuit inspection

ABR892

䊳

2

GO TO 2.

CHECK FUSE

Check 10A fuse No. 8. For fuse layout, refer to EL-10, “POWER SUPPLY ROUTING”. Is fuse OK? Yes

䊳

GO TO 3.

No

䊳

GO TO 6.

3

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? Yes

䊳

GO TO 4.

No

䊳

INSPECTION END

4

CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to “Ground Circuit Check”, BR-36. Is ground circuit OK? Yes

䊳

GO TO 5.

No

䊳

Repair harness or connector.

BR-62

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Low Voltage (Cont’d)

5

CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E39 terminal 4 and ground.

GI MA EM LC ABR893

EC

Does battery voltage exist when ignition switch is turned ON? Yes

䊳

Replace ABS actuator and electric unit.

FE

No

䊳

Check the following. If NG, repair harness or connector. 쐌 Harness connector E39 쐌 Harness for open or short between ABS actuator and electric unit and fuse

CL MT

6

REPLACE FUSE

Replace fuse.

AT Does the fuse blow out when ignition switch is turned ON?

Yes

䊳

GO TO 7.

No

䊳

INSPECTION END

7

TF PD

CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT FOR SHORT

1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector E39 terminal 4 and ground.

AX SU

ST ABR894

Continuity should not exist.

RS

Does continuity exist? Yes

No

䊳

䊳

Check the following. If NG, repair harness or connector. 쐌 Harness connector E39 쐌 Harness for open or short between ABS actuator and electric unit and fuse

BT HA

Replace ABS actuator and electric unit.

SC EL

BR-63

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

G Sensor and Circuit

G Sensor and Circuit DIAGNOSTIC PROCEDURE

NGBR0118

With CONSULT-II: Malfunction code No. C1113 Without CONSULT-II: Malfunction code No. 17 1

INSPECTION START

G sensor inspection

ABR895

䊳

2

GO TO 2.

CHECK G SENSOR POWER

1. Turn ignition switch OFF and disconnect G sensor harness connector. 2. Turn ignition switch ON. 3. Check voltage between G sensor harness connector M69 terminal 3 (B/P) and ground.

ABR896

Does approx. 5V exist? Yes

䊳

GO TO 3.

No

䊳

GO TO 4.

BR-64

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

G Sensor and Circuit (Cont’d)

3

CHECK G SENSOR

1. Turn ignition switch OFF. 2. Remove G sensor from bracket. 3. Reconnect harness connector to G sensor and hold sensor in same attitude/position as when installed in vehicle. 쐌 Check voltage between G sensor connector M69 terminal 1 (G/OR) and ground for the following tests. There should be approx. 2.5V. 4. Turn sensor 90° with connector point up. 쐌 There should be approx. 3.7V. 5. Turn sensor 180° with connector pointing down. 쐌 There should be approx. 1.3V.

GI MA EM LC EC FE CL ABR897

Were the voltage readings correct for steps 3, 4 and 5? Yes

䊳

GO TO 4.

No

䊳

Replace G Sensor.

4

MT AT

CHECK G SENSOR CIRCUIT

1. Disconnect ABS actuator and electric unit connector. 2. Check continuity from G sensor connector M69 terminal 3 (B/P) to ABS actuator and electric unit connector E39 terminal 14 (B/P). 3. Check continuity from G sensor connector M69 terminal 1 (G/OR) to ABS actuator and electric unit connector E39 terminal 13 (G/OR). 4. Check continuity from G sensor connector M69 terminal 2 (G/B) to ABS actuator and electric unit connector E39 terminal 17 (G/B).

TF PD AX SU

ST ABR898

RS

Does continuity exist? Yes

䊳

Replace ABS actuator and electric unit.

No

䊳

Repair harness or connector.

BT HA SC EL

BR-65

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Control Unit

Control Unit DIAGNOSTIC PROCEDURE

=NGBR0108

With CONSULT-II: Malfunction code No. C1110 Without CONSULT-II: Malfunction code No. 71 1

INSPECTION START

ABS actuator and electric unit power supply and ground circuit inspection

ABR899

䊳

2

GO TO 2.

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? Yes

䊳

GO TO 3.

No

䊳

INSPECTION END

3

CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

Check voltage. Refer to Test No. 4 in “DIAGNOSTIC PROCEDURE”, BR-62. Does battery voltage exist when ignition switch is turned ON? Yes

䊳

GO TO 4.

No

䊳

Repair.

4

CHECK WARNING LAMP INDICATION

Does warning lamp indicate code No. 71 again? Yes or No Yes

䊳

Replace ABS actuator and electric unit.

No

䊳

Inspect the system according to the code No.

BR-66

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS 1. ABS Works Frequently

1. ABS Works Frequently 1

NGBR0109

CHECK BRAKE FLUID PRESSURE

GI

Check brake fluid pressure distribution. Is brake fluid pressure distribution normal? Yes

䊳

GO TO 2.

No

䊳

Repair. Then perform Preliminary Check. Refer to BR-33.

2

MA EM LC

CHECK WHEEL SENSOR

1. Check wheel sensor connector for terminal damage or loose connections. 2. Perform wheel sensor mechanical check. Refer to Test No. 7 in “DIAGNOSTIC PROCEDURE”, BR-57.

EC

Is wheel sensor mechanism OK? Yes

䊳

GO TO 3.

No

䊳

Repair.

3

FE CL

CHECK FRONT AXLE

MT

Check front axles for excessive looseness. Refer to AX-5 , “Front Wheel Bearing”. Is front axle installed properly? Yes

䊳

Go to Test No. 3 in “2. Unexpected Pedal Action”, BR-68.

No

䊳

Repair.

AT TF PD AX

2. Unexpected Pedal Action 1

NGBR0110

SU

CHECK BRAKE PEDAL STROKE

Check brake pedal stroke.

ST RS BT SBR540A

HA

Is brake pedal stroke excessively large? Yes

䊳

Perform “Preliminary Check”. Refer to BR-33.

No

䊳

GO TO 2.

SC EL

BR-67

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

2. Unexpected Pedal Action (Cont’d)

2

CHECK MECHANICAL BRAKE SYSTEM PERFORMANCE

Disconnect ABS actuator and electric unit connector and check whether brake is effective. Does brake system function properly when brake pedal is depressed? Yes

䊳

GO TO 3.

No

䊳

Perform “Preliminary Check”. Refer to BR-33.

3

CHECK WARNING LAMP INDICATION

Ensure warning lamp remains off while driving.

LBR380

Is warning lamp turned off? Yes

䊳

GO TO 4.

No

䊳

Carry out self-diagnosis. Refer to BR-46.

4

CHECK WHEEL SENSOR

1. Check wheel sensor connector for terminal damage or loose connection. 2. Perform wheel sensor mechanical check. Refer to Test No. 7 in “DIAGNOSTIC PROCEDURE”, BR-57. Is wheel sensor mechanism OK? Yes

䊳

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.

No

䊳

Repair.

BR-68

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS 3. Long Stopping Distance

3. Long Stopping Distance 1

=NGBR0111

CHECK MECHANICAL BRAKE SYSTEM PERFORMANCE

GI

Disconnect ABS actuator and electric unit connector and check whether stopping distance is still long. Does brake system function properly when brake pedal is depressed? Yes

䊳

Perform Preliminary Check and air bleeding (if necessary).

No

䊳

Go to Test No. 3 in “2. Unexpected Pedal Action”, BR-68.

MA EM

NOTE: Stopping distance may be longer for vehicles without ABS when road condition is slippery.

LC EC FE CL MT

4. ABS Does Not Work 1

NGBR0112

CHECK WARNING LAMP INDICATION

Does the ABS warning lamp activate?

TF

Yes or No Yes

䊳

Carry out self-diagnosis. Refer to BR-46.

No

䊳

Go to Test No. 3 in “2. Unexpected Pedal Action”, BR-68.

PD

NOTE: ABS does not work when vehicle speed is under 10 km/h (6 MPH).

5. Pedal Vibration and Noise 1

AT

NGBR0113

AX SU

INSPECTION START

Pedal vibration and noise inspection

ST RS BT SAT797A

NOTE: ABS may operate and cause vibration under any of the following conditions. 쐌 Applying brake gradually when shifting or operating clutch. 쐌 Low friction (slippery) road. 쐌 High speed cornering. 쐌 Driving over bumps and pot holes. 쐌 Engine speed is over 5,000 rpm with vehicle stopped. 䊳

HA SC EL

GO TO 2.

BR-69

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

5. Pedal Vibration and Noise (Cont’d)

2

CHECK SYMPTOM

1. Apply brake. 2. Start engine. Does the symptom appear only when engine is started? Yes

䊳

Carry out self-diagnosis. Refer to BR-46.

No

䊳

Go to Test No. 3 in “2. Unexpected Pedal Action”, BR-68.

6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On 1

NGBR0114

INSPECTION START

Warning lamp circuit inspection

WBR321

䊳

2

GO TO 2.

CHECK FUSE

Check 10A fuse No. 11. For fuse layout, refer to EL-10, “POWER SUPPLY ROUTING”. Is fuse OK? Yes

䊳

GO TO 3.

No

䊳

Replace fuse.

3

CHECK WARNING LAMP ACTIVATE

Disconnect ABS actuator and electric unit connector.

LBR380

Does the warning lamp activate? Yes

䊳

Replace ABS actuator and electric unit.

No

䊳

GO TO 4.

BR-70

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On (Cont’d)

4

CHECK HARNESS FOR SHORT

1. Disconnect ABS actuator and electric unit connector E39 and combination meter connector M38. 2. Check continuity between ABS actuator and electric unit connector E39 (body side) terminal 15 (L/W) (2WD) or terminal 16 (L/W) (4WD) and ground.

GI MA EM LC EC

ABR901

Continuity should not exist.

FE

Does continuity exist? Yes

䊳

Repair harness or connectors.

No

䊳

Check combination meter. Refer to EL-94, “WARNING LAMPS”.

CL MT

7. Warning Lamp Stays On When Ignition Switch Is Turned On 1

AT NGBR0115

INSPECTION START

TF

ABS control unit inspection

PD AX SU WBR322

䊳

2

GO TO 2.

ST

CHECK FUSE

Check 10A fuse No. 8. For fuse layout, refer to EL-10, “POWER SUPPLY ROUTING”.

RS

Is fuse OK? Yes

䊳

GO TO 3.

No

䊳

GO TO 8.

BT HA SC EL

BR-71

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

7. Warning Lamp Stays On When Ignition Switch Is Turned On (Cont’d)

3

CHECK HARNESS CONNECTOR

Check ABS actuator and electric unit pin terminals for damage or bad connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest. Does warning lamp stay on when ignition switch is turned ON? Yes

䊳

GO TO 4.

No

䊳

INSPECTION END

4

CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to “Ground Circuit Check”, BR-36. Is ground circuit OK? Yes

䊳

GO TO 5.

No

䊳

Repair harness or connector.

5

CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E39 terminal 4 and ground.

ABR893

Does battery voltage exist when ignition switch is turned ON? Yes

䊳

GO TO 6.

No

䊳

Check the following. If NG, repair harness or connector. 쐌 Harness connector E39 쐌 Harness for open or short between ABS actuator and electric unit and fuse

BR-72

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

7. Warning Lamp Stays On When Ignition Switch Is Turned On (Cont’d)

6

CHECK WARNING LAMP

1. Disconnect ABS actuator and electric unit connector. 2. Connect suitable wire between ABS actuator and electric unit connector E39 terminal 15 (2WD) terminal 16 (4WD) and ground.

GI MA EM LC EC

ABR903

Does the warning lamp deactivate? Yes

䊳

Replace ABS actuator and electric unit.

No

䊳

GO TO 7.

7

FE CL

CHECK ABS WARNING LAMP CONTROL CIRCUIT FOR OPEN

1. Disconnect combination meter connector M38. 2. Check continuity between combination meter connector M38 (body side) terminal 24 (L/W) and ABS actuator and electric unit connector E39 (body side) terminal 15 (L/W) (2WD) or terminal 16 (L/W) (4WD). NOTE: Connect positive lead of multimeter to combination meter connector M38 (body side) terminal 24 (L/W) and negative lead to ABS actuator and electric unit connector E39 (body side) terminal 15 (L/W) (2WD) or terminal 16 (L/W) (4WD).

MT AT TF PD AX SU

WBR323

Continuity should exist. Does continuity exist? Yes

䊳

Check combination meter. Refer to EL-94, “WARNING LAMPS”.

ST

No

䊳

Repair harness or connectors.

RS

8

REPLACE FUSE

BT

Replace fuse. Does the fuse blow out when ignition switch is turned ON? Yes

䊳

GO TO 9.

No

䊳

INSPECTION END

HA SC EL

BR-73

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

7. Warning Lamp Stays On When Ignition Switch Is Turned On (Cont’d)

9

CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT FOR SHORT

1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector E39 (body side) terminal 4 and ground.

ABR894

Continuity should not exist. Does continuity exist? Yes

䊳

Check the following. If NG, repair harness or connector. 쐌 Harness connector E39 쐌 Harness for open or short between ABS actuator and electric unit and fuse

No

䊳

Replace ABS actuator and electric unit.

BR-74

NGBR0079

REMOVAL AND INSTALLATION

ABS Front Wheel Sensor

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.

Front Wheel Sensor

GI MA

NGBR0079S01

EM LC EC FE CL MT AT TF PD

Rear Wheel Sensor 4WD MODELS

ABR869

AX

NGBR0079S02

SU

NGBR0079S0201

ST RS BT HA SC EL ABR868

BR-75

IDX

REMOVAL AND INSTALLATION

ABS

Rear Wheel Sensor (Cont’d)

2WD MODELS

=NGBR0079S0202

CAUTION: Be careful not to damage sensor edge and sensor rotor teeth. In case the final drive assembly needs to be removed, disconnect the ABS sensor from the final drive assembly and move it away. Failure to do so may result in damage to the sensor wires making the sensor inoperative. For final drive models using collapsible spacer (C200), bearing preload must be adjusted whenever companion flange is removed. Therefore, final drive overhaul is required.

LBR115

Front Sensor Rotor REMOVAL 1. 2.

NGBR0079S03 NGBR0079S0301

Remove the front wheel hub. Refer to AX-5, “FRONT AXLE”. Remove the sensor rotor using suitable puller, drift and bearing replacer.

SBR873C

INSTALLATION

NGBR0079S0302

Install the sensor rotor using suitable drift and press. 쐌 Always replace sensor rotor with new one. 쐌 Pay attention to the direction of front sensor rotor as shown in figure.

SBR400DA

BR-76

REMOVAL AND INSTALLATION

ABS Rear Sensor Rotor (4WD)

Rear Sensor Rotor (4WD) REMOVAL 쐌

NGBR0079S04 NGBR0079S0401

Remove the sensor rotor using Tool.

GI MA EM LC

ARA097

INSTALLATION

NGBR0079S0402

Install the sensor rotor using suitable drift and press. 쐌 Always replace sensor rotor with new one. 쐌 Pay attention to the direction of front sensor rotor as shown in figure.

EC FE CL MT

SBR402D

G Sensor

NGBR0079S06

Always replace G sensor if bumped or dropped. Otherwise, performance characteristics of G sensor will be changed, which in turn changes ABS control performance characteristics.

AT TF PD AX

ABR859

SU

ST RS BT HA SC EL

BR-77

IDX

REMOVAL AND INSTALLATION

ABS

ABS Actuator and Electric Unit

ABS Actuator and Electric Unit

=NGBR0079S07

LBR383

REMOVAL 1. 2. 3. 4.

NGBR0079S0701

Disconnect battery cable. Drain brake fluid. Refer to “Changing Brake Fluid”, BR-6. Remove mounting bracket fixing bolts and nuts. Disconnect connector, brake pipes and remove fixing nuts and actuator ground cable.

INSTALLATION

NGBR0079S0702

CAUTION: After installation, refill brake fluid. Then bleed air. Refer to “Bleeding Brake System”, BR-8. 1. Tighten actuator ground cable. Place ground cable at a notch of mounting bracket. 2. Connect brake pipes temporarily. 3. Tighten fixing bolts and nuts. 4. Tighten brake pipes. 5. Connect connector and battery cable.

BR-78

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

General Specifications

NGBR0080

Unit: mm (in) Applied model

KA24DE

VG33E and VG33ER

Brake model

CL33VD

Cylinder bore diameter × number of pistons Front brake

Pad Length × width × thickness Rotor outer diameter × thickness

132.0 × 52.5 × 11 (5.20 × 2.067 × 0.43)

LC

LT30

Lining length × width × thickness

22.23 (7/8) 296 × 501, 402 × 5.8 (11.65 × 1.971, 1.572 × 0.228)

EC

295.0 (11.61)

FE

Drum inner diameter Bore diameter

25.40 (1)

Valve model Control valve

EM

283 x 28(11.14 × 1.10)

Cylinder bore diameter

Master cylinder

MA

46.4 (1.827) × 2

Brake model

Rear brake

GI

Proportioning valve within master cylinder

Split point kPa (kg/cm2, psi) × reducing ratio

2,942 (30, 427) × 0.2

Booster model

MT

M215T

Brake booster Diaphragm diameter

CL

Pri: 230 (9.06) Sec: 205 (8.07)1 Sec: 230 (9.06)2

Recommended brake fluid

Pri: 230 (9.06) Sec: 230 (9.06)

AT

DOT 3

TF

1. Early production 2. Late production

PD

Disc Brake

NGBR0081

Unit: mm (in) Brake model

AX

CL33VD

Pad wear limit

Minimum thickness

2.0 (0.079)

Rotor repair limit

Minimum thickness

26.0 (1.024)

SU

Drum Brake

NGBR0082

Unit: mm (in) Brake model Lining wear limit

LT30 Minimum thickness

ST

1.5 (0.059)

Maximum inner diameter

296.5 (11.67)

Out-of-round limit

0.03 (0.0012)

RS

Drum repair limit

Brake Pedal

NGBR0083

BT

Unit: mm (in) Transmission Free height “H”* Depressed height “D” [under force of 490 N (50 kg, 110 lb) with engine running] Clearance “C” between pedal stopper and threaded end of stop lamp switch or ASCD switch Pedal free play

At pedal pad

BR-79

M/T

A/T

191 - 201 (7.52 - 7.91)

201 - 211 (7.91 - 8.31)

100 (3.94)

110 (4.33)

0.3 - 1.0 (0.012 - 0.039)

HA SC EL

1 - 3 (0.04 - 0.12)

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) Parking Brake Control *: Measured from surface of dash lower panel to pedal pad

Parking Brake Control

NGBR0084

Unit: notch Control Type

Pedal

Pedal stroke [under force of 196 N (20 kg, 44 lb)]

5-6

Pedal stroke when warning switch comes on

1

BR-80

STEERING SYSTEM SECTION

ST

GI MA EM LC EC

CONTENTS PRECAUTIONS ...............................................................2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 Precautions for Steering System.................................2 PREPARATION ...............................................................3 Special Service Tools ..................................................3 POWER STEERING ...................................................3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................5 NVH Troubleshooting Chart.........................................5 ON-VEHICLE SERVICE ..................................................6 Steering System ..........................................................6 Checking Steering Wheel Play....................................6 Checking Neutral Position on Steering Wheel ............7 PRE-CHECKING ........................................................7 CHECKING ...............................................................7 Checking Front Wheel Turning Angle..........................7 Checking and Adjusting Drive Belts ............................7 Checking Fluid Level ...................................................8 Checking Fluid Leakage ..............................................8 Bleeding Hydraulic System..........................................8 Checking Steering Wheel Turning Force ....................9 Checking Hydraulic System.........................................9 STEERING WHEEL AND STEERING COLUMN .........11 Components...............................................................11 Removal and Installation ...........................................11 STEERING WHEEL .................................................11 STEERING COLUMN ...............................................12 Disassembly and Assembly.......................................13 Inspection...................................................................14

TILT MECHANISM ...................................................14

POWER STEERING GEAR (MODEL: D600) ...............15 Description .................................................................15 Removal and Installation ...........................................15 Inspection and Adjustment ........................................16 TURNING TORQUE MEASUREMENT .......................16 POWER STEERING OIL PUMP....................................18 Components...............................................................18 Pre-disassembly Inspection.......................................18 Disassembly...............................................................18 Inspection...................................................................19 Assembly ...................................................................19 STEERING LINKAGE....................................................21 Components...............................................................21 Removal and Installation ...........................................21 Disassembly and Assembly.......................................22 IDLER ARM ASSEMBLY ...........................................22 CROSS ROD AND TIE-ROD .....................................22 Inspection...................................................................23 BALL JOINT AND SWIVEL JOINT .............................23 IDLER ARM ASSEMBLY ...........................................23 CROSS ROD AND TIE-ROD .....................................23 FIXING LOCATION ..................................................23 SERVICE DATA AND SPECIFICATIONS (SDS) .........24 General Specifications...............................................24 Steering Wheel ..........................................................24 Steering Column ........................................................24 Power Steering Gear .................................................24 Steering Linkage........................................................25

FE CL MT AT TF PD AX SU BR

RS BT HA SC EL IDX

PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGST0001

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 Supplemental Restraint System consists of a 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), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. WARNING: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

Precautions for Steering System 쐌 쐌 쐌 쐌 쐌 쐌 쐌 *:

NGST0002

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. For easier and proper assembly, place disassembled parts in order on a parts rack. Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might interfere with their operation. Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable solvent. Before assembly, apply a coat of recommended power steering fluid* to hydraulic parts. Petroleum jelly 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. Genuine NISSAN PSF II or equivalent. Refer to MA-13, “Fluids and Lubricants”.

ST-2

PREPARATION Special Service Tools

Special Service Tools POWER STEERING

NGST0003S02

The actual shape of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

NGST0003

GI MA

Description

ST27180001 (J25726-A) Steering wheel puller

Removing steering wheel

EM LC EC

NT544

Removing ball joint and swivel joint a: 33 mm (1.30 in) b: 50 mm (1.97 in) r: 11.5 mm (0.453 in)

HT72520000 (J25730-B) Ball joint remover

FE CL MT

NT546

Removing pitman arm a: 34 mm (1.34 in) b: 6.5 mm (0.256 in) c: 61.5 mm (2.421 in)

ST29020001 (J24319-01) Steering gear arm puller

AT TF PD

NT694

Adjusting worm bearing preload

KV48100700 (J26364) Torque adapter

AX SU

NT169

ST3127S000 (see J25765-A) 1: GG91030000 (J25765-A) Torque wrench 2: HT62940000 ( — ) Socket adapter 3: HT62900000 ( — ) Socket adapter

Measuring turning torque

BR

RS

NT541

BT Steering gear installation. a: 162 mm (6.38 in) b: 110 mm (4.33 in) c: 190 mm (7.48 in) d: 9 mm (0.35 in)

KV48100301 ( — ) Strut & steering gearbox attachment

HA SC EL

NT688

ST-3

IDX

PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

(J44372) 5 - 60 Pound pull gauge

Measuring steering wheel turning force

KV48103500 (J26357 or J26357-10) Pressure gauge

Measuring oil pressure

NT547

Measuring oil pressure (Use with KV48103500)

KV48102500 ( — ) Pressure gauge adapter

NT542

KV481009S0 ( — ) Oil seal drift set 1: KV48100910 ( — ) Drift 2: KV48100920 (J26367) Adapter 3: KV48100930 (J26367) Adapter

Installing oil seal

NT174

Remove outer tie rod

(J-24319) Tie rod puller

LST092

ST-4

STEERSymptom ING Tie-rod ball joint end play Steering gear fluid leakage Steering wheel play Steering gear turning force Drive belt looseness

X X X X X X X X X

Judder

X: Applicable

ST-5

Shake X X

Vibration X X

Shimmy X X X X

PROPELLER SHAFT DIFFERENTIAL DRIVE SHAFT AXLE SUSPENSION TIRES ROAD WHEEL BRAKES

Steering linkage looseness

Improper installation or looseness of steering column

Steering column deformation or damage

Improper installation or looseness of tilt lock lever

Improper steering wheel

Tie-rod ball joint rotating torque

Noise Tie-rod ball joint swinging force

SUSPECTED PARTS (Possible cause) Air in hydraulic system

Refer to BR-5, NVH

NVH Troubleshooting Chart Refer to SU-3, NVH

Refer to SU-3, NVH

Refer to SU-3, NVH

Refer to AX-4, NVH

Refer to AX-4, NVH

Refer to PD-42, NVH

Refer to PD-42, NVH

ST-21

ST-11

ST-14

ST-14

—

Refer to MA-16, MA-28

ST-16

ST-6

ST-8

ST-23

ST-23

ST-23

ST-8

ST-7

Reference page

Fluid level

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NGST0004

NVH Troubleshooting Chart NGST0004S01

X X X X X X X X

GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

X X X X X X X

PD

X X X X X

X X X X X X

AX

X X X X X X

SU

BR

RS

BT

HA

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EL

IDX

ON-VEHICLE SERVICE Steering System

Steering System

NGST0005

WST089

1. 2. 3.

Steering wheel Tilt mechanism (if equipped) Steering gear assembly

4. 5.

Steering linkage Power steering oil tank

6. 7.

Power steering oil pump Steering column

Checking Steering Wheel Play 쐌

쐌 a) b) SST489B

NGST0006

Place wheels in straight ahead position and check steering wheel play. Steering wheel play: 35 mm (1.38 in) or less If steering wheel play is not within specification, check the following for loose or worn components. Steering column. Refer to “STEERING COLUMN”, ST-12. Front suspension and axle. Refer to AX-4, “Front Axle Parts” and SU-6, “Front Suspension Parts”.

ST-6

ON-VEHICLE SERVICE Checking Neutral Position on Steering Wheel

c)

Steering gear. Refer to “Description”, ST-15.

GI MA EM LC

Checking Neutral Position on Steering Wheel

NGST0007

PRE-CHECKING 쐌

쐌

CHECKING 1. SST490BA

2. 3. a. b.

NGST0007S01

Make sure that wheel alignment is correct. Wheel alignment: Refer to SU-18, “Wheel Alignment (Unladen *1)”. Verify that the steering gear is centered before removing the steering wheel.

EC FE CL

NGST0007S02

Check that the steering wheel is in the neutral position when driving straight ahead. If it is not in the neutral position, remove the steering wheel and reinstall it correctly. If the neutral position is still not correct: Loosen tie-rod lock nuts. Move tie-rods, in opposite direction, the same amount on both left and right sides. This will compensate for error in the neutral position.

MT AT TF PD AX

Checking Front Wheel Turning Angle 1.

2.

NGST0008

Rotate steering wheel fully right, then left; measure turning angle. Turning angle of full turns: Refer to SU-10, “Front Wheel Turning Angle”. If it is not within specification, check stopper bolt adjustment. Refer to SU-10, “Front Wheel Turning Angle”.

SU BR

RS SMA127

Checking and Adjusting Drive Belts

NGST0009

Refer to MA-16, “Checking Drive Belts” (KA24DE) or MA-26, “Checking Drive Belts” (VG33E and VG33ER).

BT HA SC EL

ST-7

IDX

ON-VEHICLE SERVICE Checking Fluid Level

Checking Fluid Level

NGST0010

Check fluid level with engine off. Check fluid level referring to the scale on the reservoir tank. Use “HOT” range for fluid temperatures of 50 to 80°C (122 to 176°F). Use “COLD” range for fluid temperatures of 0 to 30°C (32 to 86°F). CAUTION: 쐌 Do not overfill. 쐌 Recommended fluid is Genuine NISSAN PSF II or equivalent. Refer to MA-13, “Fluids and Lubricants”. AST253

Checking Fluid Leakage

AST255

Bleeding Hydraulic System

NGST0012

1.

Raise front end of vehicle until wheels are clear of the ground.

2.

Add fluid to reservoir tank to specified level. Quickly turn steering wheel fully to right and left and lightly touch steering stoppers. Repeat steering wheel operation until fluid level no longer decreases. Start engine. Repeat step 2 above. Incomplete air bleeding will cause the following to occur: Air bubbles in reservoir tank Clicking noise in power steering pump Excessive buzzing in power steering pump

3.

AST253

NGST0011

Check lines for improper attachment, leaks, cracks, damage, chafing and deterioration. 1. Run engine between idle speed and 1,000 rpm. 쐌 Make sure temperature of fluid in reservoir 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 5 seconds and carefully check for fluid leakage. CAUTION: Do not hold steering wheel at lock position for more than 15 seconds. 4. If fluid leakage from any line is noticed, loosen flare nut and then retighten. Do not overtighten connector as this can damage O-ring, washer and connector. 5. If fluid leakage from power steering pump is noticed, check power steering pump. Refer to “Pre-disassembly Inspection”, ST-18. 6. If fluid leakage from power steering gear is noticed, check power steering gear. Refer to “Inspection and Adjustment”, ST-16.

쐌 a) b) c)

ST-8

ON-VEHICLE SERVICE Bleeding Hydraulic System (Cont’d)

When this happens, bleed air again. Fluid noise may occur in the valve or power steering pump. This is common when the vehicle is stationary or while turning the steering wheel slowly. This does not affect the performance or durability of the system.

GI MA EM LC

Checking Steering Wheel Turning Force

NGST0013

1. 2. 3.

WST049

Park vehicle on a level, dry surface and set parking brake. Start engine and run at idle speed or 1,000 rpm. 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: 39 N (4 kg, 9 lb) or less 5. If steering wheel turning force is out of specification, check the following: a. Hydraulic system. Refer to “Checking Hydraulic System”, ST-9. b. Steering column. Refer to “Inspection”, ST-14. c. Front suspension and axle. Refer to AX-4, “Front Axle Parts” and SU-6, “Front Suspension Parts”. d. Steering gear turning torque. Refer to “TURNING TORQUE MEASUREMENT”, ST-16.

EC FE CL MT AT TF PD AX

Checking Hydraulic System

AST203

NGST0014

Before starting, check belt tension, driving pulley and tire pressure. 1. Set Tool. Open shut-off valve, then bleed air. Refer to “Bleeding Hydraulic System”, ST-8. 2. Run engine at idle speed or 1,000 rpm. 쐌 Make sure fluid temperature in reservoir 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, fluid pressure in the power steering pump increases to maximum. This will raise fluid temperature abnormally. 3. Check pressure with steering wheel fully turned to left and right positions while idling at 1,000 rpm. CAUTION: Do not hold the steering wheel at full lock position for more than 15 seconds. Power steering pump maximum operating pressure: 7,551 - 8,336 kPa (77 - 85 kg/cm2, 1,095 - 1,209 psi) at idle 쐌 If pressure reaches maximum operating pressure, system is OK.

ST-9

SU BR

RS BT HA SC EL IDX

ON-VEHICLE SERVICE Checking Hydraulic System (Cont’d)

쐌

If pressure increases above maximum operating pressure, check power steering pump flow control valve. Refer to “Components”, ST-18. 4. If power steering pressure is below the maximum operating pressure, slowly close shut-off valve and check pressure again. CAUTION: Do not close shut-off valve for more than 15 seconds. 쐌 If pressure increases to maximum operating pressure, gear is damaged. Refer to “Removal and Installation”, ST-15. 쐌 If pressure remains below maximum operating pressure, pump is damaged. Refer to “Components”, ST-18. 5. After checking hydraulic system, remove Tool and add fluid as necessary. Completely bleed air out of system. Refer to “Bleeding Hydraulic System”, ST-8.

ST-10

STEERING WHEEL AND STEERING COLUMN Components

Components

NGST0015

GI MA EM LC EC FE CL MT AT TF PD WST066

AX

Removal and Installation STEERING WHEEL 1. 2.

NGST0016

SU

NGST0016S01

Remove air bag module and spiral cable. Refer to RS-16, “Driver Air Bag Module and Spiral Cable”. Disconnect horn connector and remove steering wheel nut.

BR

RS WRS283

3. 쐌

Remove steering wheel using Tool. For installation, refer to RS-16, “Driver Air Bag Module and Spiral Cable”.

BT HA SC EL

AST226

ST-11

IDX

STEERING WHEEL AND STEERING COLUMN Removal and Installation (Cont’d)

STEERING COLUMN Removal

NGST0016S02 NGST0016S0201

CAUTION: 쐌 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. 쐌 Remove the steering wheel before removing the steering lower joint to avoid damaging the SRS spiral cable. Refer to “STEERING WHEEL”, ST-11. 1. Remove steering wheel. Refer to “STEERING WHEEL”, ST-11. 2. Remove steering column covers. 3. Remove instrument lower panel. Disconnect security lamp indicator. 4. Disconnect combination switch electrical connectors and air bag harness connector. 5. Remove knee protector. 6. Disconnect ignition switch and shift lock solenoid connectors. 7. Disconnect shift cable. 8. Remove bolt from lower joint. 9. Remove two steering column bolts and remove steering column.

Installation 쐌

SST666A

NGST0016S0202

When installing steering column, finger-tighten all lower bracket and clamp retaining bolts; then tighten them securely. Make sure that undue stress is not applied to steering column. 쐌 When fitting steering lower joint, be sure tightening bolt faces cutout portion. 쐌 Align spiral cable correctly when installing steering wheel. Refer to RS-16, “REMOVAL AND INSTALLATION”. CAUTION: After installation, turn steering wheel to make sure it moves smoothly. Ensure the number of turns from the straight forward position to left and right locks are the same. Be sure that the steering wheel is in a neutral position when driving straight ahead.

ST-12

STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly

Disassembly and Assembly

NGST0017

GI MA EM LC EC FE CL WST090

1. 2. 3.

Steering column shaft Steering column upper shaft Tilt mechanism (Do not disassemble)

4. 5.

Lower tube assembly Bellows

6.

Steering column lower shaft

MT AT TF PD AX

쐌 쐌

When disassembling and assembling, unlock steering lock with key. Install lock nut on steering column shaft and tighten the nut to specification. : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft. lb)

SU BR

RS AST206

쐌 a)

Steering lock Break self-shear type screws using a drill or other appropriate tool.

BT HA SC EL

SST741A

ST-13

IDX

STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly (Cont’d)

b)

Install self-shear type screws, then tighten until heads break off.

SST742A

Inspection 쐌 a)

b) 쐌 SST723C

NGST0018

If steering wheel does not turn smoothly, check the steering column as follows and replace damaged parts. Check column bearings for damage and unevenness. Lubricate with recommended multi-purpose grease or replace steering column as an assembly, if necessary. Check jacket tube for deformation and breakage. Replace if necessary. If the vehicle is involved in a light collision, check dimension “L”. If it is not within specification, replace steering column as an assembly. Column length “L”: 863.1 - 864.7 mm (33.980 - 34.043 in)

TILT MECHANISM

NGST0018S01

After installing steering column, check tilt mechanism operation.

SST582BB

ST-14

POWER STEERING GEAR (MODEL: D600) Description

Description

NGST0051

GI MA EM LC EC FE CL MT AT

WST091

1. 2.

Power steering oil tank High pressure hose

3. 4.

Power steering oil pump Steering gear

5.

TF PD

Low pressure hose

CAUTION: 쐌 Parts which can be disassembled are strictly limited. Never disassemble parts other than those specified. 쐌 Disassemble in as clean a place as possible. 쐌 Clean your hands before disassembly. 쐌 Do not use rags; use nylon cloths or paper towels. 쐌 Follow the procedures and cautions indicated in the Service Manual.

AX SU BR

RS

Removal and Installation

NGST0052

Before removal, clean gear housing and oil pump exteriors using a steam cleaner, then dry with compressed air.

BT HA SC EL

ST-15

IDX

POWER STEERING GEAR (MODEL: D600) Removal and Installation (Cont’d)

WST070

Inspection and Adjustment

NGST0053

Before replacing power steering, make sure there is no oil leakage around sealing portion and check steering turning torque as follows: Check sealing portion. 쐌 Sector shaft cover O-ring 쐌 Sector shaft U-packing 쐌 Sector shaft oil seal 쐌 Rear housing O-ring 쐌 Gear housing O-ring

TURNING TORQUE MEASUREMENT

NGST0053S01

1. a.

Measure turning torque at 360° position. Install steering gear on Tool.

b. c.

Turn stub shaft all the way to right and left several times. Measure turning torque at 360° position from straight-ahead position with Tools. Turning torque at 360°: 0.20 - 0.90 N·m (2.0 - 9.2 kg-cm, 1.8 - 8.0 in-lb)

AST209

AST208

ST-16

POWER STEERING GEAR (MODEL: D600) Inspection and Adjustment (Cont’d)

WST039

d. Measure turning torque at straight-ahead position. Straight-ahead position is a position where stub shaft is turned 1.93 turns (two full turns and 50°) from lock position. Turning torque at straight-ahead position: 0.45 - 0.80 N·m (4.6 - 8.2 kg-cm, 4.0 - 7.1 in-lb) higher than turning torque at 360° Maximum turning torque: 1.7 N·m (17.3 kg-cm, 15.0 in-lb) If turning torque is not within specifications, adjust by turning sector shaft adjusting screw. 2.

GI MA EM LC

Tighten adjusting screw lock nut with tools.

EC FE CL MT

SST654A

AT TF PD AX SU BR

RS BT HA SC EL

ST-17

IDX

POWER STEERING OIL PUMP Components

Components

NGST0036

WST068

Pre-disassembly Inspection

NGST0037

Disassemble the power steering oil pump only if the following items are found. 쐌 Oil leak from any point shown in the figure. 쐌 Deformed or damaged pulley. 쐌 Poor performance.

WST056

Disassembly

NGST0038

CAUTION: 쐌 Parts which can be disassembled are strictly limited. Never disassemble parts other than those specified. 쐌 Disassemble in as clean a place as possible. 쐌 Clean your hands before disassembly. 쐌 Do not use rags; use nylon cloth or paper towels. 쐌 When disassembling and reassembling, do not let foreign matter enter or contact the parts.

ST-18

POWER STEERING OIL PUMP Disassembly (Cont’d)

쐌 쐌

Remove snap ring, then draw drive shaft out. Be careful not to drop drive shaft.

GI MA EM LC

SST010B

쐌 쐌

Remove oil seal. Be careful not to damage front housing.

EC FE CL MT

SST034A

쐌 쐌

Remove connector and flow control valve with spring. Be careful not to drop flow control valve.

AT TF PD AX

SST036A

Inspection 쐌 쐌

NGST0039

If pulley is cracked or deformed, replace it. If fluid leak is found around the pulley shaft, replace the oil seal.

SU BR

RS

Assembly

NGST0040

Assemble oil pump, noting the following instructions. 쐌 Make sure O-rings and oil seal are properly installed. 쐌 Always install new O-rings and oil seal. 쐌 Be careful of oil seal direction. 쐌 Cam ring, rotor and vanes must be replaced as a set if necessary. 쐌 When assembling, coat each part with Genuine NISSAN PSF II or equivalent.

BT HA SC EL

SST038A

ST-19

IDX

POWER STEERING OIL PUMP Assembly (Cont’d)

쐌

Pay attention to the direction of rotor.

쐌

When assembling vanes to rotor, rounded surfaces of vanes must face cam ring side.

쐌

Insert pin 2 into pin groove 1 of front housing and front side plate. Then install cam ring 3 as shown at left. Cam ring: D1 is less than D2

SST289A

SST843A

SST497A

ST-20

STEERING LINKAGE Components

Components

NGST0041

GI MA EM LC EC FE CL WST072

MT

Removal and Installation Remove pitman arm with Tool.

NGST0042

AT TF PD AX

AST211

Remove tie-rod from knuckle arm with Tool.

SU BR

RS WST038

BT HA SC EL

ST-21

IDX

STEERING LINKAGE Disassembly and Assembly

Disassembly and Assembly IDLER ARM ASSEMBLY 쐌 쐌

NGST0043 NGST0043S01

Apply coat of multi-purpose grease to bushing. Press bushing into idler body, and insert shaft of idler bracket carefully until bushing protrudes.

CROSS ROD AND TIE-ROD 1.

NGST0043S02

When tie-rod ball joints and tie-rod bar are separated, adjust tie-rod length correctly. Adjustment should be done between ball stud centers. 2. Lock tie-rod clamp nut so that ball joint on outer ball stud is as follows with respect to that on inner ball stud. L: Standard dimension before toe-in adjustment 2WD and 4WD: 297.6 mm (11.72 in) CAUTION: Make sure that tie-rod bars are screwed into tie-rod tube more than 22 mm (0.87 in) 2WD and 4WD.

AST250

ST-22

STEERING LINKAGE Inspection

Inspection BALL JOINT AND SWIVEL JOINT

=NGST0044 NGST0044S01

1.

SST827C

SFA817A

Check joints for play. If ball or swivel stud is worn and play in axial direction is excessive, or joint is hard to swing, replace as a complete unit. Swinging force (Measure point: Cotter pin hole) “A”: Ball joint 15.7 - 147.1 N (1.6 - 15.0 kg, 3.5 - 33.1 lb) Rotating torque “B”: Ball joint 0.5 - 4.9 N·m (5 - 50 kg-cm, 4.3 - 43.4 in-lb) Swivel joint 1.0 - 5.9 N·m (10 - 60 kg-cm, 8.7 - 52.1 in-lb) Axial end play “C”: Ball joint and swivel joint 0 mm (0 in) 2. Check condition of dust cover. If it is cracked excessively, replace as a complete unit. CAUTION: Be careful not to apply grease or oil to taper of joint.

IDLER ARM ASSEMBLY 쐌 쐌

쐌 쐌 쐌

EM LC EC FE CL MT AT TF

NGST0044S03

Check tie-rod and cross rod for breakage, bends and cracks, and replace with a new one if necessary.

FIXING LOCATION

MA

NGST0044S02

Check rubber bushing of idler arm for breakage, wear or play, and if necessary replace. Lubricate idler arm assembly with multi-purpose grease, if necessary.

CROSS ROD AND TIE-ROD

GI

NGST0044S04

Check fixing location (nuts and cotter pins) for looseness, play or breakage. When looseness or play is found, check for wear on tapered portion of joints, gear arm or idler arm. When reassembling each joint, use new cotter pins.

PD AX SU BR

RS BT HA SC EL

ST-23

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

General Specifications

NGST0045

Power steering Steering column type (Collapsible) 2WD, 4WD Steering gear type

D600

Turns of steering wheel on the vehicle (Lock-to-lock)

2WD: 3.7, 4WD: 3.4

Steering gear ratio

17.6:1

Steering Wheel

NGST0046

Unit: mm (in) Steering wheel axial play

0 (0)

Steering wheel play

35 (1.38) or less

Steering Column

NGST0047

Unit: mm (in) Dimension “L”

863.1 - 864.7 (33.980 - 34.043)

SST841C

Power Steering Gear Steering wheel turning force (at 360° from neutral position and circumference of steering wheel)

39 N (4 kg, 9 lb) or less 7,551 - 8,336 kPa (77 - 85 kg/cm2, 1,095 - 1,209 psi) at idle

Oil pump pressure Fluid capacity

Approximately 1,000 - 1,100 m
(35.2 - 38.7 Imp fl oz)

Normal operating temperature

60 - 80 °C (140 - 176 °F) 360° position from straight-ahead position

Steering gear turning torque

NGST0049

Straight-ahead position (As compared with steering wheel turned 360°) Maximum turning torque

0.20 - 0.90 N·m (2.0 - 9.2 kg-cm, 1.8 - 8.0 in-lb) 0.45 - 0.80 N·m (4.6 - 8.2 kg-cm, 4.0 - 7.1 in-lb) higher 1.7 N·m (17.3 kg-cm, 15.0 in-lb)

Backlash at pitman arm top end (in straight-ahead position)

0 - 0.1 mm (0 - 0.004 in)

End play (at sector shaft end in neutral position)

0.1 mm (0.004 in) or less

ST-24

SERVICE DATA AND SPECIFICATIONS (SDS) Steering Linkage

Steering Linkage Applied model

NGST0050

GI

2WD, 4WD Rotating torque

1.0 - 5.9 N·m (10 - 60 kg-cm, 8.7 - 52.1 in-lb)

Axial end play

0 mm (0 in)

Relay-rod swivel joint

Tie-rod & relay-rod ball joint

Tie-rod standard length (L)

MA

Swinging force at cotter pin hole

15.7 - 147.1 N (1.6 - 15.0 kg, 3.5 - 33.1 lb)

Rotating torque

0.5 - 4.9 N·m (5 - 50 kg-cm, 4.3 - 43.4 in-lb)

Axial end play

0 mm (0 in)

2WD and 4WD

297.6 mm (11.72 in)

EM LC EC FE CL

AST251

MT AT TF PD AX SU BR

RS BT HA SC EL

ST-25

IDX

NOTES

RESTRAINT SYSTEM SECTION

RS

GI MA EM LC EC

CONTENTS SEAT BELTS ...................................................................3 Precautions ..................................................................3

REMOVAL ...............................................................19 INSTALLATION........................................................21

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ ........3 PRECAUTIONS FOR SEAT BELT SERVICE ...............3

Disposal of Air Bag Module and Seat Belt Pretensioner ....................................................................21 CHECKING DEPLOYMENT TOOL .............................22

Front Seat Belt.............................................................4 REMOVAL AND INSTALLATION .................................4 Rear Seat Belt .............................................................5 REMOVAL AND INSTALLATION .................................5 Seat Belt Inspection.....................................................6 AFTER A COLLISION .................................................6 PRELIMINARY CHECKS ............................................6 SEAT BELT RETRACTOR ON-VEHICLE CHECK .........7 SEAT BELT RETRACTOR OFF-VEHICLE CHECK .......8 Top Tether Strap Child Restraint .................................9 REMOVAL AND INSTALLATION .................................9 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .........10 Precautions ................................................................10

DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE) ...........................23 DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE .................................................................27 DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER ...........................................27

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ ......10 PRECAUTIONS FOR SRS ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ SERVICE ..........................10 AFTER A COLLISION ...............................................11 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS .....11

Preparation ................................................................12 SPECIAL SERVICE TOOLS ......................................12 Description .................................................................13 SRS Component Parts Location ...............................13 DIRECT-CONNECT SRS COMPONENT CONNECTORS........................................................14

Diagnosis Sensor Unit ...............................................14 REMOVAL AND INSTALLATION ...............................14 Crash Zone Sensor ...................................................15 REMOVAL AND INSTALLATION ...............................15 Seat Belt Pre-tensioner .............................................15 REMOVAL AND INSTALLATION ...............................15 Driver Air Bag Module and Spiral Cable ...................16 REMOVAL AND INSTALLATION ...............................16 REMOVAL ...............................................................16 INSTALLATION........................................................18 Front Passenger Air Bag Module ..............................19

Trouble Diagnoses Introduction.................................28 DIAGNOSIS FUNCTION ...........................................28 DIAGNOSIS MODE FOR CONSULT-II .......................28 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II ...................................................29 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II ............................................29 HOW TO ERASE SELF-DIAGNOSIS RESULTS .........29

How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................31 INFORMATION FROM CUSTOMER ..........................31 PRELIMINARY CHECK ............................................31 WORK FLOW ..........................................................32 Schematic ..................................................................33 Wiring Diagram - SRS -.............................................34 SRS Operation Check ...............................................37 DIAGNOSTIC PROCEDURE 1 ..................................37 Trouble Diagnoses with CONSULT-II...................38 DIAGNOSTIC PROCEDURE 2 ..................................38 DIAGNOSTIC PROCEDURE 3 ..................................41

FE CL MT AT TF PD AX SU BR ST

BT HA

DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) ......................44 DIAGNOSTIC PROCEDURE 5 ..................................44

SC

Trouble Diagnoses without CONSULT-II..............47 DIAGNOSTIC PROCEDURE 6 ..................................47 DIAGNOSTIC PROCEDURE 7 ..................................51

EL

DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6) ......................53

IDX

CONTENTS Trouble Diagnoses: ″AIR BAG″ Warning Lamp Does Not Turn Off .....................................................54 DIAGNOSTIC PROCEDURE 9 ..................................54 Trouble Diagnoses: ″AIR BAG″ Warning Lamp Does Not Turn On .....................................................56

RS-2

(Cont’d)

DIAGNOSTIC PROCEDURE 10 ................................56 Collision Diagnosis ....................................................57 SRS INSPECTION (FOR FRONTAL COLLISION) .......57

SEAT BELTS Precautions

Precautions SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER”

GI NGRS0001

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 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), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. WARNING: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harness can be identified by yellow and/or orange harness connectors.

MA EM LC EC FE CL

PRECAUTIONS FOR SEAT BELT SERVICE

NGRS0002

CAUTION: 쐌 Before removing the seat belt pre-tensioner assembly, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. 쐌 After replacing or reinstalling seat belt pre-tensioner assembly, or reconnecting seat belt pre-tensioner assembly connector, ensure entire SRS operates properly. Refer to “SRS Operation Check”, RS-37. 쐌 Do not disassemble buckle or seat belt assembly. 쐌 Do not reuse seat belt anchor bolts after removal. Replace with new ones. 쐌 Replace anchor bolts if they are deformed or worn out. 쐌 Never oil tongue and buckle. 쐌 If any component of seat belt assembly is questionable, do not repair. Replace the whole seat belt assembly. 쐌 If webbing is cut, frayed, or damaged, replace seat belt assembly. 쐌 When replacing seat belt assembly, use a genuine NISSAN seat belt assembly.

After A Collision

NGRS0002S01

WARNING: Inspect all seat belt assemblies including retractors and attaching hardware after any collision. NISSAN recommends that all seat belt assemblies in use during a collision be replaced unless the collision was minor and the belts show no damage and continue to operate properly. Failure to do so could result in serious personal injury in an accident. Seat belt assemblies not in use during a collision should also be replaced if either damage or improper operation is noted. Seat belt pre-tensioner should be replaced even if the seat belts are not in use during a frontal collision in which the air bags are deployed. Replace any seat belt assembly (including anchor bolts) if: 쐌 The seat belt was in use at the time of a collision (except for minor collisions and the belts, retractors and buckles show no damage and continue to operate properly). 쐌 The seat belt was damaged in an accident. (i.e., torn webbing, bent retractor or guide, etc.) 쐌 The seat belt attaching point was damaged in an accident. Inspect the seat belt attaching area for damage or distortion and repair as necessary before installing a new seat belt assembly. 쐌 Anchor bolts are deformed or worn out. 쐌 The seat belt pre-tensioner should be replaced even if the seat belts are not in use during the collision in which the air bags are deployed.

MT AT TF PD AX SU BR ST

BT HA SC EL

RS-3

IDX

SEAT BELTS Front Seat Belt

Front Seat Belt REMOVAL AND INSTALLATION

=NGRS0003

Slide the seat all the way forward and tilt the seatback toward the front. 1. Remove buckle. For driver and passenger side, disconnect seat belt switch connector. 2. Remove floor anchor bolts. 3. Remove adjuster cover and upper guide loop anchor bolt. 4. Remove center pillar lower and upper garnishes. Refer to BT-24, “SIDE AND FLOOR TRIM”. 5. Remove two adjuster bolts and adjuster assembly. 6. Disconnect seat belt pre-tensioner connector. 7. Remove retractor anchor bolt and screw. 8. Remove retractor.

WRS251

RS-4

SEAT BELTS Rear Seat Belt

Rear Seat Belt REMOVAL AND INSTALLATION

=NGRS0004

Remove rear seat. Refer to BT-38, “REAR SEAT”. 1. Remove lower seat belt anchor bolt. 2. Remove shoulder anchor bolt. 3. Remove retractor bolt. 4. Remove retractor.

GI MA EM LC EC FE CL MT AT TF PD AX SU

LRS136

BR ST

BT HA SC EL

RS-5

IDX

SEAT BELTS Seat Belt Inspection

Seat Belt Inspection AFTER A COLLISION

=NGRS0029 NGRS0029S01

WARNING: Inspect all seat belt assemblies including retractors and attaching hardware after any collision. NISSAN recommends that all seat belt assemblies in use during a collision be replaced unless the collision was minor and the belts show no damage and continue to operate properly. Failure to do so could result in serious personal injury in an accident. Seat belt assemblies not in use during a collision should also be replaced if either damage or improper operation is noted. Seat belt assemblies which are equipped with pre-tensioners should be replaced even if the seat belts are not in use during a frontal collision in which the air bags are deployed. Replace any seat belt assembly (including anchor bolts) if: 쐌 The seat belt was in use at the time of a collision (except after minor collisions when the belts, retractors and buckles show no damage and continue to operate properly). 쐌 The seat belt was damaged in an accident (i.e., torn webbing, bent retractor or guide, etc.). 쐌 The seat belt attaching point was damaged in an accident. Inspect the seat belt attaching area for damage or distortion and repair as necessary before installing a new seat belt assembly. 쐌 The seat belt assembly is equipped with a pre-tensioner, even if the seat belt is not in use during a collision in which the air bags are deployed.

PRELIMINARY CHECKS

NGRS0029S02

1. Check the “SEAT BELT” warning lamp for proper operation as follows: a. Switch ignition ON. With driver seat belt unfastened, the “SEAT BELT” warning lamp should illuminate. Also, the “SEAT BELT” warning chime should sound for about seven seconds. b. Fasten driver’s seat belt. The “SEAT BELT” warning lamp should go out. 2. If the “AIR BAG” warning lamp is blinking, conduct self-diagnosis using “AIR BAG” warning lamp or CONSULT-II. Refer to “SRS Operation Check”, RS-37. 3. Check that the seat belt retractor, seat belt anchor and buckle bolts are securely attached. 4. Check the shoulder seat belt guide and shoulder belt height adjuster for front seats. Ensure guide swivels freely and that belt lays flat and does not bind in guide. Ensure height adjuster operates properly and holds securely. 5. Check retractor operation: a. Fully extend the seat belt webbing and check for twists, tears or other damage. b. Allow the seat belt to retract. Ensure that belt returns smoothly and completely into the retractor. If the seat belt does not return smoothly, wipe the inside of the loops with a clean paper cloth etc. Dirt built up in the loops of the upper anchors can cause the seat belts to retract slowly.

ARS340

c. Fasten the seat belt. Pull firmly on belt and buckle to ensure belt remains latched. Unfasten seat belt. Ensure belt releases freely and buckle button returns to original position. 6. For non-retractable seat belts, check that the seat belts are accessible. Check seat belt webbing for twists, tears or other damage. Fasten the seat belt. Pull firmly on belt and buckle to ensure belt remains latched. Unfasten seat belts. Ensure belt releases freely and buckle button returns to original position. 7. Repeat steps above as necessary to check the other seat belts.

RS-6

SEAT BELTS Seat Belt Inspection (Cont’d)

SEAT BELT RETRACTOR ON-VEHICLE CHECK Emergency Locking Retractors (ELR) and Automatic Locking Retractors (ALR)

=NGRS0029S03 NGRS0029S0301

NOTE: All seat belt retractors are of the Emergency Locking (ELR) type. In an emergency (sudden stop) the retractor will lock and prevent the belt from extending any further. All outboard 3-point type seat belt retractors except the driver’s seat belt also have an Automatic Locking (ALR) mode. The ALR mode (also called child restraint mode) is used when installing child seats in outboard seating positions. The ALR mode is activated when the seat belt is fully extended. When the belt is then retracted partially, the ALR mode automatically locks the seat belt in a specific position so the belt cannot be extended any further. To cancel the ALR mode, allow the seat belt to fully wind back into the retractor. Check the seat belt retractors using the following test(s) to determine if a retractor assembly is operating properly.

ELR Function Stationary Check

NGRS0029S0302

Grasp the shoulder belt and pull forward quickly. The retractor should lock and prevent the belt from extending further.

GI MA EM LC EC FE

ALR Function Stationary Check

NGRS0029S0304

1. Pull out entire length of seat belt from retractor until a click is heard. 2. Retract the belt partially. A clicking noise should be heard as the belt retracts, indicating that the retractor is in the Automatic Locking (ALR) mode. 3. Grasp the seat belt and try to pull out of retractor. The belt must lock and not extend any further. If NG, replace the retractor assembly. 4. Allow the entire length of the belt to retract to cancel the automatic locking mode.

ELR Function Moving Check (all outboard seating positions)

NGRS0029S0303

WARNING: Perform the following test in a safe, open area clear of other vehicles and obstructions (for example, a large, empty parking lot). Road surface must be paved and dry. DO NOT perform the following test on wet roads, gravel roads, public streets or highways. This could result in an accident and serious personal injury. The driver and passenger must be prepared to brace themselves in the event the retractor does not lock. 1. Fasten driver’s seat belt. Buckle a passenger into the seat for the belt that is to be tested. 2. Proceed to the designated safe area. 3. Drive the vehicle at approximately 16 km/h (10 MPH). Notify any passengers of a pending sudden stop and the driver and passenger must be prepared to brace themselves in the event the retractor does not lock. Apply brakes firmly and make a very hard stop. During stop, seat belts should lock and not extend. If the seat belt retractor assembly does not lock, perform the retractor off-vehicle check.

CL MT AT TF PD AX SU BR ST

BT HA SC EL

RS-7

IDX

SEAT BELTS Seat Belt Inspection (Cont’d)

SEAT BELT RETRACTOR OFF-VEHICLE CHECK

=NGRS0029S04

1. Remove the seat belt retractor assembly. 2. Slowly pull out belt while tilting the retractor assembly forward from the mounted position as shown in the illustration. 15 degrees or less tilt: Belt can be pulled out. 35 degrees or more tilt: Belt locks and cannot be pulled out.

WRS250

If NG, replace the retractor assembly.

RS-8

SEAT BELTS Top Tether Strap Child Restraint

Top Tether Strap Child Restraint REMOVAL AND INSTALLATION

NGRS0065

GI MA EM LC EC FE CL

WRS236

MT AT TF PD AX SU BR ST

BT HA SC EL

RS-9

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Precautions

Precautions SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER”

NGRS0005

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 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), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. WARNING: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harness can be identified by yellow and/or orange harness connectors.

PRECAUTIONS FOR SRS “AIR BAG” AND “SEAT BELT PRE-TENSIONER” SERVICE 쐌 쐌

쐌 쐌 쐌 쐌 쐌

NGRS0006

Do not use a circuit tester to check SRS circuits unless instructed to 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 bags and seat belt pre-tensioners to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes have passed. Air bag diagnosis sensor unit must always be installed with forward mark “g” pointing toward the front of the vehicle for proper operation. Also check air bag diagnosis sensor unit for deformities, dents, cracks and rust before installation and replace as required. The spiral cable must be aligned in the neutral position since its rotations are limited. Do not rotate steering column while steering gear is removed to avoid damaging spiral cable. Handle air bag module carefully. Always place it with air bag lid surface facing upward. Conduct Self-diagnosis to check entire SRS for proper function after replacing any components. Refer to “SRS Operation Check”, RS-37. After air bag inflates, the instrument panel assembly should be replaced if damaged.

RS-10

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Precautions (Cont’d)

AFTER A COLLISION

=NGRS0067

WARNING: Inspect all seat belt assemblies including retractors, buckles and attaching hardware after any collision. NISSAN recommends that all seat belt assemblies in use during a collision be replaced unless the collision was minor and the belts show no damage and continue to operate properly. Failure to do so could result in serious personal injury in an accident. Seat belt assemblies not in use during a collision should also be replaced if either damage or improper operation is noted. Seat belt assemblies which are equipped with pre-tensioners should be replaced even if the seat belts are not in use during a frontal collision in which the air bags are deployed. Replace any seat belt assembly (including anchor bolts) if: 쐌 The seat belt was in use at the time of a collision (except after minor collisions when the belts, retractors and buckles show no damage and continue to operate properly). 쐌 The seat belt was damaged in an accident (i.e., torn webbing, bent retractor or guide, etc.). 쐌 The seat belt attaching point was damaged in an accident. Inspect the seat belt attaching area for damage or distortion and repair as necessary before installing a new seat belt assembly. 쐌 Anchor bolts are deformed or worn out. 쐌 The seat belt assembly is equipped with a pre-tensioner, even if the seat belt is not in use during a collision in which the air bags are deployed.

WIRING DIAGRAMS AND TROUBLE DIAGNOSIS

GI MA EM LC EC FE CL

NGRS0007

When you read wiring diagrams, refer to the following: 쐌 Refer to GI-10, “HOW TO READ WIRING DIAGRAMS”. 쐌 Refer to EL-10, “POWER SUPPLY ROUTING” for power distribution circuit. When you perform trouble diagnosis, refer to the following: 쐌 Refer to GI-33, “How to Follow Test Groups in Trouble Diagnoses”. 쐌 Refer to GI-22, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.

MT AT TF PD AX SU BR ST

BT HA SC EL

RS-11

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Preparation

Preparation SPECIAL SERVICE TOOLS

=NGRS0008

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description

KV991072S0 (J38381-KIT) Air bag deployment kit KV99106400 (J38381) Deployment tool

Disposing of air bag module and seat belt pre-tensioner

NT357

(J38381-65) Deployment tool adapter for passenger air bag module

WRS287

(J38381–80) Deployment tool adapter for driver air bag module and seat belt pre-tensioner

WRS288

KV99105300 (J41246) Air bag module bracket

Anchoring air bag module

NT354

Removing and installing accessory air bag locking bolts.

(J–44615) Air bag master key set

LRS210

*: Special tool or commercial equivalent

RS-12

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Description

Description

NGRS0009

GI MA EM LC EC FE CL WRS252

The air bags and seat belt pre-tensioners deploy if the air bag diagnosis sensor unit activates while the ignition switch is in the ON or START position. The air bag diagnosis sensor unit will deploy the air bags and seat belt pre-tensioners if the G sensor activates simultaneously with the safing sensor while the ignition switch is ON.

SRS Component Parts Location

NGRS0010

MT AT TF PD AX SU BR ST

BT HA SC WRS253

EL

RS-13

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS Component Parts Location (Cont’d)

DIRECT-CONNECT SRS COMPONENT CONNECTORS

NGRS0010S01

The following SRS components use direct-connect style harness connectors. 쐌 Driver air bag module 쐌 Front LH seat belt pre-tensioner 쐌 Front RH seat belt pre-tensioner Always pull up to release black locking tab prior to removing connector from SRS component. Always push down to lock black locking tab after installing connector to SRS component.

WRS284

Diagnosis Sensor Unit REMOVAL AND INSTALLATION

NGRS0012

CAUTION: 쐌 Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait for at least 3 minutes. 쐌 The special bolts are coated with bonding agent while the other bolt is for ground. Do not reuse bolts after removal; replace with new ones. 쐌 Check air bag diagnosis sensor unit for proper installation. 쐌 Check air bag diagnosis sensor unit to ensure it is free of deformities, dents, cracks and rust. If there are any visible signs of damage, replace it with a new one. 쐌 Check air bag diagnosis sensor unit brackets to ensure they are free of deformities or rust. 쐌 Replace air bag diagnosis sensor unit if it has been dropped or has sustained an impact.

1.

WRS228

Disconnect driver and passenger air bag module connectors and seat belt pre-tensioner connectors. 2. Remove console box. Refer to “INSTRUMENT PANEL ASSEMBLY”, BT-20. 3. Disconnect air bag diagnosis sensor unit connector. 4. Remove ground bolt and also remove hex head bolts from air bag diagnosis sensor unit. Then remove the air bag diagnosis sensor unit. NOTE: 쐌 To install, reverse the removal procedure and tighten new bolts in the sequence indicated in the illustration.

RS-14

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Diagnosis Sensor Unit (Cont’d)

쐌

After replacement, perform self-diagnosis for SRS. Refer to “SRS Operation Check”, RS-37. CAUTION: Air bag diagnosis sensor unit must always be installed with forward mark “⇐” pointing toward the front of the vehicle for proper operation. Also check air bag diagnosis sensor unit for deformities, dents, cracks and rust before installation and replace as required.

GI MA EM LC

Crash Zone Sensor REMOVAL AND INSTALLATION

NGRS0066

CAUTION: 쐌 Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait at least 3 minutes. 쐌 Check crash zone sensor for proper installation. 쐌 Check crash zone sensor to ensure they are free of deformities, dents, cracks or rust. If it shows any visible signs of damage, replace it with new one. 쐌 After replacement of crash zone sensor, check SRS function and perform self-diagnosis for SRS. Refer to “SRS Operation Check” for details. (RS-37) 쐌 Do not attempt to disassemble crash zone sensor. 쐌 Replace crash zone sensor if it has been dropped or sustained an impact.

EC FE CL MT AT TF PD AX

1. 2.

Disconnect crash zone sensor. Remove nuts from crash zone sensor and bracket. Then remove bracket and crash zone sensor from radiator support. NOTE: 쐌 To install, reverse the removal procedure sequence.

SU BR ST

LRS263

Seat Belt Pre-tensioner REMOVAL AND INSTALLATION

WRS233

BT NGRS0040

CAUTION: 쐌 Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait at least 3 minutes. 쐌 Check seat belt pre-tensioner for proper installation. 쐌 After replacement of seat belt pre-tensioner, check SRS function and perform self-diagnosis for SRS. Refer to “SRS Operation Check”, RS-37. 쐌 Do not attempt to disassemble air bag diagnosis sensor unit or seat belt pre-tensioner.

RS-15

HA SC EL IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Seat Belt Pre-tensioner (Cont’d)

쐌

Replace seat belt pre-tensioner if it has been dropped or sustained an impact. 쐌 Do not expose seat belt pre-tensioner to temperatures exceeding 80°C (176°F). For removal of seat belt pre-tensioner, refer to “Front Seat Belt”, RS-4. NOTE: 쐌 To install, reverse removal procedure.

Driver Air Bag Module and Spiral Cable REMOVAL AND INSTALLATION

NGRS0013

WRS282

REMOVAL

NGRS0014

CAUTION: 쐌 Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. 쐌 Always work from the side of an air bag module. 1. Remove side lids and/or switch covers and switches.

2.

Remove right and left special hex head bolts.

WRS283

RS-16

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Driver Air Bag Module and Spiral Cable (Cont’d)

3. 쐌

Disconnect the air bag harness connectors, and remove the air bad module. For removal/installation of the direct-connect SRS connectors, refer to RS-14, “DIRECT-CONNECT SRS COMPONENT CONNECTORS”

GI MA EM LC

WRS285

CAUTION: 쐌 Always place air bag module with air bag lid surface facing upward. 쐌 Do not attempt to disassemble air bag module. 쐌 Do not use old bolts after removal; replace with new ones. 쐌 Do not insert any foreign objects (screwdriver, etc.) into air bag module connector.

EC FE CL MT

ARS369

쐌 쐌 쐌

Do not drop or impact air bag module. If any portion is deformed or cracked, replace the module. 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.

AT TF PD AX

SBF814E

4. 5.

SST480C

Set steering wheel in the neutral position. Disconnect spiral cable connector from steering wheel subharness and remove nut. 6. Remove dynamic damper, then using steering wheel puller, remove steering wheel. Be careful not to over-tighten puller bolt on steering wheel. CAUTION: 쐌 Do not tap or bump the steering wheel. 7. Remove steering column covers, instrument panel lower LH and knee protector. 8. Disconnect spiral cable connector from air bag harness. 9. Remove the four spiral cable retaining screws. Remove the spiral cable. CAUTION: 쐌 Do not attempt to disassemble spiral cable. 쐌 Do not apply lubricant to the spiral cable.

SU BR ST

BT HA SC EL

WRS237

RS-17

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Driver Air Bag Module and Spiral Cable (Cont’d)

INSTALLATION 1. 2.

NGRS0015

Set the front wheels in the straight-ahead position. Align the turn signal cancel tab with the notch of the combination switch as shown.

ARS152

3. 4.

Rotate the spiral cable fully clockwise until tight. Rotate the spiral cable counterclockwise approximately 2.25 turns and align white pin with arrow on housing. 쐌 When the spiral cable is centered, white pin is aligned with arrow on housing and yellow wheel shows in window. CAUTION: 쐌 The spiral cable may snap during steering operation if the spiral cable is installed in an improper position. 쐌 Also, with the steering linkage disconnected, the cable may snap by turning the steering wheel beyond the limited number of turns. The spiral cable can be turned counterclockwise approximately 2.25 turns. Always perform SRS self-diagnosis after installing the air bag module. Refer to “SRS Operation Check”, RS-37. 5. Connect spiral cable to air bag harness and tighten screws. Install steering column covers.

WRS238

6. 7. 8.

Install steering wheel, setting spiral cable pin guide, and pull spiral cable connectors through. Install dynamic damper. Tighten steering wheel nut. : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)

WRS239

RS-18

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Driver Air Bag Module and Spiral Cable (Cont’d)

9.

WRS283

Position driver air bag module and install two new hex head bolts. 10. Connect driver air bag module connector. 쐌 For removal/installation of the direct-connect SRS connectors, refer to RS-14, “DIRECT-CONNECT SRS COMPONENT CONNECTORS”. 11. Install all lids and steering switches. 12. Connect both battery cables. 13. Conduct self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or “AIR BAG” warning lamp check.) Turn the steering wheel fully to the right and left to check that the spiral cable is set in the neutral position. 14. If “AIR BAG” warning lamp blinks (in User mode), it shows the spiral cable may be snapped due to its improper position. Perform self-diagnosis again. (Use CONSULT-II or “AIR BAG” warning lamp check.) If a malfunction is detected, replace the spiral cable with a new one. NOTE: 쐌 After replacement, perform self-diagnosis for SRS. Refer to “SRS Operation Check”, RS-37.

GI MA EM LC EC FE CL MT

Front Passenger Air Bag Module REMOVAL

WRS261

AT NGRS0016

CAUTION: 쐌 Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait for at least 3 minutes. 쐌 Always work from the side of an air bag module. 1. Open glove box assembly. 2. Reach up and bend down deformable connector mounting bracket assembly. 3. Remove passenger air bag module connector clip from bracket. 4. Disconnect passenger air bag module connector from air bag harness connector. 5. Remove glove box and instrument panel lower passenger side. Refer to “INSTRUMENT PANEL ASSEMBLY”, BT-20.

TF PD AX SU BR ST

BT HA SC EL

RS-19

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Front Passenger Air Bag Module (Cont’d)

6. 7. 8. 쐌

Remove two hex head bolts. Remove four mounting nuts. Remove passenger air bag module by releasing the clips from the top of the instrument panel. The air bag module is heavy and should be supported using both hands during removal.

WRS240

CAUTION: 쐌 Always place air bag module with pad side facing upward. 쐌 Do not attempt to disassemble air bag module. 쐌 The special bolts are coated with a bonding agent. Do not use old bolts after removal; replace with new coated bolts. 쐌 Do not insert any foreign objects (screwdriver, etc.) into air bag module connector.

ARS330

쐌 쐌 쐌 쐌

Do not drop or impact air bag module. If any portion is deformed or cracked, replace the module. 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 instrument panel assembly should be replaced if damaged.

SBF814E

RS-20

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Front Passenger Air Bag Module (Cont’d)

INSTALLATION

NGRS0017

CAUTION: 쐌 Always work from the side of an air bag module. 1. Install passenger air bag module in instrument panel. 1) Insert front edge of passenger air bag module first to ease installation. 쐌 Ensure harness is not caught between passenger air bag module and support bracket. 2) Install four mounting nuts. 3) Install two new hex head bolts. 2. Install instrument panel lower passenger side and glove box.

GI MA EM LC EC FE CL MT AT TF PD AX

WRS240

3.

Connect passenger air bag module connector to air bag harness connector. 4. Attach passenger air bag module connector clip to lid. 5. Close lid and glove box. 6. Connect both battery cables. 7. Conduct self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or “AIR BAG” warning lamp check.) NOTE: 쐌 After replacement, perform self-diagnosis for SRS. Refer to “SRS Operation Check”, RS-37.

SU BR ST

WRS261

Disposal of Air Bag Module and Seat Belt Pretensioner 쐌

쐌 쐌

BT

NGRS0018

Before disposing of air bag modules and seat belt pretensioners, 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 air bag module or seat belt pre-tensioner, always use the Special Service Tool; Deployment tool KV99106400 (Kent-Moore No. J38381). When deploying air bag module or seat belt pre-tensioner,

RS-21

HA SC EL IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d)

쐌

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

stand at least 5 m (16 ft) away from the deployment component. When deploying air bag module or 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 as it irritates the throat and can cause choking. Only activate one air bag module or seat belt pre-tensioner at a time. Due to heat, leave air bag module unattended for more than 30 minutes after deployment. 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 or seat belt pre-tensioner. Never apply water to a deployed air bag module or 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 or 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 or seat belt pre-tensioner un-deployed.

CHECKING DEPLOYMENT TOOL Connecting to Battery

SRS019

NGRS0018S01 NGRS0018S0101

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. 쐌 Wait 3 minutes after the vehicle battery is disconnected before proceeding. 쐌 Connect red clip of deployment tool [SST: KV99106400 (J38381)] to battery positive terminal and black clip to negative terminal. CAUTION: Make sure the polarity is correct. The right side lamp on the deployment tool [SST: KV99106400 (J38381)], 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

NGRS0018S0102

Press the deployment tool [SST: KV99106400 (J38381)] switch to the ON position. The left side lamp on the deployment tool [SST: KV99106400 (J38381)], marked “AIR BAG CONNECTOR VOLTAGE”, should illuminate. If it does not illuminate, replace the tool.

GI MA

Air Bag Deployment Tool Lamp Illumination Chart (Battery connected) EM NGRS0018S0103 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.

LC EC FE CL MT

DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE) AT NGRS0018S02 Unless the vehicle is being scrapped, deploying the air bag modules in the vehicle is not recommended. This may cause damage to the vehicle interior. Anchor air bag module bracket [KV99105300 (J41246)] in a vise secured to a firm foundation during deployment.

TF PD AX

ARS185

Deployment of Driver Air Bag Module (Outside of SU vehicle) NGRS0018S0201 1.

WRS241

Using wire, secure driver air bag module to air bag module bracket [SST: KV99105300 (J41246)] at two places. CAUTION: If a gap exists between driver air bag module and air bag module bracket, use a piece of wood inserted in the gap to stabilize the air bag module. Use wire of at least 1 mm (0.04 in) diameter. 2. Firmly secure air bag module bracket [SST: KV99105300 (J41246)] with driver air bag module attached, in a vise. 3.

4.

5.

6. WRS242

Connect deployment tool adapter (J38381–80) to deployment tool [SST: KV99106400 (J38381)] connector and to driver air bag module connector. Connect red clip of deployment tool [SST: KV99106400 (J38381)] to battery positive terminal and black clip to negative terminal. The right side lamp on the deployment tool [SST: KV99106400 (J38381)], marked “DEPLOYMENT TOOL POWER”, should glow green, not red. Press the button on the deployment tool [SST: KV99106400 (J38381)]. The left side lamp on the deployment tool [SST:

RS-23

BR ST

BT HA SC EL IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d)

KV99106400 (J38381)], 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.

Deployment of Passenger Air Bag Module (Outside of vehicle) NGRS0018S0202 1.

Make an 8.5 mm (0.335 in) diameter hole in air bag module bracket [SST: KV99105300 (J41246)] at the position shown in figure at left.

2.

Firmly secure air bag module bracket [SST: KV99105300 (J41246)] in a vise.

ARS371

ARS185

3.

Match the two holes in air bag module bracket [SST: KV99105300 (J41246)] (held in vise) and passenger 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 air bag module and air bag module bracket, use a piece of wood inserted in the gap to stabilize the air bag module.

ARS234

4.

Connect deployment tool adapter (J38381–65) to deployment tool [SST: KV99106400 (J38381)] connector and passenger air bag module connector.

WRS262

RS-24

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d)

5.

ARS236

Connect red clip of deployment tool [SST: KV99106400 (J38381)] to battery positive terminal and black clip to negative terminal. 6. The right side lamp on the deployment tool [SST: KV99106400 (J38381)], marked “DEPLOYMENT TOOL POWER”, should glow green, not red. 7. Press the button on the deployment tool [SST: KV99106400 (J38381)]. The left side lamp on the deployment tool [SST: KV99106400 (J38381)], marked “AIR BAG CONNECTOR VOLTAGE”, will illuminate and the air bag module will deploy. CAUTION: 쐌 When deploying the air bag module, stand at least 5 m (16 ft) away from the air bag module.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST

BT HA SC EL

RS-25

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d)

Deployment of Seat Belt Pre-tensioner (Outside of vehicle) =NGRS0018S0203 1.

Firmly anchor seat belt pre-tensioner in a vise, then cut webbing off.

2.

Connect deployment tool adapter (J38381–80) connector to seat belt pre-tensioner connector. Use deployment tool adapter [SST: KV99109000 (J44230)] for pre-tensioner that have a built in harness lead.

LRS205

쐌

WRS243

3.

WRS244

Connect red clip of deployment tool [SST: KV99106400 (J38381)] to battery positive terminal and black clip to negative terminal. 4. The right side lamp on the deployment tool [SST: KV99106400 (J38381)], marked “DEPLOYMENT TOOL POWER”, should glow green, not red. 5. Press the button on the deployment tool [SST: KV99106400 (J38381)]. The left side lamp on the deployment tool [SST: KV99106400 (J38381)], marked “AIR BAG CONNECTOR VOLTAGE”, will illuminate and the seat belt pre-tensioner will deploy. CAUTION: 쐌 When deploying the seat belt pre-tensioner, stand at least 5 m (16 ft) away from the seat belt pre-tensioner.

RS-26

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d)

DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE =NGRS0018S03 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 module or seat belt pre-tensioner, ensure vehicle is empty. 1. Disconnect both battery cables and wait 3 minutes. 2. Disconnect air bag module connector or seat belt pre-tensioner connector. 3. Connect deployment tool [SST: KV99106400 (SST: J38381)] to air bag module or seat belt pre-tensioner. For passenger air bag module, use deployment tool adapter (J38381–65), or for pre-tensioner, use deployment tool adapter (J38381–80), or for driver air bag module, use deployment tool adapter (J38381–80) to attach to the deployment tool [SST: KV99106400 (J38381)] connector.

GI MA EM LC EC FE CL MT

4.

5.

6.

ARS343

Connect red clip of deployment tool [SST: KV99106400 (J38381)] to battery positive terminal and black clip to negative terminal. The right side lamp on the deployment tool [SST: KV99106400 (J38381)], marked “DEPLOYMENT TOOL POWER”, should glow green, not red. Press the button on the deployment tool [SST: KV99106400 (J38381)]. The left side lamp on the deployment tool [SST: KV99106400 (J38381)], marked “AIR BAG CONNECTOR VOLTAGE”, will illuminate and the air bag module or seat belt pre-tensioner will deploy.

AT TF PD AX

DISPOSING OF AIR BAG MODULE AND SEAT BELT SU PRE-TENSIONER NGRS0018S04

SBF276H

Deployed air bag modules and seat belt pre-tensioners are very hot. Before disposing of air bag modules and seat belt pretensioners, wait at least 30 minutes and 10 minutes, respectively. Seal them in a plastic bag before disposal. CAUTION: 쐌 Never apply water to a deployed air bag module or seat belt pre-tensioner. 쐌 Be sure to wear gloves when handling a deployed air bag module or seat belt pre-tensioner. 쐌 No poisonous gas is produced upon air bag module or seat belt pre-tensioner deployment. However, be careful not to inhale gas since it irritates the throat and can cause choking. 쐌 Do not attempt to disassemble air bag module or seat belt pre-tensioner. 쐌 Air bag module or seat belt pre-tensioner cannot be reused. 쐌 Wash your hands clean after finishing work.

RS-27

BR ST

BT HA SC EL IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses Introduction

Trouble Diagnoses Introduction

=NGRS0055

CAUTION: 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow harness connectors. 쐌 Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged, replace it with a new one. 쐌 Keep ground portion clean.

DIAGNOSIS FUNCTION

NGRS0055S01

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

NOTE: Seat belt pre-tensioner malfunction is indicated by “AIR BAG” warning lamp.

DIAGNOSIS MODE FOR CONSULT-II 쐌

쐌 쐌 쐌

NGRS0055S02

“SELF-DIAG [CURRENT]” A current Self-diagnosis result (also indicated by the number of warning lamp flashes in the Diagnosis mode) is displayed on the CONSULT-II screen in real time. This refers to a malfunctioning part requiring repairs. “SELF-DIAG [PAST]” Diagnosis results previously stored in the memory are displayed on the CONSULT-II screen. The stored results are not erased until memory erasing is executed. “TROUBLE DIAG RECORD” With TROUBLE DIAG RECORD, diagnosis results previously erased by a reset operation can be displayed on the CONSULT-II screen. “ECU DISCRIMINATED NO.” The diagnosis sensor unit for each vehicle model is assigned with its own, individual classification number. This number will be displayed on the CONSULT-II screen, as shown. When replacing the diagnosis sensor unit, refer to the part number for the compatibility. After installation, replacement with a correct unit can be checked by confirming this classification number on the CONSULT-II screen.

ARS366

ECU Part No. 28556 8Z800

RS-28

ECU Discriminated No. F60E

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses Introduction (Cont’d)

HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II From User Mode to Diagnosis Mode

=NGRS0055S03 NGRS0055S0301

After selecting “AIR BAG” on the “SELECT SYSTEM” screen, User mode automatically changes to Diagnosis mode.

GI MA EM LC EC

SRS803

FE

From Diagnosis Mode to User Mode

NGRS0055S0302

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.

CL MT AT TF

SRS804

HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II From User Mode to Diagnosis Mode

NGRS0055S04 NGRS0055S0401

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

AX SU BR ST

NGRS0055S0402

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”.

HOW TO ERASE SELF-DIAGNOSIS RESULTS With CONSULT-II 쐌

PD

“SELF-DIAG [CURRENT]” A current Self-diagnosis result is displayed on the CONSULT-II screen in real time.

RS-29

BT HA SC

NGRS0055S05 NGRS0055S0501

EL IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses Introduction (Cont’d)

After the malfunction is repaired completely, no malfunction is detected on “SELF-DIAG [CURRENT]”. 쐌 “SELF-DIAG [PAST]” Return to the “SELF-DIAG [CURRENT]” CONSULT-II screen by pushing “BACK” key of CONSULT-II and select “SELF-DIAG [CURRENT]” in SELECT DIAG MODE. Touch “ERASE” in “SELF-DIAG [CURRENT]” mode. NOTE: If the memory of the malfunction in “SELF-DIAG [PAST]” is not erased, the User mode shows the system malfunction by the operation of the warning lamp even if the malfunction is repaired completely.

SRS701

쐌

“TROUBLE DIAG RECORD” The memory of “TROUBLE DIAG RECORD” cannot be erased.

Without CONSULT-II

NGRS0055S0502

After a malfunction is repaired, switch the ignition “OFF” for at least one second, then back “ON”. Diagnosis mode returns to the User mode. At that time, the self-diagnostic result is cleared.

RS-30

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) How to Perform Trouble Diagnoses for Quick and Accurate Repair

How to Perform Trouble Diagnoses for Quick and Accurate Repair

=NGRS0056

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

GI MA

NGRS0056S01

WHAT ..... Vehicle model WHEN ..... Date, Frequencies WHERE ..... Road conditions HOW ..... Operating conditions, Symptoms

EM LC

PRELIMINARY CHECK

NGRS0056S02

Check that the following parts are in good order. 쐌 Battery, refer to SC-4, “BATTERY”. 쐌 System component-to-harness connections. 쐌 Check fuse.

EC FE CL MT AT TF PD AX SU BR ST

BT HA SC EL

RS-31

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont’d)

WORK FLOW

=NGRS0056S03

NOTE: Seat belt pre-tensioner malfunction is indicated by “AIR BAG” warning lamp.

SRS799

*1: RS-31 *2: RS-37

*3: RS-38 *4: RS-47

*5: RS-41 *6: RS-51

RS-32

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Schematic

Schematic

NGRS0057

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST

BT HA SC WRS224

RS-33

EL IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Wiring Diagram — SRS —

Wiring Diagram — SRS —

NGRS0058

WRS225

RS-34

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Wiring Diagram — SRS — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST

BT HA SC WRS286

EL

RS-35

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Wiring Diagram — SRS — (Cont’d)

WRS281

RS-36

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS Operation Check

SRS Operation Check

NGRS0059

DIAGNOSTIC PROCEDURE 1 NGRS0059S01 GI Checking Air Bag Operation by Using “AIR BAG” Warning Lamp — User Mode NGRS0059S0101 1. 2.

After turning ignition switch from “OFF” to “ON”, “AIR BAG” warning lamp operates. Compare “AIR BAG” warning lamp operation to the chart below.

MA EM LC

SRS800

“AIR BAG” warning lamp operation — User mode —

SRS condition No malfunction is detected. No further action is necessary.

Reference item

EC —

MRS095A

FE CL

The system is malfunction- Go to “DIAGNOSTIC ing and needs to be PROCEDURE 2”, RS-38 repaired as indicated. or “DIAGNOSTIC PROCEDURE 6” RS-47. MRS096A

MT AT

Air bag is deployed. Seat belt pre-tensioner is deployed. Air bag fuse, diagnosis sensor unit or harness is MRS097A malfunctioning and needs to be repaired.

Go to “Collision Diagnosis”, RS-57. Go to “DIAGNOSTIC PROCEDURE 9”, RS-54.

One of the following has Go to “DIAGNOSTIC occurred and needs to be PROCEDURE 10”, RS-56. repaired. 쐌 Meter fuse is blown. 쐌 “AIR BAG” warning lamp circuit has open or short. MRS098A 쐌 Diagnosis sensor unit is malfunctioning.

TF PD AX SU BR ST

BT HA SC EL

RS-37

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II

Trouble Diagnoses with CONSULT-II DIAGNOSTIC PROCEDURE 2

=NGRS0060 NGRS0060S01

Inspecting SRS malfunctioning parts by using CONSULT-II — Diagnosis mode

1. 2.

Turn ignition switch “OFF”. Connect “CONSULT-II” to data link connector.

3. 4.

Turn ignition switch “ON”. Touch “START”.

5.

Touch “AIR BAG”.

6.

Touch “SELF-DIAG [CURRENT]”.

LEC104A

SRS695

SRS771

SRS697

RS-38

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d)

7.

Diagnostic codes are displayed on “SELF-DIAG [CURRENT]”.

GI MA EM LC

WRS254

SRS701

If no malfunction is detected on “SELF-DIAG [CURRENT]” even though malfunction is detected in “SRS Operation Check”, check the battery voltage. If the battery voltage is less than 9V, charge the battery. Then go to “DIAGNOSTIC PROCEDURE 3”, RS-41. If the battery voltage is OK, refer to “DIAGNOSTIC PROCEDURE 4 (CONTINTUE FROM DIAGNOSTIC PROCEDURE 2)”, RS-44, to diagnose the following cases: 쐌 Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. 쐌 The SRS system malfunctions intermittently. 8. 9.

10. 11. 12.

13.

Touch “COPY”. Compare diagnostic codes to “CONSULT-II Diagnostic Code Chart”. Refer to “CONSULT-II Diagnostic Code Chart (’SELFDIAG [CURRENT]’)”, RS-39. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears in order to return to User mode from Diagnosis mode. Turn ignition switch “OFF”, then turn off and disconnect CONSULT-II, and disconnect both battery cables. 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 “REMOVAL AND INSTALLATION”, RS-14. After repairing the system, refer to “DIAGNOSTIC PROCEDURE 3”, RS-41 for final checking.

EC FE CL MT AT TF PD AX SU

CONSULT-II Diagnostic Code Chart (“SELF-DIAG BR [CURRENT]”) NGRS0060S0101 Diagnostic item NO DTC IS DETECTED.

Explanation When malfunction is indicated by the “AIR BAG” warning lamp in User mode

Repair order “Recheck SRS at each replacement.”

쐌 Low battery voltage (Less than 9V)

쐌 Go to “DIAGNOSTIC PROCEDURE 3”, RS-41 after charging battery.

쐌 Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. 쐌 Intermittent malfunction has been detected in the past.

쐌 Go to “DIAGNOSTIC PROCEDURE 4”, RS-44.

쐌 No malfunction is detected.

ST

BT HA

쐌 Go to “DIAGNOSTIC PROCEDURE 3”, RS-41.

SC EL

RS-39

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d)

Diagnostic item

Explanation

Repair order “Recheck SRS at each replacement.”

DRIVER AIRBAG MODULE [OPEN]

쐌 Driver air bag module circuit is open. (including the spiral cable)

1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace driver air bag module. (Before disposal of it, it must be deployed.) 4. Replace the spiral cable. 5. Replace the air bag diagnosis sensor unit. 6. Replace the related harness.

DRIVER AIRBAG MODULE [VB-SHORT]

쐌 Driver air bag module circuit is shorted to some power supply circuit. (including the spiral cable)

DRIVER AIRBAG MODULE [GND-SHORT]

쐌 Driver air bag module circuit is shorted to ground. (including the spiral cable)

DRIVER AIRBAG MODULE [SHORT]

쐌 Driver air bag module circuits are shorted to each other.

1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the spiral cable. 4. Replace driver air bag module. (Before disposal of it, it must be deployed.) 5. Replace the air bag diagnosis sensor unit. 6. Replace the related harness.

ASSIST A/B MODULE [VB-SHORT]

쐌 Passenger air bag module circuit is shorted to some power supply circuit.

ASSIST A/B MODULE [OPEN]

쐌 Passenger air bag module circuit is open.

ASSIST A/B MODULE [GND-SHORT]

쐌 Passenger air bag module circuit is shorted to ground.

ASSIST A/B MODULE [SHORT]

쐌 Passenger air bag module circuits are shorted to each other.

PRE-TEN FRONT LH [OPEN]

쐌 The circuit for driver seat belt pre-tensioner is open.

PRE-TEN FRONT LH [VB-SHORT] PRE-TEN FRONT LH [GND-SHORT]

1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace passenger air bag module. (Before disposal of it, it must be deployed.) 4. Replace the air bag diagnosis sensor unit. 5. Replace the related harness.

1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 쐌 The circuit for driver seat belt pre-tensioner is shorted to some 3. Replace driver seat belt. power supply circuit. (Before disposing, it must be deactivated.) 쐌 The circuit for driver seat belt pre-tensioner is shorted to ground. 4. Replace the air bag diagnosis sensor unit. 5. Replace the related harness.

PRE-TEN FRONT RH [OPEN]

쐌 The circuit for passenger seat belt pre-tensioner is open.

PRE-TEN FRONT RH [VB-SHORT]

쐌 The circuit for passenger seat belt pre-tensioner is shorted to some power supply circuit.

PRE-TEN FRONT RH [GND-SHORT]

쐌 The circuit for passenger seat belt pre-tensioner is shorted to ground.

RS-40

1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace passenger seat belt. (Before disposing, it must be deactivated.) 4. Replace the air bag diagnosis sensor unit. 5. Replace the related harness.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d)

Diagnostic item CRASH ZONE SEN [UNIT FAIL] CRASH ZONE SEN [COMM FAIL]

CONTROL UNIT

Explanation 쐌 Crash zone sensor

Repair order “Recheck SRS at each replacement.” 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the crash zone sensor. 4. Replace the diagnosis sensor unit. 5. Replace the related harness.

쐌 Air bag diagnosis sensor unit is malfunctioning.

1. Visually check the wiring harness connection. 2. Replace the air bag diagnosis sensor unit.

* 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.

GI MA EM LC EC FE CL MT

DIAGNOSTIC PROCEDURE 3

NGRS0060S02

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”.

AT TF PD AX

LEC104A

4.

Touch “START”.

SU BR ST

SRS695

5.

Touch “AIR BAG”.

BT HA SC EL

SRS771

RS-41

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d)

6.

Touch “SELF-DIAG [CURRENT]”.

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”, RS-38, and repair malfunctioning part completely.

SRS697

SRS701

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.

WRS255

9.

Touch “BACK” key of CONSULT-II to “SELECT SYSTEM” screen. Touch “SELF-DIAG [PAST]”.

SRS697

10. Check that no malfunction is detected on “SELF-DIAG [PAST]”.

SRS702

RS-42

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d)

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”, RS-37 to check SRS operation by using “AIR BAG” warning lamp with User mode.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST

BT HA SC EL

RS-43

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d)

DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) =NGRS0060S03 Inspecting SRS malfunctioning record 1

CONSIDER POSSIBILITY OF NOT ERASING SELF-DIAGNOSTIC RESULT AFTER REPAIRING

Is it the first time for maintenance of SRS? Yes or No Yes

䊳

Go to “DIAGNOSTIC PROCEDURE 5”, RS-44.

No

䊳

Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. Go to “DIAGNOSTIC PROCEDURE 3”, RS-41.

DIAGNOSTIC PROCEDURE 5

NGRS0060S04

Inspecting SRS intermittent malfunction by using CONSULT-II — Diagnosis mode 1. Turn ignition switch “OFF”. 2. Connect “CONSULT-II” to data link connector.

LEC104A

3. 4.

Turn ignition switch “ON”. Touch “START”.

5.

Touch “AIR BAG”.

6.

Touch “SELF-DIAG [PAST]”.

SRS695

SRS771

SRS697

RS-44

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d)

7.

If diagnostic codes are displayed on “SELF-DIAG [PAST]”, go to step 10.

GI MA EM LC

WRS256

If no malfunction is detected on “SELF-DIAG [PAST]”, touch “BACK” and go back to “SELECT DIAG MODE”.

EC FE CL MT

SRS702

8. Touch “TROUBLE DIAG RECORD”. NOTE: With “TROUBLE DIAG RECORD”, diagnosis results previously erased by a reset operation can be displayed.

AT TF PD AX

SRS697

9.

Diagnostic code is displayed on “TROUBLE DIAG RECORD”.

SU BR ST

WRS257

10. Touch “COPY”. 11. Compare diagnostic codes to “Intermittent Malfunction Diagnostic Code Chart”. Refer to “Intermittent Malfunction Diagnostic Code Chart (“SELF-DIAG [PAST]” or “TROUBLE DIAG RECORD”)”, 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 disconnect both battery cables. 14. Repair the system as outlined by the “Repair order” in “Intermittent Malfunction Diagnostic Code Chart”, that corresponds

RS-45

BT HA SC EL IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d)

to the self-diagnostic result. For replacement procedure of component parts, refer to “REMOVAL AND INSTALLATION”, RS-14. 15. Go to “DIAGNOSTIC PROCEDURE 3”, RS-41, for final checking.

Intermittent Malfunction Diagnostic Code Chart (“SELFDIAG [PAST]” or “TROUBLE DIAG RECORD”) NGRS0060S0401 Diagnostic item NO DTC IS DETECTED.

Explanation When malfunction is indicated by the “AIR BAG” warning lamp in User mode

쐌 Low battery voltage (Less than 9V)

쐌 No malfunction is detected. DRIVER AIRBAG MODULE [OPEN] DRIVER AIRBAG MODULE [VB-SHORT] DRIVER AIRBAG MODULE [GND-SHORT]

Repair order 쐌 Go to “DIAGNOSTIC PROCEDURE 3”, RS-41 after charging battery.

쐌 Go to “DIAGNOSTIC PROCEDURE 3”, RS-41.

쐌 Driver air bag module circuit is open. (including the spiral cable)

1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 쐌 Driver air bag module circuit is shorted to some power supply 3. If the harness check result is OK, circuit. (including the spiral cable) replace driver air bag module (Before disposal of it, it must be deployed.), air bag diagnosis sensor 쐌 Driver air bag module circuit is shorted to ground. (including unit and spiral cable. the spiral cable)

DRIVER AIRBAG MODULE [SHORT]

쐌 Driver air bag module circuits are shorted to each other.

ASSIST A/B MODULE [VB-SHORT]

쐌 Passenger air bag module circuit is shorted to some power supply circuit.

ASSIST A/B MODULE [OPEN]

쐌 Passenger air bag module circuit is open.

ASSIST A/B MODULE [GND-SHORT]

쐌 Passenger air bag module circuit is shorted to ground.

ASSIST A/B MODULE [SHORT]

쐌 Passenger air bag module circuits are shorted to each other.

PRE-TEN FRONT LH [OPEN]

쐌 The circuit for driver seat belt pre-tensioner is open.

PRE-TEN FRONT LH [VB-SHORT]

쐌 The circuit for driver seat belt pre-tensioner is shorted to some power supply circuit.

PRE-TEN FRONT LH [GND-SHORT]

쐌 The circuit for driver pre-tensioner is shorted to ground.

PRE-TEN FRONT RH [OPEN]

쐌 The circuit for passenger seat belt pre-tensioner is open.

PRE-TEN FRONT RH [VB-SHORT]

쐌 The circuit for passenger seat belt pre-tensioner is open or shorted to some power supply circuit.

PRE-TEN FRONT RH [GND-SHORT]

쐌 The circuit for passenger pre-tensioner is shorted to ground.

RS-46

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 passenger air bag module (Before disposal of it, it must be deployed.), and air bag diagnosis sensor unit. 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 air bag diagnosis sensor unit and driver seat belt. (Before disposing the driver seat belt pre-tensioner, it must be deployed.) 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 air bag diagnosis sensor unit and passenger seat belt. (Before disposing the passenger seat belt pre-tensioner, it must be deployed.)

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Diagnostic item

Explanation

CRASH ZONE SEN [UNIT FAIL] CRASH ZONE SEN [COMM FAIL]

쐌 Crash zone sensor

CONTROL UNIT

쐌 Air bag diagnosis sensor unit is malfunctioning.

Repair order 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 crash zone sensor. 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 air bag diagnosis sensor unit.

GI MA EM LC EC

* Follow the procedures in numerical order when repairing malfunctioning parts, then make the final system check.

FE CL MT

Trouble Diagnoses without CONSULT-II DIAGNOSTIC PROCEDURE 6

SRS800

NGRS0061

AT

NGRS0061S01

Inspecting SRS malfunctioning parts by using “AIR BAG” warning lamp — Diagnosis mode NOTE: SRS will not enter Diagnosis mode if no malfunction is detected in User mode. 1. Turn ignition switch “ON”. 2. After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second. 3. Wait more than 3 seconds. 4. Repeat 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 refer to “DIAGNOSTIC PROCEDURE 7”, RS-51. If the battery voltage is OK, replace the air bag diagnosis sensor unit.

TF PD AX SU BR ST

BT HA SC EL

RS-47

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) No.

“AIR BAG” warning lamp flash pattern — Diagnosis mode — a through b are repeated.

1

SRS333

a through d are repeated. b — Driver and passenger air bag and seat belt pre-tensioner marker (For identifying driver air bag, passenger air bag and/or seat belt pre-tensioners malfunctioning) d — Indicates malfunctioning part. The number of flash varies SRS341 with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.)

2

7.

SRS condition 쐌 Diagnosis results (previously stored in the memory) might not be erased after repair. 쐌 Intermittent malfunction has been detected in the past. Go to “DIAGNOSTIC PROCEDURE 8”, RS-53. The system is malfunctioning and needs to be repaired.

Malfunctioning part is indicated by the number of flashes (part d). Compare the number of flashes to “Air Bag Warning Lamp Flash Code Chart”. Refer to “Air Bag Warning Lamp Flash Code Chart (Diagnosis mode)”, RS-49, 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 “REMOVAL AND INSTALLATION”, RS-14. 10. After repairing the system, refer to “DIAGNOSTIC PROCEDURE 7”, RS-51.

RS-48

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d)

Air Bag Warning Lamp Flash Code Chart (Diagnosis mode) NGRS0061S0101

GI

Flash pattern a through b are repeated.

쐌 Diagnosis results (previously stored in the memory) might not be erased after repair. 쐌 Intermittent malfunction has been detected in the past.

MA EM LC

SRS333

Repair order 쐌 Go to “DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6)”RS-53. Flash pattern a through d are repeated. d — One flash indicates malfunctioning passenger pre-tensioner circuit. The passenger seat belt pre-tensioner circuit is malfunctioning. (d: 1 flash)

EC FE CL MT AT

SRS801

Repair order (Recheck SRS at each replacement. Refer to “SRS Operation Check”, RS-37.) 1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace passenger seat belt pre-tensioner. (Before disposing, it must be deactivated.) 4. Replace the air bag diagnosis sensor unit. 5. Replace the related harness.

TF PD AX

Flash pattern a through d are repeated. d — Two flashes indicate malfunctioning driver air bag module circuit. The driver air bag module circuit is malfuncSRS334 tioning. (d: 2 flashes) Repair order (Recheck SRS at each replacement. Refer to “SRS Operation Check”, RS-37.) 1. 2. 3. 4.

Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the spiral cable. Replace driver air bag module. (Before disposal, it must be deployed.) 5. Replace the air bag diagnosis sensor unit. 6. Replace the related harness.

SU BR ST

BT HA SC EL

RS-49

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Flash pattern a through d are repeated. d — Three flashes indicate malfunctioning driver pre-tensioner circuit. The driver seat belt pre-tensioner circuit is malfunctioning. (d: 3 flashes)

SRS802

Repair order (Recheck SRS at each replacement. Refer to “SRS Operation Check”, RS-37.). 1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace driver seat belt pre-tensioner. (Before disposing, it must be deactivated.) 4. Replace the air bag diagnosis sensor unit. 5. Replace the related harness. Flash pattern a through d are repeated. d — Six flashes indicate malfunctioning crash zone sensor circuit. The crash zone sensor circuit is malfunctioning. (d: 6 flashes) SRS911

Repair order (“Recheck SRS at each replacement”). 1. 2. 3. 4. 5.

Visually check the wiring harness connections. Replace the harness if it has visible damage. Replace crash zone sensor. Replace the diagnosis sensor unit. Replace the related harness. Flash pattern a through d are repeated. d — Seven flashes indicate malfunctioning air bag diagnosis sensor unit.

The air bag diagnosis sensor unit is malfunctioning. (d: 7 flashes)

SRS335

Repair order (Recheck SRS at each replacement. Refer to “SRS Operation Check”, RS-37.) 1. 2. 3. 4.

Visually check the wiring harness connections. Replace the harness if it has visible damage. Replace the air bag diagnosis sensor unit. Replace the related harness.

RS-50

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Flash pattern

The passenger air bag module circuit is malfunctioning. (d: 8 flashes)

a through d are repeated. d — Eight flashes indicate malfunctioning passenger air bag module circuit.

GI MA EM

SRS336

Repair order (Recheck SRS at each replacement. Refer to “SRS Operation Check”, RS-37.)

LC

1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace passenger air bag module. (Before disposal, it must be deployed.) 4. Replace the air bag diagnosis sensor unit. 5. Replace the related harness.

EC FE

* 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.

CL MT

DIAGNOSTIC PROCEDURE 7

NGRS0061S02

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:

AT TF PD AX

SRS800

No.

“AIR BAG” warning lamp flash pattern — Diagnosis mode — a through b are repeated.

1

SRS333

a through d are repeated. b — Driver and passenger air bag and seat belt pre-tensioner marker (For identifying driver air bag, passenger air bag and/or seat belt pre-tensioners malfunctioning) d — Indicates malfunctioning part. The number of flashes varSRS341 ies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.)

2

RS-51

SRS condition

SU

No malfunction is detected or repair is completed. No further action is necessary.

BR

The system is malfunctioning and needs to be repaired.

ST

BT HA SC EL IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d)

NOTE: When diagnosis sensor unit is replaced with 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 the 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. Refer to “DIAGNOSTIC PROCEDURE 6”, RS-47, 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 below. NOTE: 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”. SRS is now in User mode. “AIR BAG” warning lamp operation — User mode —

SRS condition No malfunction is detected. No further action is necessary.

Reference item

—

MRS095A

The system is malfunctioning and needs to be repaired as indicated.

Go to “DIAGNOSTIC PROCEDURE 6”, RS-47.

Air bag is deployed. Seat belt pre-tensioner is deployed.

Go to “COLLISION DIAGNOSIS”, RS-57.

MRS096A

Air bag fuse, air bag diag- Go to “DIAGNOSTIC nosis sensor unit or harPROCEDURE 9”, RS-54. MRS097A ness is malfunctioning and needs to be repaired. One of the following has Go to “DIAGNOSTIC occurred and needs to be PROCEDURE 10”, RS-56. repaired. 쐌 Meter fuse is blown. 쐌 “AIR BAG” warning lamp circuit has open or short. MRS098A 쐌 Air bag diagnosis sensor unit is malfunctioning.

RS-52

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d)

DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6) NGRS0061S03 Inspecting SRS malfunctioning record 1

GI

CONSIDER POSSIBILITY OF NOT ERASING SELF-DIAGNOSTIC RESULT AFTER REPAIRING

MA

Is it the first time for maintenance of SRS? Yes or No Yes

䊳

Go to “DIAGNOSTIC PROCEDURE 5”, RS-44. (Further inspection cannot be performed without CONSULT-II.)

EM

No

䊳

Diagnosis results (previously stored in the memory) might not be erased after repair. Go to “DIAGNOSTIC PROCEDURE 7”, RS-51.

LC EC FE CL MT AT TF PD AX SU BR ST

BT HA SC EL

RS-53

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn Off

Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn Off

=NGRS0062

DIAGNOSTIC PROCEDURE 9 1

NGRS0062S01

SEE THE DEPLOYMENT OF AIR BAG MODULE

Is air bag module deployed? Yes or No Yes

䊳

Refer to “COLLISION DIAGNOSIS”, RS-57.

No

䊳

GO TO 2.

2

CHECK AIR BAG FUSE

Is SRS “AIR BAG” fuse OK?

WRS264

OK or NG OK

䊳

GO TO 4.

NG

䊳

GO TO 3.

3

CHECK AIR BAG FUSE AGAIN

Replace “AIR BAG” fuse and turn ignition switch ON. Is “AIR BAG” fuse blown again? Yes

䊳

Repair main harness.

No

䊳

INSPECTION END

RS-54

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn Off (Cont’d)

4

CHECK DIAGNOSIS SENSOR UNIT

GI

Connect CONSULT-II and touch “START”. 쐌 Is “AIR BAG” displayed on CONSULT-II?

MA EM LC EC SRS771

Yes or No Yes

䊳

GO TO 5.

No

䊳

Visually check the wiring harness connection of air bag diagnosis sensor unit. If the harness connection check result is OK, replace air bag diagnosis sensor unit.

5

FE CL MT

CHECK HARNESS CONNECTION

Is harness connection between warning lamp and air bag diagnosis sensor unit OK? OK or NG OK

䊳

Replace air bag diagnosis sensor unit.

NG

䊳

Connect “AIR BAG” warning lamp and air bag diagnosis sensor unit connector properly. If “AIR BAG” warning lamp still does not go off, replace harness.

AT TF PD AX SU BR ST

BT HA SC EL

RS-55

IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn On

Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn On

=NGRS0063

DIAGNOSTIC PROCEDURE 10 1

NGRS0063S01

CHECK “METER” FUSE

Refer to “Wiring Diagram — SRS —”, RS-34 Is meter fuse OK? OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

CHECK “METER” FUSE AGAIN

Replace meter fuse and turn ignition switch ON. Is meter fuse blown again? Yes

䊳

Repair main harness.

No

䊳

INSPECTION END

3

CHECK HARNESS CONNECTION BETWEEN AIR BAG DIAGNOSIS SENSOR UNIT AND “AIR BAG” WARNING LAMP

Disconnect air bag diagnosis sensor unit connector and turn ignition switch “ON”. 쐌 Does “AIR BAG” warning lamp turn on? Yes or No Yes

䊳

Replace air bag diagnosis sensor unit.

No

䊳

Check the ground circuit of “AIR BAG” warning lamp. If ground circuit is OK, replace combination meter.

RS-56

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Collision Diagnosis

Collision Diagnosis

=NGRS0064

To repair the SRS, perform the following steps. When SRS is activated in a collision: 1) Replace the air bag diagnosis sensor unit. 2) Remove the air bag modules and seat belt pre-tensioner assemblies. 3) Check the SRS components using the table shown below: 쐌 Replace any SRS components showing visible signs of damage (dents, cracks and deformation). 4) Install new air bag modules and seat belt pre-tensioner assemblies. 5) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check”, 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: 쐌 Replace any SRS components showing visible signs of damage (dents, cracks and deformation). 2) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check”, RS-37. Ensure entire SRS operates properly.

SRS INSPECTION (FOR FRONTAL COLLISION) Part

SRS is activated

Air bag module (driver REPLACE and passenger side) Install with new special bolts coated with bonding agent.

Seat belt pre-tensioner assembly

Crash zone sensor

Air bag diagnosis sensor unit

Steering wheel

REPLACE Install seat belt pretensioner with new bolts.

GI MA EM LC EC FE

NGRS0064S01

SRS is NOT activated 1. Remove air bag module. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. 2. a. Install driver air bag module into the steering wheel to check fit and alignment with the wheel. b. Install passenger 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 air bag modules with new special bolts coated with bonding agent. Air bag must be deployed before discarding. 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 seat belt pre-tensioner assembly. 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.

CL MT AT TF PD AX SU

REPLACE the crash 1. Remove the crash zone sensor. Check harness connectors for damage, terminals for deformities, and harness for binding. zone sensor and bracket with new nuts 2. Check for visible signs of damage (dents, cracks, deformation) of the crash and bolts coated with zone sensor and bracket. 3. Install the crash zone sensor to check fit. bonding agent. 4. If no damage is found, reinstall the crash zone sensor with new nuts coated with bonding agent. 5. If damaged—REPLACE the crash zone sensor and bracket with new nuts and bolts coated with bonding agent.

BR

REPLACE Install with new bolts coated with bonding agent.

BT

1. 2. 3. 4. 5. 6.

1. Check case for dents, cracks or deformities. 2. Check connectors for damage, and terminals for deformities. 3. If no damage is found, reinstall with new special bolts and ground bolt coated with bonding agent. 4. If damaged—REPLACE. Install diagnosis sensor unit with new special bolts and ground bolt coated with bonding agent.

Visually check steering wheel for deformities. Check harness and connectors for damage, and terminals for deformities. Install air bag module to check fit or alignment with steering wheel. Check steering wheel for excessive free play. If no damage is found, reinstall with new bolts. If damaged—REPLACE.

RS-57

ST

HA SC EL IDX

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Collision Diagnosis (Cont’d) Part Spiral cable

SRS is activated 1. 2. 3. 4. 5.

Harness and Connec- 1. tors 2. 3. 4. Instrument panel

SRS is NOT activated

Visually check spiral cable and combination switch for damage. Check connectors and protective tape for damage. Check steering wheel for noise, binding or heavy operation. If no damage is found, reinstall with new bolts. If damaged—REPLACE. Check connectors for poor connection, damage, and terminals for deformities. Check harness for binding, chafing, cuts, or deformities. If no damage is found, reinstall the harness and connectors. Damaged—REPLACE damaged harness. Do not attempt to repair, splice or modify any SRS harness.

1. When passenger air bag inflates, check the following points for bending, deformities or cracks. 쐌 Opening portion for passenger air bag

ARS237

쐌 Passenger air bag module brackets

ARS238

쐌 The portions securing the instrument panel

ARS372

2. If no damage is found, reinstall the instrument panel. 3. If damaged—REPLACE the instrument panel with new bolts.

RS-58

BODY & TRIM SECTION

BT

GI MA EM LC EC

CONTENTS PRECAUTIONS ...............................................................2 Service Notice..............................................................2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 PREPARATION ...............................................................3 Special Service Tools ..................................................3 Commercial Service Tools ...........................................3 SQUEAK AND RATTLE TROUBLE DIAGNOSES.........4 Work Flow....................................................................4 CUSTOMER INTERVIEW ...........................................4 DUPLICATE THE NOISE AND TEST DRIVE ................5 CHECK RELATED SERVICE BULLETINS ...................5 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE .....................................................................5 REPAIR THE CAUSE .................................................5 CONFIRM THE REPAIR .............................................6

Generic Squeak and Rattle Troubleshooting ..............6 INSTRUMENT PANEL ................................................6 CENTER CONSOLE ..................................................6 DOORS.....................................................................6 TRUNK .....................................................................7 SUNROOF AND HEADLINER .....................................7 SEATS ......................................................................7 UNDERHOOD ...........................................................7 Diagnostic Worksheet..................................................8 CLIP AND FASTENER..................................................10 Description .................................................................10 BODY FRONT END.......................................................12 Removal and Installation ...........................................12 FRONT BUMPER ASSEMBLY ..................................12 BODY REAR END AND OPENER................................15 Removal and Installation ...........................................15 REAR BUMPER ASSEMBLY ....................................15 FRONT DOOR ...............................................................18 Overhaul ....................................................................18 REAR DOOR .................................................................19 Overhaul ....................................................................19

INSTRUMENT PANEL ASSEMBLY .............................20 Removal and Installation ...........................................20 SIDE AND FLOOR TRIM...............................................24 Removal and Installation ...........................................24 DOOR TRIM ...................................................................27 Removal and Installation ...........................................27 ROOF TRIM ...................................................................30 Removal and Installation ...........................................30 BACK DOOR TRIM .......................................................31 Removal and Installation ...........................................31 EXTERIOR .....................................................................32 Removal and Installation ...........................................32 FRONT SEAT ................................................................37 Removal and Installation ...........................................37 REAR SEAT...................................................................38 Removal and Installation ...........................................38 SUNROOF......................................................................39 Removal and Installation ...........................................39 WINDSHIELD AND WINDOWS ....................................40 Removal and Installation ...........................................40 REMOVAL ...............................................................40 INSTALLATION........................................................40 WINDSHIELD ..........................................................41 ................................ REAR SIDE WINDOW ..............................................42 REAR VIEW MIRROR ...................................................44 Removal.....................................................................44 Installation..................................................................44 DOOR MIRROR .............................................................45 Removal and Installation ...........................................45 CAB AND REAR BODY................................................46 Body Mounting...........................................................46 BODY (ALIGNMENT) ....................................................47 Alignment ...................................................................47 ENGINE COMPARTMENT ........................................48 UNDERBODY ..........................................................50

FE CL MT AT TF PD AX SU BR ST RS

HA SC EL IDX

PRECAUTIONS Service Notice

Service Notice 쐌 쐌 쐌 쐌 쐌

NGBT0001

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”

NGBT0002

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 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), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, seat belt buckle switches, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

BT-2

PREPARATION Special Service Tools

Special Service Tools

NGBT0027

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

GI

Description

MA Locating the noise

(J-39570) Chassis Ear

EM LC EC FE ABT465

CL

Locating the noise

(J-43980) NISSAN Squeak and Rattle Kit

MT AT TF PD ABT474

AX

Commercial Service Tools Tool name

NGBT0028

SU

Description

Engine Ear

Locating the noise

BR ST RS

HA

ABT466

SC EL

BT-3

IDX

NGBT0026

SQUEAK AND RATTLE TROUBLE DIAGNOSES Work Flow

Work Flow

NGBT0026S01

ABT488

CUSTOMER INTERVIEW

NGBT0026S0101

Interview the costumer, if possible, to determine the conditions that exist when the noise occurs. Use the Diagnostic Worksheet during the interview to document the facts and conditions when the noise occurs and any customers comments; refer to “Diagnostic Worksheet”, BT-8. This information is necessary to duplicate the conditions that exist when the noise occurs. 쐌 The customer may not be able to provide a detail description or location of the noise. Attempt to obtain all the facts and conditions that exist when the noise occurs (or does not occur). 쐌 If there is more than one noise in the vehicle , be sure to diagnose and repair the noise that the customer is concerned about. This can be accomplished by test driving the vehicle with the customer. 쐌 After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics are provided so the customer, service adviser and technician are all speaking the same language when defining the noise. 쐌 Squeak-(Like tennis shoes on a clean floor) Squeak characteristics include the light contact / fast movement / brought on by road conditions / hard surfaces = higher pitch noise / softer surfaces = lower pitch noises / edge to surface = chirping. 쐌 Creak-(Like walking on an old wooden floor) Creak characteristics include firm contact / slow movement / twisting with a rotational movement / pitch dependent on materials / often brought on by activity. 쐌 Rattle-(Like shaking a baby rattle) Rattle characteristics include the fast repeated contact / vibration or similar movement / loose parts / missing clip or fastener / incorrect clearance. 쐌 Knock-(Like a knock on a door) Knock characteristics include hollow sound / something repeating / often brought on by driver action. 쐌 Tick-(Like a clock second hand) Tick characteristics include light contact of light material / loose components / can be caused by driver action on road conditions. 쐌 Thump-(Heavy, muffled knock noise) Thump characteristics include softer knock / dead sound often brought on by activity. 쐌 Buzz-(Like a bumblebee) Buzz characteristics include high frequency rattle / firm contact 쐌 Often the degree of acceptable noise level will vary depending upon the person. A noise that you may judge as acceptable may be very irritating to the customer. 쐌 Weather conditions, especially humidity and temperature, may have a great effect on noise level.

BT-4

SQUEAK AND RATTLE TROUBLE DIAGNOSES Work Flow (Cont’d)

DUPLICATE THE NOISE AND TEST DRIVE

NGBT0026S0102

If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on the Diagnostic Worksheet regarding the conditions or locations of the noise. This information can be used to duplicate the same conditions when you confirm the repair. If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to duplicate the noise with the vehicle stopped by doing one or all of the following: 1) Close a door. 2) Tap or push / pull around the area where the noise appears to be coming from. 3) Rev the engine. 4) Use a floor jack to recreate vehicle “twist”. 5) At idle, apply engine load (electric load, half-clutch on M/T model, drive position on A/T model). 6) Raise the vehicle on a hoist and hit a tire with rubber hammer. 쐌 Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs. 쐌 If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the vehicle body.

GI MA EM LC EC FE

CHECK RELATED SERVICE BULLETINS

NGBT0026S0103

After verifying the customer concern or symptom, check ASSIST for Technical Service Bulletins (TSBs) related to that concern or symptom. If a TSB relates to the symptom, follow the procedure to repair the noise.

LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE

NGBT0026S0104

1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool (Chassis Ear : J-39570, Engine Ear and mechanic’s stethoscope). 2. Narrow down the noise to a more specific area and identify the cause of the noise by: 쐌 Removing the components in the area that you suspect the noise is coming from. Do not use too much force when removing clips and fasteners, otherwise clips and fasteners can be broken or lost during the repair, resulting in the creation of new noise. 쐌 Tapping or pushing/pulling the component that you suspect is causing the noise. Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only temporarily. 쐌 Feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the noise. 쐌 Placing a piece of paper between components that you suspect are causing the noise. 쐌 Looking for loose components and contact marks. Refer to Generic Squeak and Rattle Troubleshooting.

REPAIR THE CAUSE

NGBT0026S0105

쐌 쐌 − −

If the cause is a loose component, tighten the component securely. If the cause is insufficient clearance between components: Separate components by repositioning or loosening and retightening the component, if possible. insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or urethane tape. A NISSAN Squeak and Rattle Kit (J-43980) is available through your authorized NISSAN Parts Department. CAUTION: Do not use excessive force as many components are constructed of plastic and may be damaged. Always check with the Parts Department for the latest parts information. The following material are contained in the NISSAN Squeak and Rattle Kit (J-43980) Each item can be ordered separately as needed. URETHANE PADS (1.5 mm thick) insulates connectors, harness, etc. 76268–9E005 : 100 x 135 mm / 76884–71L01 : 60 x 85 mm / 76884–71L02 : 15 x 25 mm INSULATOR (foam blocks) Insulates components from contact. Can be used to fill space behind a panel. 73982–9E000 : 45 mm thick, 50 x 50 mm / 73982–50Y00 : 10 mm thick, 50 x 50 mm

BT-5

CL MT AT TF PD AX SU BR ST RS

HA SC EL IDX

SQUEAK AND RATTLE TROUBLE DIAGNOSES Work Flow (Cont’d)

INSULATOR (Light foam block) 80845–71L00 :30 mm thick, 30 x 50 mm FELT CLOTH TAPE Used to insulate where movement does not occur. Ideal for instrument panel applications. 68370–4B000 : 15 x 25 mm pad / 68239–13E00 : 5 mm wide tape roll The following materials, not found in the kit, can also be used to repair squeaks and rattles. UHMW (TEFLON) TAPE Insulates where slight movement is present. Ideal for instrument panel applications. SILICONE GREASE Used in place of UHMW tape that will be visible or not fit. Note : Will only last a few months. SILICONE SPRAY Use when grease cannot be applied. DUCT TAPE Use to eliminate movement.

CONFIRM THE REPAIR

NGBT0026S0106

Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.

Generic Squeak and Rattle Troubleshooting

NGBT0026S02

INSTRUMENT PANEL

NGBT0026S0201

Most incidents are caused by contact and movement between: 1. Cluster lid A and instrument panel 2. Acrylic lens and combination meter housing 3. Instrument panel to front pillar garnish 4. Instrument panel to windshield 5. Instrument panel mounting pins 6. Wiring harness behind the combination meter 7. A/C defroster duct and duct joint These incidents can usually be located by tapping or moving the components to duplicate the noise or by pressing on the components while driving to stop the noise. Most of these incidents can be repaired by applying felt cloth tape or silicone spray (in hard to reach areas). Urethane pads can be used to insulate wiring harness. CAUTION: Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will not be able to recheck the repair.

CENTER CONSOLE

NGBT0026S0202

Components to pay attention to include: 1. Shifter assembly cover to finisher. 2. A/C control unit and cluster lid C 3. Wiring harness behind audio and A/C control unit The instrument panel repair and isolation procedures also apply to center console.

DOORS

NGBT0026S0203

Pay attention to the: 1. Finisher on inner panel making a slapping noise 2. Inside handle escutcheon to door finisher 3. Wiring harnesses tapping 4. Door striker out of alignment causing a popping noise on starts and stops Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate many of these incidents. You can usually insulate the areas with felt cloth or insulator foam blocks from the NISSAN Squeak and Rattle Kit (J-43980) to repair the noise.

BT-6

SQUEAK AND RATTLE TROUBLE DIAGNOSES Generic Squeak and Rattle Troubleshooting (Cont’d)

TRUNK

NGBT0026S0204

Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner. In addition look for: 1. Trunk lid bumpers out of adjustment 2. Trunk lid striker out of adjustment 3. The trunk lid torsion bars knocking together 4. A loose license plate or bracket Most of these incidents can be repaired by adjusting, securing, or insulating the item(s) or component(s) causing the noise.

SUNROOF AND HEADLINER

NGBT0026S0205

Noises in the sunroof and headliner area can often be traced to one of the following: 1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise 2. Sunvisor shaft shaking in the holder 3. Front or rear windshield touching headliner and squeaking Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these incidents. Repairs usually consist of insulating with felt cloth tape.

SEATS

NGBT0026S0206

When isolating seat noises it’s important to note the position of the seat and the load placed on the seat when the noise is present. These conditions should be duplicated when verifying and isolating the cause of the noise. Cause of seat noise include: 1. Headrest rods and holders 2. A squeak between the seat pad cushion and frame 3. The rear seat back lock and bracket These noises can be isolated by moving or pressing on the suspected components while duplicating the conditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component or applying urethane tape to the contact area.

GI MA EM LC EC FE CL MT AT TF PD

UNDERHOOD

NGBT0026S0207

Some interior noises may be caused by components under the hood or on the engine wall. The noise is then transmitted into the passenger compartment. Causes of transmitted underhood noises include: 1. Any components mounted to the engine wall 2. Components that pass through the engine wall 3. Engine wall mounts and connectors 4. Loose radiator mounting pins 5. Hood striker out of adjustment These noises can be difficult to isolate since they can not be reached from the interior of the vehicle. The best method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM or load can be changed to isolate the noise. Repair can usually be made by moving, adjusting, securing, or insulating the component causing the noise.

AX SU BR ST RS

HA SC EL

BT-7

IDX

SQUEAK AND RATTLE TROUBLE DIAGNOSES Diagnostic Worksheet

Diagnostic Worksheet

NGBT0026S03

ABT468

BT-8

SQUEAK AND RATTLE TROUBLE DIAGNOSES Diagnostic Worksheet (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC ABT469

EL

BT-9

IDX

CLIP AND FASTENER Description

Description 쐌 쐌

NGBT0003

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

C101

SBF302H SBF367BA

C103

SBT095 SBF423H

C203

SBF258G SBF708E

CE103

SBF104B SBF147B

BT-10

CLIP AND FASTENER Description (Cont’d) Symbol No.

Shapes

Removal & Installation

GI MA CG104

EM

SBF352C

SBF351C

LC EC

CE114

—

FE

SBF353C

CL MT

CG101

AT SBF145B

TF SBF085B

PD AX CR103

SU SBF768B

BR SBF770B

ST RS CS101

HA

SBF078B SBF992G

SC EL

BT-11

IDX

BODY FRONT END Removal and Installation

Removal and Installation 쐌 쐌 쐌 쐌 쐌

FRONT BUMPER ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9.

NGBT0004

When removing or installing hood, place a cloth or other padding on hood. 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. Remove Remove Remove Remove Remove Remove Remove Remove Remove

NGBT0004S01

clips securing front grille and remove the front grille. the side marker lamps. bolts securing left and right bumper stays. the lower grille opening trim. bolts securing left and right bumper side brackets. the front fascia. bolts securing left and right bumper from bumper brackets. bumper assembly. the frame crossmember.

BT-12

BODY FRONT END Removal and Installation (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC LBT168

EL

BT-13

IDX

BODY FRONT END Removal and Installation (Cont’d)

LBT169

BT-14

BODY REAR END AND OPENER Removal and Installation

Removal and Installation 쐌 쐌

Remove Remove Remove Remove

GI MA

REAR BUMPER ASSEMBLY 1. 2. 3. 4.

NGBT0005

Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it. Back door lock system adjustment: Adjust lock and striker so that they are in the center. After adjustment, check back door lock operation. NGBT0005S01

screws securing left and right bumper side. bumper side left and right. nuts securing rear bumper. rear bumper.

EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC EL

BT-15

IDX

BODY REAR END AND OPENER Removal and Installation (Cont’d)

ABT443

BT-16

BODY REAR END AND OPENER Removal and Installation (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC WBT197

EL

BT-17

IDX

FRONT DOOR Overhaul

Overhaul 쐌 쐌

NGBT0006

For removal of door trim, refer to “Removal and Installation”, BT-27. After adjusting door or door lock, check door lock operation.

WBT171

BT-18

REAR DOOR Overhaul

Overhaul

NGBT0023

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC WBT172

BT-19

EL IDX

INSTRUMENT PANEL ASSEMBLY Removal and Installation

Removal and Installation

NGBT0008

CAUTION: 쐌 Disconnect both terminals from battery in advance. 쐌 Disconnect air bag module connectors in advance. 쐌 Be careful not to scratch finishers and other parts. 쐌 Never tamper with or force air bag lid open, as this may adversely affect air bag performance.

LBT187

BT-20

INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d)

GI MA EM LC EC FE CL MT AT LBT188

*1

RS-19

*2

TF

BT-24

PD AX SU BR ST RS

HA SC EL

BT-21

IDX

INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d)

WBT198

BT-22

INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC WBT199

EL

BT-23

IDX

SIDE AND FLOOR TRIM Removal and Installation

Removal and Installation CAUTION: Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnishes. 1. Remove front and rear seats . Refer to “Removal and Installation”, BT-37 or 38. 2. Remove front and rear kicking plates. 3. Remove dash side lower finishers. 4. Remove front and rear body side welts. 5. Remove RH front pillar assist grip. 6. Remove front pillar garnishes. 7. Remove center pillar lower garnishes. 8. Remove center pillar upper garnishes. 9. Remove rear gate kicking plate. 10. Remove rear wheel well garnish. 11. Remove rear side lower garnishes. 12. Remove cargo hooks. 13. Remove rear side upper garnishes.

BT-24

NGBT0009

SIDE AND FLOOR TRIM Removal and Installation (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC WBT200

EL

BT-25

IDX

SIDE AND FLOOR TRIM Removal and Installation (Cont’d)

WBT201

BT-26

DOOR TRIM Removal and Installation

Removal and Installation Door trim (Formed type) Remove manual window regulator handle, if equipped. 1. Remove inside handle escutcheon. 2. Remove door armrest. 3. Remove screw securing door pull handle. 4. Remove power window switch, then disconnect the connector. 5. Remove two screws. 6. Remove clips securing door finisher. 7. Lift out door finisher. 8. Remove inside escutcheon. 9. Remove screw securing door pull handle. 10. Remove clips securing door finisher. 11. Lift out door finisher.

NGBT0010

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC EL

BT-27

IDX

DOOR TRIM Removal and Installation (Cont’d)

WBT183

BT-28

DOOR TRIM Removal and Installation (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC ABT299

EL

BT-29

IDX

ROOF TRIM Removal and Installation

Removal and Installation 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove

NGBT0011

the front map lamps (if equipped). front and rear seats. Refer to “Removal and Installation”, BT-37 or 38. front and rear seat belts. Refer to “SEAT BELTS”, RS-4 or RS-5. the rear roof garnish trim. body side trim. Refer to “SIDE AND FLOOR TRIM”, BT-24. sun visors. assist grips. interior lamp assembly and luggage room lamp assembly. clips securing headlining. coat hooks. sunroof welt (if equipped). headlining.

WBT174

BT-30

BACK DOOR TRIM Removal and Installation

Removal and Installation 1. 2.

NGBT0024

Remove back door grip. Remove back door finisher assembly.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS WBT082

HA SC EL

BT-31

IDX

EXTERIOR Removal and Installation

Removal and Installation

NGBT0013

ABT453

BT-32

EXTERIOR Removal and Installation (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC WBT175

EL

BT-33

IDX

EXTERIOR Removal and Installation (Cont’d)

WBT176

BT-34

EXTERIOR Removal and Installation (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC WBT177

EL

BT-35

IDX

EXTERIOR Removal and Installation (Cont’d)

WBT203

BT-36

FRONT SEAT Removal and Installation

Removal and Installation 쐌

NGBT0014

When removing and installing the seat trim, carefully handle it to keep dirt out and avoid damage.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC EL WBT164

BT-37

IDX

REAR SEAT Removal and Installation

Removal and Installation

NGBT0015

WBT153

BT-38

SUNROOF Removal and Installation

Removal and Installation 쐌

NGBT0016

Roof rack and gear basket must be removed before sunroof removal.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC EL ABT464

BT-39

IDX

WINDSHIELD AND WINDOWS Removal and Installation

Removal and Installation REMOVAL

SBF034B

쐌

SBT473

NGBT0017S01

After removing moldings, remove glass using piano wire or power cutting tool and an inflatable pump bag. WARNING: When cutting the glass from the vehicle, always wear safety glasses and heavy gloves to help prevent glass splinters from entering your eyes or cutting your hands. CAUTION: 쐌 Be careful not to scratch the glass when removing. 쐌 Do not set or stand the glass on its edge. Small chips may develop into cracks.

INSTALLATION

SBT472

NGBT0017

NGBT0017S02

Use genuine NISSAN Urethane Adhesive Kit or equivalent and follow the instructions furnished with it. 쐌 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. 쐌 The molding must be installed securely so that it is in position and leaves no gap. 쐌 Inform the customer that the vehicle should remain stationary until the urethane adhesive has completely cured (preferably 24 hours). Curing time varies with temperature and humidity. WARNING: 쐌 Keep heat and open flames away as primers and adhesive are flammable. 쐌 The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Avoid contact with the skin and eyes. 쐌 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. 쐌 Driving the vehicle before the urethane adhesive has completely cured may affect the performance of the windshield in case of an accident. CAUTION: 쐌 Do not use an adhesive which is past its usable term. Shelf life of this product is limited to six months after the date of manufacture. Carefully adhere to the expiration or manufacture date printed on the box. 쐌 Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator.

BT-40

WINDSHIELD AND WINDOWS Removal and Installation (Cont’d)

쐌 쐌

Do not leave primers or adhesive cartridge unattended with their caps open or off. The vehicle should not be driven for at least 24 hours or until the urethane adhesive has completely cured. Curing time varies depending on temperature and humidities. The curing time will increase under higher temperatures and lower humidities.

WINDSHIELD

NGBT0017S03

GI MA EM LC EC FE CL MT AT TF PD AX

WBT095

SU BR ST RS

HA SC EL

BT-41

IDX

WINDSHIELD AND WINDOWS Removal and Installation (Cont’d)

REAR SIDE WINDOW

NGBT0017S04

ABT448

BT-42

WINDSHIELD AND WINDOWS Removal and Installation (Cont’d) NGBT0017S05

Repairing Water Leaks for Windshield, Side Window NGBT0017S0501 Leaks can be repaired without removing and reinstalling glass. If water is leaking between urethane adhesive material and body or glass, determine the extent of leakage. This can be done by applying water to the windshield or side window area while pushing glass outward. To stop the leak, apply primer (if necessary) and then urethane adhesive to the leak point.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC EL

BT-43

IDX

REAR VIEW MIRROR Removal

Removal

NGBT0018

Remove rear view mirror by deflecting spring with screwdriver as shown in the figure.

ABT188

Installation 1. a.

b. c. d. ABF150

e. f. g. h. 2.

NGBT0019

Install mounting bracket as follows: Determine mounting bracket position on windshield by measuring from top of windshield to top of mounting bracket as shown in the figure. Mark location on outside of windshield with wax pencil or equivalent. Clean attaching point on inside of windshield with an alcoholsaturated paper towel. Sand bonding surface of mounting bracket with sandpaper (No. 320 or No. 360). Clean bonding surface of mounting bracket with an alcoholsaturated paper towel. Apply Loctite Adhesive 11067-2 or equivalent to bonding surface of mounting bracket. Install mounting bracket at pre-marked position and press mounting bracket against glass for 30 to 60 seconds. After five minutes, wipe off excess adhesive with an alcoholmoistened paper towel. Install rear view mirror.

BT-44

DOOR MIRROR Removal and Installation

Removal and Installation

NGBT0020

CAUTION: Be careful not to scratch door rear view mirror body. ★ For Wiring Diagram, refer to EL-154, “DOOR MIRROR”. 1. Remove door trim or inner cover from front corner of door. Refer to “Removal and Installation”, BT-27. 2. Disconnect door mirror harness connector. 3. Remove bolts securing door mirror, then remove door mirror assembly.

GI MA EM LC EC FE CL MT AT TF PD AX

ABT300

SU BR ST RS

HA SC EL

BT-45

IDX

CAB AND REAR BODY Body Mounting

Body Mounting

NGBT0021

When removing, be sure to replace bolts and nuts (sealant applied bolts or self-lock nuts are used for all mounting).

WBT202

BT-46

BODY (ALIGNMENT) Alignment

Alignment 쐌 쐌 쐌 쐌 쐌 쐌

NGBT0022

All dimensions indicated in the figures are actual. When using a tracking gauge, adjust both pointers to equal length, then check pointers and the gauge 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”.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC WBT184

EL

BT-47

IDX

BODY (ALIGNMENT) Alignment (Cont’d)

ENGINE COMPARTMENT Measurement

NGBT0022S01 NGBT0022S0103

ABM374

Figure marked with * indicate symmetrically identical dimensions on both right- and left-hand sides of the vehicle.

BT-48

BODY (ALIGNMENT) Alignment (Cont’d)

Measurement Points

NGBT0022S0104

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC ABT314

BT-49

EL IDX

BODY (ALIGNMENT) Alignment (Cont’d)

UNDERBODY Measurement

NGBT0022S02 NGBT0022S0205

WBT084

BT-50

BODY (ALIGNMENT) Alignment (Cont’d)

Measurement Points

NGBT0022S0206

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

HA SC ABM437

BT-51

EL IDX

NOTES

HEATER & AIR CONDITIONER SECTION

HA

GI MA EM LC EC

CONTENTS PRECAUTIONS ...............................................................2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 Precautions for Working with HFC-134a (R-134a) .....3 Contaminated Refrigerant............................................3 General Refrigerant Precautions .................................3 Precautions for Leak Detection Dye............................4 A/C Identification Label................................................4 Precautions for Refrigerant Connection ......................4 Precautions for Servicing Compressor........................8 Precautions for Service Equipment .............................8 Wiring Diagrams and Trouble Diagnosis...................11 PREPARATION .............................................................12 Special Service Tools ................................................12 HFC-134a (R-134a) Service Tools and Equipment..................................................................13 Commercial Service Tool...........................................16 DESCRIPTION ...............................................................17 Refrigeration System .................................................17 Control Operation ......................................................18 Discharge Air Flow.....................................................19 Component Layout ....................................................20 TROUBLE DIAGNOSES................................................22 Component Location..................................................22 Wiring Diagram - A/C - ..............................................26 How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................28

Symptom Table ..........................................................28 Operational Check .....................................................29 Blower Motor..............................................................31 Mode Door .................................................................38 Intake Door Motor......................................................40 Magnet Clutch............................................................43 Insufficient Cooling ....................................................53 Insufficient Heating ....................................................61 Noise..........................................................................63 SERVICE PROCEDURE................................................64 HFC-134a (R-134a) Service Procedure ....................64 Maintenance of Lubricant Quantity in Compressor ...............................................................66 Compressor ...............................................................70 Magnet Clutch............................................................72 Thermal Protector ......................................................76 Refrigerant Lines .......................................................77 Checking for Refrigerant Leaks.................................79 Electronic Refrigerant Leak Detector ........................79 Fluorescent Dye Leak Detector.................................82 In-cabin Microfilter .....................................................83 Belt.............................................................................84 IACV-FICD Solenoid Valve ........................................84 Heater Core ...............................................................84 Evaporator Core ........................................................85 SERVICE DATA AND SPECIFICATIONS (SDS) .........87 Manual .......................................................................87

FE CL MT AT TF PD AX SU BR ST RS BT

SC EL IDX

PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGHA0060

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 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), 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 this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

HA-2

PRECAUTIONS Precautions for Working with HFC-134a (R-134a)

Precautions for Working with HFC-134a (R-134a)

=NGHA0061

WARNING: 쐌 CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants are mixed, compressor failure is likely to occur. Refer to “Contaminated Refrigerant”, HA-3. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant Recovery/Recycling Recharging equipment (ACR4) (J-39500–NI) and Refrigerant Identifier. 쐌 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. 쐌 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 R) to come in contact with styrofoam parts. Damage may result.

Contaminated Refrigerant

NGHA0267

If a refrigerant other than pure R-134a is identified in a vehicle, your options are: 쐌 Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into the atmosphere. 쐌 Explain that recovery of the contaminated refrigerant could damage your service equipment and refrigerant supply. 쐌 Suggest the customer return the vehicle to the location of previous service where the contamination may have occurred. 쐌 If you choose to perform the repair, recover the refrigerant using only dedicated equipment and containers. Do not recover contaminated refrigerant into your existing service equipment. If your facility does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for available service. This refrigerant must be disposed of in accordance with all federal and local regulations. In addition, replacement of all refrigerant system components on the vehicle is recommended. 쐌 If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact Nissan Customer Affairs for further assistance.

General Refrigerant Precautions

MA EM LC EC FE CL MT AT TF PD AX SU BR ST

NGHA0062

WARNING: 쐌 Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the refrigerant every time an air conditioning system is discharged. 쐌 Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system. 쐌 Do not store or heat refrigerant containers above 52°C (125°F). 쐌 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. 쐌 Do not intentionally drop, puncture, or incinerate refrigerant containers. 쐌 Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. 쐌 Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suffocation. 쐌 Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and R-134a have been

HA-3

GI

RS BT

SC EL IDX

PRECAUTIONS Precautions for Leak Detection Dye

shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.

Precautions for Leak Detection Dye 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NGHA0287

The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks. Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of the fluorescent dye. A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995). Always remove any dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service. Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). Do not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system. Leak detection dyes for R-134a and R12 A/C systems are different. Do not use R-134a leak detection dye in R-12 A/C system or R-12 leak detection dye in R-134a A/C systems or A/C system damage may result. The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure occurs.

A/C Identification Label

NGHA0288

Vehicles with factory installed fluorescent dye have this identification label on the under side of hood. NOTE: Vehicles with factory installed fluorescent dye have a green label.

LHA242

Precautions for Refrigerant Connection

NGHA0063

A new type refrigerant connection has been introduced to all refrigerant lines except the following portion. 쐌 Thermal expansion valve connections.

FEATURES OF NEW TYPE REFRIGERANT CONNECTION 쐌 쐌

NGHA0063S01

The O-ring is relocated in a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections.

HA-4

PRECAUTIONS Precautions for Refrigerant Connection (Cont’d)

GI MA EM LC EC FE AHA534A

CL MT AT TF PD AX SU BR ST RS BT

SC EL

HA-5

IDX

PRECAUTIONS Precautions for Refrigerant Connection (Cont’d)

O-RING AND REFRIGERANT CONNECTION KA24DE Models

=NGHA0063S02 NGHA0063S0202

LHA238

VG33E and VG33ER Models

NGHA0063S0203

LHA239

CAUTION: Refrigerant connections in some systems use different O-ring configurations. Do not confuse O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at or around the connection.

HA-6

PRECAUTIONS Precautions for Refrigerant Connection (Cont’d)

O-Ring Part Numbers and Specifications

=NGHA0063S0201

Connection type

O-ring size

Part number*

D

92471 N8210

6.8 (0.268)

1.85 (0.0728)

Former

92470 N8200

6.07 (0.23990)

1.78 (0.0701)

New

92472 N8210

10.9 (0.429)

2.43 (0.0957)

92475 71L00

11.0 (0.433)

2.4 (0.094)

New

mm (in)

W

mm (in)

8

GI MA EM

12 Former

SHA814E

New

16

92473 N8210

13.6 (0.535)

2.43 (0.0957)

New

19

92474 N8210

16.5 (0.650)

2.43 (0.0957)

*: Always check with the Parts Department for the latest parts information.

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. 쐌 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. 쐌 When connecting tubes, always use a torque wrench and a back-up wrench. 쐌 After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. 쐌 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 required for connection. 쐌 Allow components stored in cool areas to warm to working area temperature before removing seal caps. This prevents condensation from forming inside A/C components. 쐌 Thoroughly remove moisture from the refrigeration system before charging the refrigerant. 쐌 Always replace used O-rings. 쐌 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 Lubricant Type R Part number: KLH00-PAGR0 쐌 O-ring must be closely attached to inflated portion of tube. 쐌 After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque. 쐌 After connecting line, conduct leak test and make sure that there is no leakage. 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.

LC EC FE CL MT AT TF PD AX SU BR ST RS BT

SC EL

HA-7

IDX

PRECAUTIONS Precautions for Servicing Compressor

AHA514A

Precautions for Servicing Compressor 쐌 쐌 쐌 쐌 쐌 쐌

NGHA0064

Plug all openings to prevent moisture and foreign matter from entering. Do not keep the compressor in the upside down position or laid on its side for more than 10 minutes. When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compressor” exactly. Refer to “Maintenance of Lubricant Quantity in Compressor”, HA-66. 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.

Precautions for Service Equipment RECOVERY/RECYCLING EQUIPMENT

NGHA0065 NGHA0065S01

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

NGHA0065S02

Follow the manufacturer’s instructions for tester operation and tester maintenance.

HA-8

PRECAUTIONS Precautions for Service Equipment (Cont’d)

VACUUM PUMP

NGHA0065S03

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 situated near the hose-to-pump connection, as follows. 쐌 Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. 쐌 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. 쐌 If the hose has an automatic shut off valve, disconnect the hose from the pump: when 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. AHA559A

MANIFOLD GAUGE SET

NGHA0065S04

Be certain that the gauge face indicates R-134a or 134a. Make 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) along with specified lubricant.

GI MA EM LC EC FE CL MT AT TF PD AX

SHA533D

SERVICE HOSES

NGHA0065S05

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.

SU BR ST RS

AHA560A

SERVICE COUPLERS

NGHA0065S06

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

BT

SC

A/C service valve

Clockwise

Open

Counterclockwise

Close

EL

RHA273D

HA-9

IDX

PRECAUTIONS Precautions for Service Equipment (Cont’d)

REFRIGERANT WEIGHT SCALE

NGHA0065S07

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.

CALIBRATING ACR4 WEIGHT SCALE

RHA274D

NGHA0065S10

Calibrate the scale every 3 months. To calibrate the weight scale on the ACR4 (J-39500–NI): 1. Press Shift/Reset and Enter at the same time. 2. Press 8787. “A1” will be displayed. 3. Remove all weight from the scale. 4. Press 0, then press Enter. “0.00” will be displayed and changed to “A2”. 5. Place a known weight (dumbbell or similar weight), between 10 and 19 lbs., on the center of the weight scale. 6. Enter the known weight using 4 digits (Example 10 lbs = 10.00, 10.5 lbs = 10.50). 7. Press Enter — the display returns to the vacuum mode. 8. Press Shift/Reset and Enter at the same time. 9. Press 6 — the known weight on the scale is displayed. 10. Remove the known weight from the scale. “0.00” will be displayed. 11. Press Shift/Reset to return the ACR4 to the program mode.

CHARGING CYLINDER

NGHA0065S08

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.

THERMOMETER AND HYGROMETER

NGHA0065S09

An etched stem-type thermometer and a hygrometer can be used to check the air conditioning system performance. A hygrometer is used because the air conditioning performance depends on the humidity.

AHA274

HA-10

PRECAUTIONS Wiring Diagrams and Trouble Diagnosis

Wiring Diagrams and Trouble Diagnosis

NGHA0066

When you read wiring diagrams, refer to the following: 쐌 Refer to GI-10, “HOW TO READ WIRING DIAGRAMS”. 쐌 Refer to EL-10, “POWER SUPPLY ROUTING”. When you perform trouble diagnosis, refer to the following: 쐌 Refer to GI-33, “How to Follow Test Groups in Trouble Diagnoses”. 쐌 Refer to GI-22, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

SC EL

HA-11

IDX

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 (Kent-Moore No.) Tool name

Description Removing shaft nut and clutch disc

KV99231260 (J-38874) Clutch disc wrench

NT204

Removing clutch disc

KV99232340 (J-38874) Clutch disc puller

NT206

Installing pulley

KV99234330 (J-39024) Pulley installer

NT207

Removing pulley

KV99233130 (J-39023) Pulley puller

NT208

HA-12

=NGHA0286

PREPARATION HFC-134a (R-134a) Service Tools and Equipment

HFC-134a (R-134a) Service Tools and Equipment

=NGHA0068

Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant. Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant. Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will occur and compressor failure will result. Tool number (Kent-Moore No.) Tool name

GI MA EM LC EC

Description

FE Container color: Light blue Container marking: HFC-134a (R-134a) Fitting size: Thread size 쐌 large container 1/2″-16 ACME

HFC-134a (R-134a) refrigerant

CL MT

NT196

Type: Polyalkylene glycol oil (PAG), type R Application: HFC-134a (R-134a) vane rotary compressors (NISSAN only) Lubricity: 40 m
(1.4 US fl oz, 1.4 Imp fl oz)

KLH00-PAGR0 ( — ) NISSAN A/C System Lubricant Type R

AT TF

NT197

Function: Refrigerant Recovery and Recycling and Recharging

(J-39500-NI) Recovery/Recycling Recharging equipment (ACR4)

PD AX SU BR

NT195

Power supply: 쐌 DC 12 V (Cigarette lighter) Function: Checks for refrigerant leaks.

(J-41995) Electrical leak detector

ST RS BT

AHA281A

SC EL

HA-13

IDX

PREPARATION HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

(J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety glasses (J-41459) Refrigerant dye injector (J-41447) qty. 24 R-134a refrigerant dye (J-43872) Refrigerant dye cleaner

Power supply: DC 12V (Battery terminal)

SHA437F

(J-42220) Fluorescent dye leak detector

UV lamp

Power supply: DC 12V (Battery terminal) For checking refrigerant leak when fluorescent dye is installed in A/C system. Includes: UV lamp and UV safety glasses

Dye

Application: For R-134a PAG oil Container: 1/4 ounce (7.4 cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.)

Dye injector

For injecting 1/4 ounce of Fluorescent Leak Detection Dye into A/C system.

LHA177

(J-41447) R134a Fluorescent Leak Detection Dye (Box of 24, 1/4 ounce bottles)

SHA439F

(J-41459) R134a Dye Injector Use with J-41447, 1/4 ounce bottle

SHA440F

For cleaning dye spills.

(J-43872) Dye cleaner

SHA441F

HA-14

PREPARATION HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

GI

(J-39183) Manifold gauge set (with hoses and couplers)

Identification: 쐌 The gauge face indicates R-134a. Fitting size: Thread size 쐌 1/2″-16 ACME

MA EM LC

NT199

Hose color: 쐌 Low hose: Blue with black stripe 쐌 High hose: Red with black stripe 쐌 Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: 쐌 1/2″-16 ACME

Service hoses 쐌 High side hose (J-39501-72) 쐌 Low side hose (J-39502-72) 쐌 Utility hose (J-39476-72)

EC FE CL

NT201

Hose fitting to service hose: 쐌 M14 x 1.5 fitting is optional or permanently attached.

Service couplers 쐌 High side coupler (J-39500-20) 쐌 Low side coupler (J-39500-24)

MT AT

NT202

For measuring of refrigerant Fitting size: Thread size 쐌 1/2″-16 ACME

(J-39650) Refrigerant weight scale

TF PD AX

NT200

Capacity: 쐌 Air displacement: 4 CFM 쐌 Micron rating: 20 microns 쐌 Oil capacity: 482 g (17 oz) Fitting size: Thread size 쐌 1/2″-16 ACME

(J-39649) Vacuum pump (Including the isolator valve)

SU BR ST

NT203

RS BT

SC EL

HA-15

IDX

PREPARATION Commercial Service Tool

Commercial Service Tool Tool name

Description

=NGHA0067

Note

Refrigerant Identifier Equipment

Checking refrigerant purity and for system contamination

NT765

For details of handling methods, refer to the Instruction Manual attached to the service tool.

HA-16

DESCRIPTION Refrigeration System

Refrigeration System REFRIGERATION CYCLE Refrigerant Flow

NGHA0069

GI

NGHA0069S01

The refrigerant flows in the standard pattern. Refrigerant flows through the compressor, condenser, liquid tank, expansion valve, 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.

MA

Freeze Protection

EM

NGHA0069S02

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

NGHA0069S03

Dual Pressure Switch NGHA0069S0301 The refrigerant system is protected against excessively high or low pressure. The protection is effected by a dual pressure switch located on the liquid tank. If the pressure falls out of specifications, the switch opens to interrupt compressor operation. Pressure Relief Valve NGHA0069S0302 The refrigerant system is also protected by a pressure relief valve located on the flexible high pressure hose near 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.

LC EC FE CL MT AT TF PD AX SU BR ST RS BT

WHA304

SC EL

HA-17

IDX

DESCRIPTION Control Operation

Control Operation

NGHA0072

WHA303

FAN CONTROL KNOB

NGHA0072S01

This knob turns the fan ON and OFF, and controls fan speed.

MODE CONTROL KNOB

NGHA0072S03

This knob controls the direction of air flow through the front discharge outlets.

TEMPERATURE CONTROL KNOB

NGHA0072S04

This knob allows adjustment of the outlet air temperature.

RECIRCULATION (REC) SWITCH

NGHA0072S06

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 CONDITIONER SWITCH

NGHA0072S05

The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the A/C relay is activated by the ECM allowing compressor operation. The indicator lamp will also light. The air conditioner cooling function operates only when the engine is running and ambient air temperature is above 2°C (35°F).

REAR WINDOW DEFOGGER SWITCH

NGHA0072S07

OFF position: Rear window defogger is not operating. ON position: Rear window defogger is operating.

HA-18

DESCRIPTION Discharge Air Flow

Discharge Air Flow

NGHA0073

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

SC AHA290A

HA-19

EL IDX

DESCRIPTION Component Layout

Component Layout FRONT

NGHA0272 NGHA0272S01

WHA333

HA-20

DESCRIPTION Component Layout (Cont’d)

REAR

NGHA0272S02

GI MA EM LC EC FE CL MT AT AHA571A

TF PD AX SU BR ST RS BT

SC EL

HA-21

IDX

TROUBLE DIAGNOSES Component Location

Component Location ENGINE COMPARTMENT KA24DE Models

NGHA0085 NGHA0085S01 NGHA0085S0101

AHA452A

HA-22

TROUBLE DIAGNOSES Component Location (Cont’d)

ENGINE COMPARTMENT VG33E Models

NGHA0085S05 =NGHA0085S0501

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

WHA305

SC EL

HA-23

IDX

TROUBLE DIAGNOSES Component Location (Cont’d)

VG33ER Models

=NGHA0085S0502

WHA306

HA-24

TROUBLE DIAGNOSES Component Location (Cont’d)

PASSENGER COMPARTMENT

NGHA0085S02

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

SC LHA231

HA-25

EL IDX

TROUBLE DIAGNOSES Wiring Diagram — A/C —

Wiring Diagram — A/C —

NGHA0274

WHA302

HA-26

TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

SC WHA336

EL

HA-27

IDX

TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair

How to Perform Trouble Diagnoses for Quick and Accurate Repair

NGHA0075

WORK FLOW

NGHA0075S01

LHA244

*1: HA-29

*2: HA-28

Symptom Table Symptom

NGHA0235

Reference page

쐌 Blower motor does not rotate.

쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR”.

HA-31

쐌 Mode door does not change positions.

쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR MODE DOOR”.

HA-38

쐌 Intake door position does not change.

쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR”.

HA-40

쐌 Magnet clutch does not engage when A/C switch and fan switch are ON.

쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH ”.

HA-43

쐌 Insufficient cooling

쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING”.

HA-53

쐌 Insufficient heating

쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING”.

HA-61

쐌 Noise

쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR NOISE”.

HA-63

HA-28

TROUBLE DIAGNOSES Operational Check

Operational Check

=NGHA0076

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, and compressor.

CONDITIONS:

GI MA

NGHA0076S01

Engine running at normal operating temperature.

EM LC

PROCEDURE: 1. Check Blower Motor

NGHA0076S02 NGHA0076S0208

1)

Turn fan control knob to 1-speed. Blower should operate on 1-speed. 2) Then turn fan control knob to 2-speed, and continue checking blower speed until all four speeds are checked. 3) Leave blower on 4-speed. If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR”, HA-31. If OK, continue with the check. WHA317

2. Check Discharge Air 1)

NGHA0076S0202

Turn mode control knob to each mode position.

EC FE CL MT AT TF PD AX

WHA318

2)

Confirm that discharge air comes out according to the air distribution table at left. Refer to “Discharge Air Flow”, HA-19. If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR MODE DOOR”, HA-38. If OK, continue with next check.

SU BR ST RS BT

SC EL AHA983

HA-29

IDX

TROUBLE DIAGNOSES Operational Check (Cont’d)

3. Check Recirculation

NGHA0076S0203

1)

Press recirculation switch. Recirculation indicator should light. 2) Listen for intake door position to change (you should hear blower sound change slightly). If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR”, HA-40. If OK, continue with next check.

WHA319

4. Check Temperature Decrease

NGHA0076S0204

1) Turn temperature control knob to full cold. 2) Check for cold air at discharge air outlets. If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING”, HA-53. If OK, continue with next check.

WHA320

5. Check Temperature Increase

NGHA0076S0205

1) Turn temperature control knob to full hot. 2) Check for hot air at discharge air outlets. If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING”, HA-61. If OK, continue with next check.

WHA321

6. Check A/C Switch 1) 2)

WHA322

NGHA0076S0206

Turn fan control knob to the desired (1 to 4 speed) position. Push the A/C switch to turn ON the air conditioner. The indicator lamp should come on when air conditioner is ON. 3) Confirm that the compressor clutch engages (audio or visual inspection). 4) Check for cold air at the appropriate discharge air outlets. If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH”, HA-43. If OK, continue with next check. If all operational checks are OK (symptom cannot be duplicated), go to GI-23, “Incident Simulation Tests” and perform tests as outlined to simulate driving conditions environment. If symptom appears, refer to “Symptom Table”, HA-28 and perform applicable trouble diagnoses procedures.

HA-30

TROUBLE DIAGNOSES Blower Motor

Blower Motor TROUBLE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR

=NGHA0138

Symptom: 쐌 Blower motor does not rotate. Inspection Flow

GI MA EM LC EC FE CL MT AT TF PD

WHA323

*1: HA-32

*2: HA-29

AX

*3: HA-28

SU BR ST RS BT

SC EL

HA-31

IDX

TROUBLE DIAGNOSES Blower Motor (Cont’d)

BLOWER MOTOR CIRCUIT

=NGHA0089

SYMPTOM: 쐌 Blower motor does not rotate. 1

DIAGNOSTIC PROCEDURE

Check if blower motor rotates properly at each fan speed. Does not rotate at any speed

䊳

GO TO 2.

Does not rotate at 1-3 speed

䊳

GO TO 6.

Does not rotate at 4 speed

䊳

GO TO 7.

2

CHECK FUSES.

Check 15A fuse [No. 19, located in the fuse block (J/B)] and 15A fuse [No. 24, located in the fuse block (J/B)]. For fuse layout, refer to EL-10, “POWER SUPPLY ROUTING”. Are fuses OK? YES

䊳

GO TO 3.

NO

䊳

GO TO 9.

3

CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT

1. Disconnect blower motor harness connector. 2. Check voltage between blower motor harness connector M62 terminal 1 and ground.

AHA485A

Does battery voltage exist? Yes

䊳

GO TO 4.

No

䊳

Check the following. If NG, repair harness or connector. 쐌 Harness for open between blower motor and fuse block (J/B). 쐌 Harness connectors M27 and M62

HA-32

TROUBLE DIAGNOSES Blower Motor (Cont’d)

4

CHECK BLOWER MOTOR GROUND CIRCUIT

1. Disconnect blower motor harness connector. 2. Turn fan control switch to 4-speed. 3. Check continuity between blower motor harness connector M62 terminal 2 (L) and ground.

GI MA EM LC EC WHA332

Continuity should exist.

FE OK or NG

OK

䊳

GO TO 5.

NG

䊳

Check the following. If NG, repair harness or connector. 쐌 Harness for open or short between blower motor and ground. 쐌 Harness connectors M57 and M62

5

CL MT

CHECK BLOWER MOTOR

AT

1. Disconnect blower motor harness connector. 2. Apply 12 volts to blower motor terminal 1 and ground to blower motor terminal 2.

TF PD AX AHA455A

Does blower motor rotate? Yes

䊳

Reconnect blower motor connector and go to “TROUBLE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR”, HA-31.

No

䊳

Replace blower motor.

SU BR ST RS BT

SC EL

HA-33

IDX

TROUBLE DIAGNOSES Blower Motor (Cont’d)

6

CHECK FAN RESISTOR

1. Disconnect fan resistor harness connector M61. 2. Check resistance between fan resistor terminals.

AHA458A

AHA459A

OK or NG OK

䊳

GO TO 7.

NG

䊳

Replace fan resistor.

HA-34

TROUBLE DIAGNOSES Blower Motor (Cont’d)

7

CHECK FAN SWITCH

Disconnect fan switch harness connector M57 and check continuity between terminals at each fan switch position.

GI MA EM LC AHA456A

EC FE CL MT

AHA457A

AT

OK or NG OK

䊳

GO TO 8.

NG

䊳

Replace fan switch.

TF PD

8

CHECK FAN SWITCH GROUND

1. Disconnect fan switch harness connector M57. 2. Check continuity between fan switch harness connector terminal 6 and ground.

AX SU BR ST AHA078A

RS

Continuity should exist. OK or NG OK

䊳

Check the following. If NG, repair harness or connectors. 쐌 Harness connectors M57, M61 and M62 쐌 Harness for open or short between blower motor and fan switch, fan resistor

NG

䊳

Repair harness or connector.

BT

SC EL

HA-35

IDX

TROUBLE DIAGNOSES Blower Motor (Cont’d)

9

REPLACE FUSE

1. Replace fuses. 2. Activate the blower motor system. Do the fuses blow when the front blower motor is activated? Yes

䊳

GO TO 10.

No

䊳

INSPECTION END

10

CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT FOR A SHORT

1. Disconnect battery cable and blower motor harness connector M62. 2. Check continuity between front blower motor harness connector M62 terminal 1 (L) and ground.

WHA311

Does continuity exist? Yes

䊳

Check the following. If NG, repair harness or connector. Harness connectors M27 and M62 Harness for short between blower motor and fuse block (J/B).

No

䊳

Check front blower motor. Refer to “Blower Motor”, HA-37. If necessary, clear intake unit. If OK, replace front blower motor.

ELECTRICAL COMPONENTS INSPECTION Fan Switch

NGHA0246 NGHA0246S01

Check continuity between terminals at each switch position.

AHA456A

AHA457A

HA-36

TROUBLE DIAGNOSES Blower Motor (Cont’d)

Blower Motor

NGHA0246S02

Confirm smooth rotation of the blower motor. 쐌 Check that there are no foreign particles inside the intake unit.

GI MA EM LC

AHA539A

Fan Resistor

NGHA0246S04

Terminal No. (+)

1

AHA458A

(–)

Resistance (Approx.) Ω

2

0.2 - 0.3

3

0.8 - 1.0

4

2.0 - 2.4

Check resistance between terminals.

EC FE CL MT AT TF PD AX SU BR ST RS BT

SC EL

HA-37

IDX

TROUBLE DIAGNOSES Mode Door

Mode Door TROUBLE DIAGNOSIS PROCEDURE FOR MODE DOOR

=NGHA0240

Symptom: 쐌 Mode door does not change. Inspection Flow

WHA325

*1: HA-19 *2: HA-39

*3: HA-29

*4: HA-28

HA-38

TROUBLE DIAGNOSES Mode Door (Cont’d)

MODE DOOR CONTROL LINKAGE ADJUSTMENT

NGHA0242

Mode door control linkage 쐌 Turn mode door control knob to position. 쐌 Set side link in DEF mode. 쐌 Pull on outer cable in direction of arrow and then clamp it. 쐌 After positioning mode door control cable, check that it operates properly.

GI MA EM LC

AHA121A

EC FE CL MT AT TF PD AX SU BR ST RS BT

SC EL

HA-39

IDX

TROUBLE DIAGNOSES Intake Door Motor

Intake Door Motor TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR

=NGHA0135

Symptom: 쐌 Intake door position does not change in VENT, B/L or FOOT mode. Inspection Flow

WHA326

*1: HA-42

*2: HA-29

*3: HA-28

INTAKE DOOR CIRCUIT SYMPTOM: 쐌 Intake door does not operate.

HA-40

NGHA0293

TROUBLE DIAGNOSES Intake Door Motor (Cont’d)

1

CHECK POWER FOR INTAKE DOOR MOTOR

1. Disconnect intake door motor harness connector. 2. Turn ignition switch ON. 3. Check voltage between intake door motor harness connector M96 terminals + (Y/B), – (Y) and ground as shown.

GI MA EM LC EC LHA268

OK or NG OK

䊳

GO TO 3.

NG

䊳

GO TO 2.

2

FE CL

CHECK INTAKE DOOR CIRCUIT

1. Turn ignition switch OFF. 2. Disconnect air control harness connector. 3. Check continuity between air control harness connector M95 terminals 3 (Y/B), 11 (Y) and intake door motor harness connector M96 terminals + (Y/B), – (Y).

MT AT TF PD AX

WHA312

NOTE: Mode control knob should be in

position.

SU BR

OK or NG OK

䊳

Check harness for short.

NG

䊳

Replace air control.

ST RS BT

SC EL

HA-41

IDX

TROUBLE DIAGNOSES Intake Door Motor (Cont’d)

3 1. 2. 3. 4.

CHECK INTAKE DOOR MOTOR Reconnect intake door motor connector M96. Turn ignition switch ON. Observe intake door operation when the RECIRC switch is turned ON and OFF. Intake door should change position.

AHA523A

OK or NG OK

䊳

Check harness and connectors for open or short.

NG

䊳

Replace intake door motor.

CONTROL LINKAGE ADJUSTMENT Intake Door Motor 1.

2. 3. 4. 5. AHA523A

NGHA0093 NGHA0093S05

Install intake door motor on intake unit. Ensure that the intake door motor lever is fitted into the slit portion of the intake door link. Connect the intake door motor harness connector before installing the intake door motor. Turn ignition switch on and press the recirculation switch. Turn the mode control knob to VENT, B/L or FOOT mode. Check that intake door motor operates properly when RECIRCULATION switch is turned ON and OFF.

HA-42

TROUBLE DIAGNOSES Magnet Clutch

Magnet Clutch TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH

=NGHA0119

Symptom: 쐌 Magnet clutch does not engage when A/C switch and fan switch are ON. Inspection Flow

GI MA EM LC EC FE CL MT AT TF PD AX SU

WHA327

*1: HA-74 *2: HA-79 *3: HA-44

*4: HA-29 *5: HA-28 *6: MA-16 (KA24DE models) or

MA-26 (VG33E and VG33ER models)

BR ST RS BT

SC EL

HA-43

IDX

TROUBLE DIAGNOSES Magnet Clutch (Cont’d)

MAGNET CLUTCH CIRCUIT

=NGHA0091

SYMPTOM: 쐌 Magnet clutch does not engage when A/C switch and fan switch are ON. 1

CHECK A/C COMPRESSOR POWER SUPPLY CIRCUIT

1. Disconnect A/C compressor harness connector F15–2. 2. Press the A/C switch ON. 3. Does approx. 12 volts exist between A/C compressor connector F15–2 terminal 1 (B) and ground?

WHA232

Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

CHECK A/C COMPRESSOR GROUND

Check continuity between A/C compressor connector F15–2 terminal 1 and ground.

AHA466A

Continuity should exist. OK or NG OK

䊳

Refer to “TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH″, HA-43.

NG

䊳

쐌 Check thermal protector. Refer to “Thermal Protector”, HA-51. 쐌 Check magnet clutch coil. If NG, replace magnet clutch. Refer to “MAGNET CLUTCH MOUNTING”, HA-72.

HA-44

TROUBLE DIAGNOSES Magnet Clutch (Cont’d)

3

CHECK CIRCUIT CONTINUITY

1. Disconnect A/C relay. 2. Check circuit continuity between A/C relay connector E30 terminal 3 and A/C compressor connector F15–2 terminal 1.

GI MA EM LC

AHA084A

EC

Continuity should exist. 3. Also, check harness for short.

FE

OK or NG OK

䊳

GO TO 4.

NG

䊳

Repair harness or connector.

4

CL MT

CHECK A/C RELAY POWER SUPPLY CIRCUIT

1. Disconnect A/C relay. 2. Does approx. 12 volts exist between A/C relay connector E30 terminals 2, 5 and ground?

AT TF PD AHA467A

AX

Yes or No Yes

䊳

GO TO 5.

No

䊳

GO TO 11.

5

SU BR

CHECK A/C RELAY

Refer to “A/C Relay”, HA-51. OK or NG OK

䊳

GO TO 6.

NG

䊳

Replace A/C relay.

ST RS BT

SC EL

HA-45

IDX

TROUBLE DIAGNOSES Magnet Clutch (Cont’d)

6

CHECK A/C RELAY GROUND CONTROL CIRCUIT

1. Reconnect A/C relay. 2. Engine running and A/C OFF. 3. Does approx. 12 volts exist between ECM harness connector F29 terminal 12 (P) and ground?

WHA307

Yes or No Yes

䊳

GO TO 7.

No

䊳

Check the following. If NG, repair harness or connectors. Harness for open or short between A/C relay and ECM

7

CHECK ECM OUTPUT VOLTAGE

Does approx. 5 volts exist between thermo control amp. harness connector M60 terminal 2 and ground?

AHA089A

Yes or No Yes

䊳

GO TO 14.

No

䊳

GO TO 8.

HA-46

TROUBLE DIAGNOSES Magnet Clutch (Cont’d)

8

CHECK CIRCUIT CONTINUITY

1. Disconnect dual pressure switch harness connector E3. 2. Check voltage from terminal 1 to ground.

GI MA EM LC WHA308

Do approx. 5 volts exist? 3. Also, check harness for short. Yes or No Yes

䊳

GO TO 9.

No

䊳

Repair harness or connector.

9

CHECK DUAL PRESSURE SWITCH

EC FE CL MT

Refer to “Dual Pressure Switch, HA-51. OK or NG OK

䊳

GO TO 10.

NG

䊳

Replace dual pressure switch.

AT TF PD AX SU BR ST RS BT

SC EL

HA-47

IDX

TROUBLE DIAGNOSES Magnet Clutch (Cont’d)

10

CHECK CIRCUIT CONTINUITY

1. Disconnect dual pressure switch harness connector E3. 2. Check circuit continuity between thermo control amp. harness connector M60 terminal 2 and dual pressure switch connector E3 terminal 2.

AHA267A

Continuity should exist. 3. Also check circuit continuity between dual pressure switch connector E3 terminal 1 and ECM connector F29 terminal 21.

AHA268A

Continuity should exist. OK or NG OK

䊳

Check ECM. Refer to EC-39, “Air Conditioning Cut Control”.

NG

䊳

Repair harness or connector.

11

CHECK FUSES

Check 7.5A fuse (No. 29, located in the fuse and fusible link box) and 7.5A fuse (No. 35, located in the fuse and fusible link box). For fuse layout, refer to EL-10, “POWER SUPPLY ROUTING”. Are fuses OK? YES

䊳

Check the following. If NG, repair harness or connectors. 쐌 Harness for open between fuse and fusible link box and A/C relay 쐌 Harness for open between fuse and fusible link box and thermo control amplifier

NO

䊳

GO TO 12.

12

REPLACE FUSE

Replace fuse. Does fuse blow when A/C is activated? Yes

䊳

GO TO 13.

No

䊳

INSPECTION END

HA-48

TROUBLE DIAGNOSES Magnet Clutch (Cont’d)

13

CHECK A/C RELAY POWER SUPPLY CIRCUITS FOR SHORT

1. Disconnect battery cable and A/C relay. 2. Check for continuity on A/C relay connector E30 terminals 2, 5 to ground.

GI MA EM LC AHA470A

Continuity should not exist.

EC

OK or NG OK

NG

䊳

䊳

Check the following. If NG, repair harness or connectors. 쐌 Harness connectors M95, M60 and E30. 쐌 Harness for open or short between fuse and fusible link box and A/C relay, A/C switch, or thermo control amplifier.

FE CL

Repair harness or connector.

MT 14

THERMO CONTROL AMP. GROUND CIRCUIT

1. Turn ignition switch OFF, A/C switch ON and fan switch ON. 2. Disconnect thermo control amp. connector M60. 3. Check continuity between thermo control amp. connector M60 terminal 4 (L) and ground.

AT TF PD AX SU LHA233

OK or NG OK

䊳

GO TO 11.

NG

䊳

GO TO 15.

BR ST RS BT

SC EL

HA-49

IDX

TROUBLE DIAGNOSES Magnet Clutch (Cont’d)

15

CHECK FAN SWITCH

1. Disconnect fan switch connector M57. 2. Turn fan control knob to ON (any speed position except off). 3. Check continuity between fan switch terminals 1 and 6.

LHA235

OK or NG OK

䊳

Check the following. If NG, repair harness or connectors. 쐌 Harness connectors M57 and M95. 쐌 Harness for open or short between fan switch and A/C switch. If OK, replace air control.

NG

䊳

Replace fan switch.

HA-50

TROUBLE DIAGNOSES Magnet Clutch (Cont’d)

ELECTRICAL COMPONENTS INSPECTION A/C Relay

=NGHA0092 NGHA0092S07

Check continuity between terminals 3 and 5. Conditions

Continuity

12V direct current supply between terminals 1 and 2

Yes

No current supply

No

MA EM

If NG, replace relay.

LC

SEF090M

Dual Pressure Switch

NGHA0092S09

Check continuity between terminals. Terminals Low-pressure side

AHA128A

1-2 High-pressure side

GI

EC

High-pressure side line pressure kPa (kg/cm2, psi)

Operation

Continuity

Increasing to 157 - 216 (1.6 - 2.2, 23 - 31)

ON

Yes

Decreasing to 157 - 196 (1.6 - 2.0, 23 - 28)

OFF

No

Increasing to 2,648 2,844 (27 - 29, 384 - 412)

OFF

Decreasing to 1,373 1,765 (14 - 18, 199 - 256)

ON

FE CL MT

No

AT Yes

TF PD AX

Thermal Protector

NGHA0092S11

KA24DE Models Temperature of compressor °C (°F)

SU

NGHA0092S1101

Operation

Increasing to approx. 145 - 155 (293 - 311)

Turn OFF

Decreasing to approx. 130 - 140 (266 - 284)

Turn ON

BR ST RS

AHA135A

VG33E and VG33ER Models Temperature of compressor °C (°F)

NGHA0092S1102

BT

Operation

Increasing to approx. 145 - 155 (293 - 311)

Turn OFF

Decreasing to approx. 130 - 140 (266 - 284)

Turn ON

SC EL

AHA402A

HA-51

IDX

TROUBLE DIAGNOSES Magnet Clutch (Cont’d)

Thermo Control Amp. 1) 2) 3)

NGHA0092S12

Run engine and operate A/C system. Connect the voltmeter from harness side. Check the thermo control amp. operation as shown in the table. Evaporator outlet air temperature °C (°F)

Thermo amp. operation

Tester (Approx.)

Decreasing to 2.5 - 3.5 (37 - 38)

Turn OFF

12V

Increasing to 4.0 - 5.0 (39 - 41)

Turn ON

0V

AHA561A

HA-52

TROUBLE DIAGNOSES Insufficient Cooling

Insufficient Cooling TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING

=NGHA0150

Symptom: 쐌 Insufficient cooling Inspection Flow

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

WHA328

*1: HA-38 *2: HA-57 *3: HA-54

*7: MA-16 (KA24DE models) or MA-26 (VG33E and VG33ER models)

*4: HA-29 *5: HA-28 *6: HA-70

SC EL

HA-53

IDX

TROUBLE DIAGNOSES Insufficient Cooling (Cont’d)

PERFORMANCE TEST DIAGNOSES

=NGHA0082

MHA649A

*1: HA-56

*2: HA-56

*3: HA-57

HA-54

TROUBLE DIAGNOSES Insufficient Cooling (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT LHA260

*1: HA-43

*2: MA-16 (KA24DE models) or MA-26 (VG33E and VG33ER

models)

SC EL

HA-55

IDX

TROUBLE DIAGNOSES Insufficient Cooling (Cont’d)

PERFORMANCE CHART Test Condition

=NGHA0289 NGHA0289S01

Testing must be performed as follows: Vehicle location

Indoors or in the shade (in a well-ventilated place)

Doors

Closed

Door windows

Open

Hood

Open

TEMP. switch

Max. COLD

Mode switch

(Ventilation) set

REC switch

(Recirculation) set

(blower) speed

4-speed

Engine speed

1,500 rpm

Operate the air conditioning system for 10 minutes before taking measurements.

Test Reading

NGHA0289S02

Recirculating-to-discharge Air Temperature Table

NGHA0289S0201

Inside air (Recirculating air) at blower assembly inlet Discharge air temperature at center ventilator °C (°F) Relative humidity %

Air temperature °C (°F)

50 - 60

60 - 70

20 (68)

6.6 - 8.3 (44 - 47)

25 (77)

10.4 - 12.4 (51 - 54)

30 (86)

14.2 - 16.7 (58 - 62)

35 (95)

18.2 - 21 (65 - 70)

40 (104)

22.0 - 25.2 (72 - 77)

20 (68)

8.3 - 9.8 (47 - 50)

25 (77)

12.4 - 14.4 (54 - 58)

30 (86)

16.7 - 18.9 (62 - 66)

35 (95)

21.0 - 23.6 (70 - 74)

40 (104)

25.2 - 28.1 (77 - 83)

Ambient Air Temperature-to-operating Pressure TableNGHA0289S0202 Ambient air High-pressure (Discharge side) kPa (kg/ cm2, psi)

Low-pressure (Suction side) kPa (kg/cm2, psi)

20 (68)

961 - 1,187 (9.8 - 12.1, 139 - 172)

108 - 157 (1.1 - 1.6, 16 - 23)

25 (77)

1,295 - 1,599 (13.2 - 16.3, 186 - 228)

161.8 - 215.8 (1.65 - 2.2, 23.5 - 31.3)

30 (86)

1,285 - 1,599 (13.1 - 16.0, 186 - 228)

167 - 216 (1.7 - 2.2, 24 - 31)

35 (95)

1,520 - 1,863 (15.5 - 19.0, 220 - 279)

235 - 284 (2.4 - 2.9, 34 - 41)

40 (104)

1,765 - 2,158 (18 - 22, 256 - 313)

289.3 - 353.1 (2.95 - 3.6, 41.9 - 51.2)

Relative humidity % Air temperature °C (°F)

50 - 70

HA-56

TROUBLE DIAGNOSES Insufficient Cooling (Cont’d)

TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE

NGHA0278

Whenever 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, however, differs from vehicle to vehicle, refer to “Ambient Air Temperature-to-Operating Pressure Table”, HA-56.

Both High and Low-pressure Sides are Too High. Gauge indication

Refrigerant cycle

Both high and low-pressure sides are too high.

Probable cause

Corrective action

Excessive refrigerant charge in refrigeration cycle

Air suction by cooling fan is insufficient.

Insufficient condenser cooling 쐌 Clean condenser. performance 쐌 Check and repair cooling " fan as necessary. 1. Condenser fins are clogged. 2. Improper fan rotation of cooling fan

Engine tends to overheat.

MA

NGHA0278S01

쐌 Pressure is reduced soon after water is splashed on condenser.

쐌 Low-pressure pipe is not cold. 쐌 When compressor is stopped high-pressure AC359A value quickly drops by approximately 196 kPa (2 kg/cm2, 28 psi). It then decreases gradually thereafter.

GI

Reduce refrigerant until specified pressure is obtained.

Poor heat exchange in condenser (After compressor operation stops, high pressure decreases too slowly.) " Air in refrigeration cycle

Evacuate repeatedly and recharge system.

Engine cooling systems malfunction.

Check and repair each engine cooling system.

EM LC EC FE CL MT AT

쐌 An area of the low-pres쐌 Excessive liquid refrigerant Replace expansion valve. sure pipe is colder than on low-pressure side areas near the evaporator 쐌 Excessive refrigerant disoutlet. charge flow 쐌 Plates are sometimes cov- 쐌 Expansion valve is open a ered with frost. little compared with the specification. " 1. Improper thermal valve installation 2. Improper expansion valve adjustment

TF PD AX SU BR ST RS BT

SC EL

HA-57

IDX

TROUBLE DIAGNOSES Insufficient Cooling (Cont’d)

High-pressure Side is Too High and Low-pressure Side is Too Low. Gauge indication High-pressure side is too high and low-pressure side is too low.

Refrigerant cycle

Probable cause

Upper side of condenser and high-pressure side are hot, however, liquid tank is not so hot.

High-pressure tube or parts located between compressor and condenser are clogged or crushed.

NGHA0278S02

Corrective action 쐌 Check and repair or replace malfunctioning parts. 쐌 Check lubricant for contamination.

AC360A

High-pressure Side is Too Low and Low-pressure Side is Too High. Gauge indication High-pressure side is too low and low-pressure side is too high.

NGHA0278S03

Refrigerant cycle

Probable cause

High and low-pressure sides become equal soon after compressor operation stops.

Compressor pressure operation is improper. " Damaged inside compressor packings

Replace compressor.

No temperature difference between high and low-pressure sides

Compressor pressure operation is improper. " Damaged inside compressor packings.

Replace compressor.

AC356A

HA-58

Corrective action

TROUBLE DIAGNOSES Insufficient Cooling (Cont’d)

Both High- and Low-pressure Sides are Too Low. Gauge indication

Refrigerant cycle

Both high- and low-pressure sides are too low.

쐌 There is a big temperature difference between receiver drier outlet and inlet. Outlet temperature is extremely low. 쐌 Liquid tank inlet and expansion valve are frosted.

NGHA0278S04

Probable cause Compressor discharge capacity does not change. (Compressor stroke is set at maximum.)

쐌 Expansion valve and liquid Low refrigerant charge tank are warm or only cool " when touched. Leaking fittings or components

An area of the low-pressure pipe is colder than areas near the evaporator outlet.

쐌 Replace liquid tank. 쐌 Check lubricant for contamination.

GI MA EM

쐌 Temperature of expansion High-pressure pipe located valve inlet is extremely low between receiver drier and as compared with areas expansion valve is clogged. near liquid tank. 쐌 Expansion valve inlet may be frosted. 쐌 Temperature difference AC353A occurs somewhere in highpressure side

There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted.

Corrective action

Expansion valve closes a little compared with the specification. " 1. Improper expansion valve adjustment 2. Malfunctioning thermal valve 3. Outlet and inlet may be clogged.

쐌 Check and repair malfunctioning parts. 쐌 Check lubricant for contamination.

EC FE

Check refrigerant for leaks. Refer to “Checking for Refrigerant Leaks”, HA-79. 쐌 Remove foreign particles by using compressed air. 쐌 Check lubricant for contamination.

CL MT AT TF PD

Low-pressure pipe is clogged 쐌 Check and repair malfuncor crushed. tioning parts. 쐌 Check lubricant for contamination.

Air flow volume is not enough Evaporator is frozen. or is too low. Compressor discharge capacity does not change. (Compressor stroke is set at maximum length.)

LC

쐌 Check thermo control amp. operation. 쐌 Replace compressor

AX SU BR ST RS BT

SC EL

HA-59

IDX

TROUBLE DIAGNOSES Insufficient Cooling (Cont’d)

Low-pressure Side Sometimes Becomes Negative. Gauge indication

Refrigerant cycle

Low-pressure side sometimes becomes negative.

쐌 Air conditioning system does not function and does not cyclically cool the compartment air. 쐌 The system constantly functions for a certain period of time after compressor is stopped and restarted.

NGHA0278S05

Probable cause Refrigerant does not discharge cyclically. " Moisture is frozen at expansion valve outlet and inlet. " Water is mixed with refrigerant.

Corrective action 쐌 Drain water from refrigerant or replace refrigerant. 쐌 Replace liquid tank.

AC354A

Low-pressure Side Becomes Negative. Gauge indication

NGHA0278S06

Refrigerant cycle

Low-pressure side becomes negative.

Liquid tank or front/rear side of expansion valve’s pipe is frosted or dewed.

Probable cause

Corrective action

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. 쐌 If water is the cause, initially cooling is okay. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. 쐌 If due to foreign particles, remove expansion valve and remove particles with dry and compressed air (not shop air). 쐌 If either of the above methods cannot correct the problem, replace expansion valve. 쐌 Replace liquid tank. 쐌 Check lubricant for contamination.

AC362A

HA-60

TROUBLE DIAGNOSES Insufficient Heating

Insufficient Heating TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING

=NGHA0140

Symptom: 쐌 Insufficient heating Inspection Flow

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

WHA329

*1: *2: *3: *4:

HA-62 HA-29 HA-28 LC-13 (KA24DE models) or LC-31 (VG33E and VG33ER models)

*5: MA-17 (KA24DE models) or MA-28 (VG33E and VG33ER models) *6: HA-84

*7: LC-12 (KA24DE models) or LC-28 (VG33E and VG33ER models)

SC EL

HA-61

IDX

TROUBLE DIAGNOSES Insufficient Heating (Cont’d)

TEMPERATURE CONTROL LINKAGE ADJUSTMENTNGHA0279 Temperature Control Cable NGHA0279S01 쐌 쐌 쐌

When adjusting ventilator door rod and defrost door rod, first disconnect mode control cable from side link. Reconnect and readjust mode control cable. Turn temperature control switch to max. COLD position. Set air mix door lever in full hot mode. Pull on outer cable in direction of arrow and then clamp it. After positioning temperature control cable, check that it operates properly.

AHA120A

HA-62

TROUBLE DIAGNOSES Noise

Noise TROUBLE DIAGNOSIS PROCEDURE FOR NOISE

=NGHA0080

Symptom: 쐌 Noise Inspection Flow

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

LHA262

*1: HA-72 *2: HA-75

*3: HA-66 *4: MA-16 (KA24DE models) or

MA-26 (VG33E and VG33ER models)

SC EL

HA-63

IDX

SERVICE PROCEDURE HFC-134a (R-134a) Service Procedure

HFC-134a (R-134a) Service Procedure SETTING OF SERVICE TOOLS AND EQUIPMENT

NGHA0094 NGHA0094S01

WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove R-134a form 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.

Discharging Refrigerant

NGHA0094S0101

AHA508A

Evacuating System and Charging Refrigerant

NGHA0094S0103

AHA562A

HA-64

SERVICE PROCEDURE HFC-134a (R-134a) Service Procedure (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT AHA413A

*1 *2

HA-66 HA-79

*3 *4

HA-80 HA-54

*5

HA-3

SC EL

HA-65

IDX

SERVICE PROCEDURE Maintenance of Lubricant Quantity in Compressor

Maintenance of Lubricant Quantity in Compressor

NGHA0095

The lubricant in 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: 쐌 Lack of lubricant: May lead to a seized compressor 쐌 Excessive lubricant: Inadequate cooling (thermal exchange interference)

LUBRICANT

NGHA0095S01

Name: NISSAN A/C System Lubricant Type R Part number: KLH00-PAGR0

CHECKING AND ADJUSTING

NGHA0095S02

Adjust the lubricant quantity according to the flowchart shown below. 1

LUBRICANT RETURN OPERATION

Can lubricant return operation be performed? 쐌 A/C system works properly. 쐌 There is no evidence of a large amount of lubricant leakage. Yes or No Yes

䊳

GO TO 2.

No

䊳

GO TO 3.

2

PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS

1. Start engine, and set the following conditions: 쐌 Test condition Engine speed: Idling to 1,200 rpm A/C switch: ON RECIRCULATION switch: OFF Fan speed: Max. position Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).] 2. Perform lubricant return operation for about 10 minutes. 3. Stop engine. CAUTION: If excessive lubricant leakage is noted, do not perform the lubricant return operation. 䊳

3

GO TO 3.

CHECK COMPRESSOR

Should the compressor be replaced? Yes or No Yes

䊳

Refer to “Lubricant Adjusting Procedure for Compressor Replacement”, HA-68.

No

䊳

GO TO 4.

HA-66

SERVICE PROCEDURE Maintenance of Lubricant Quantity in Compressor (Cont’d)

4

CHECK ANY PART

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 or No Yes

䊳

Refer to “Lubricant Adjusting Procedure for Components Replacement Except Compressor”, HA-68.

No

䊳

Perform “PERFORMANCE TEST DIAGNOSES”, HA-54.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

SC EL

HA-67

IDX

SERVICE PROCEDURE Maintenance of Lubricant Quantity in Compressor (Cont’d)

Lubricant Adjusting Procedure for Components Replacement Except Compressor =NGHA0095S0201 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

Remarks Amount of lubricant m
(US fl oz, Imp fl oz)

Evaporator

75 (2.5, 2.6)

—

Condenser

75 (2.5, 2.6)

—

Liquid tank

5 (0.2, 0.2)

Add if compressor is not replaced. *1

In case of refrigerant leak

30 (1.0, 1.1)

Large leak

—

Small leak *2

*1: *2:

If compressor is replaced, addition of lubricant is included in the flow chart. If refrigerant leak is small, no addition of lubricant is needed.

Lubricant Adjusting Procedure for Compressor Replacement 1)

2) 3) 4)

5)

6) 7)

8)

9)

NGHA0095S0202

Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed, recover refrigerant from equipment lines and then check refrigerant purity. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/ recycling equipment. Drain the lubricant from the old (removed) compressor into a graduated container and record the amount of lubricant drained. Drain the lubricant from the new compressor into a separate, clean container. Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this lubricant to new compressor through the suction port opening. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to new compressor through the suction port opening. If the liquid tank also needs to be replaced, add an additional 5 m
(0.2 US fl oz, 0.2 Imp fl oz) of lubricant at this time. Do not add this 5 m
(0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor.

HA-68

SERVICE PROCEDURE Maintenance of Lubricant Quantity in Compressor (Cont’d)

GI MA EM LC EC FE CL MT AT TF RHA065DD

PD AX SU BR ST RS BT

SC EL

HA-69

IDX

SERVICE PROCEDURE Compressor

Compressor COMPRESSOR MOUNTING KA24DE Models

NGHA0096 NGHA0096S01

LHA236

HA-70

SERVICE PROCEDURE Compressor (Cont’d)

VG33E and VG33ER Models

NGHA0096S02

GI MA EM LC EC FE CL MT AT LHA237

TF PD AX SU BR ST RS BT

SC EL

HA-71

IDX

SERVICE PROCEDURE Magnet Clutch

Magnet Clutch MAGNET CLUTCH MOUNTING KA24DE Models

NGHA0098 NGHA0098S04

AHA510A

HA-72

SERVICE PROCEDURE Magnet Clutch (Cont’d)

VG33E and VG33ER Models

NGHA0098S05

GI MA EM LC EC FE CL MT AT AHA507A

TF PD AX

REMOVAL 쐌

NGHA0280

When removing center bolt, hold clutch disc with clutch disc wrench.

SU BR ST RS

AHA841

쐌

Remove the drive plate using the clutch disc puller. Insert holder’s three pins into the drive plate. Rotate the holder clockwise to hook it onto the plate. Then, tighten the center bolt to remove the drive plate. While tightening the center bolt, insert a round bar (screwdriver, etc.) between two of the pins ( as shown in the figure) to prevent drive plate rotation. After removing the drive plate, remove the shims from either the drive shaft or the drive plate.

BT

SC EL

AHA506A

HA-73

IDX

SERVICE PROCEDURE Magnet Clutch (Cont’d)

쐌

Remove the snap ring using external snap ring pliers.

쐌

For pulley removal use pulley puller. Use a commercially available pulley puller. Position the center of the puller on the end of the drive shaft. Remove the pulley assembly with the puller. For Pressed Pulleys: To prevent deformation of the pulley groove, the puller claws should be hooked under (not into) the pulley groove. Remove the field coil harness clip using a screwdriver.

AHA843

쐌 RHA139E

쐌

Remove the three field coil fixing screws and remove the field coil.

RHA074C

INSPECTION Clutch Disc

NGHA0281 NGHA0281S01

If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley.

Pulley

NGHA0281S02

Check the appearance of the pulley assembly. If contact surface of pulley shows signs of excessive grooving, replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation. RHA075C

HA-74

SERVICE PROCEDURE Magnet Clutch (Cont’d)

Coil

NGHA0281S03

Check coil for loose connection or cracked insulation.

GI MA EM LC

INSTALLATION 쐌 쐌 쐌

NGHA0282

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.

EC FE CL MT

RHA076C

쐌

Install the pulley assembly using the installer and a hand press, and then install the snap ring using snap ring pliers.

AT TF PD AX

AHA504A

쐌

Install the drive plate on the drive shaft, together with the original shim(s). Press the drive plate down by hand.

SU BR ST RS

RHA078C

쐌 쐌

Using the holder to prevent drive plate 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.

BT

SC EL AHA847

HA-75

IDX

SERVICE PROCEDURE Magnet Clutch (Cont’d)

쐌

Check clearance all the way around the 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 recheck.

Break-in Operation

NGHA0282S01

When replacing magnet clutch assembly, always conduct the break-in operation. This is done by engaging and disengaging the clutch about 30 times. Break-in operation raises the level of transmitted torque.

AHA505A

Thermal Protector INSPECTION 쐌 쐌

NGHA0284

When servicing, do not allow foreign matter to get into compressor. Check continuity between two terminals.

AHA849A

HA-76

SERVICE PROCEDURE Refrigerant Lines

Refrigerant Lines REMOVAL AND INSTALLATION KA24DE Models

NGHA0101

GI

NGHA0101S02

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT

SC EL

HA-77

LHA240

IDX

SERVICE PROCEDURE Refrigerant Lines (Cont’d)

VG33E and VG33ER Models

NGHA0101S03

WHA310

HA-78

SERVICE PROCEDURE Checking for Refrigerant Leaks

Checking for Refrigerant Leaks PRELIMINARY CHECK 쐌

NGHA0102 NGHA0102S01

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent dye leak detector. 쐌 If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was repaired and not properly cleaned. 쐌 When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all system components and connections. 쐌 When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected leak area at 25 - 50 mm (1 - 2 in)/sec. and no further than 6 mm (1/4 in) from the component. NOTE: Moving the electronic leak detector probe slower and closer to the suspected leak area will improve the chances of finding a leak.

Electronic Refrigerant Leak Detector

GI MA EM LC EC FE CL MT

NGHA0291

PRECAUTIONS FOR HANDLING LEAK DETECTORNGHA0291S01 AT

AHA535A

When performing a refrigerant leak check, use a J-41995 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. 쐌 Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Clean with a dry cloth or blow off with shop air. 쐌 Do not allow the sensor tip of the detector to contact any substance. This can also cause false readings and may damage the detector.

TF PD AX SU BR ST RS

1.

Position probe approximately 5 mm (3/16 in) away from point to be checked.

BT

SC EL SHA707EA

HA-79

IDX

SERVICE PROCEDURE Electronic Refrigerant Leak Detector (Cont’d)

2.

When testing, circle each fitting completely with probe.

3.

Move probe along component approximately 25 - 50 mm (1 2 in)/sec.

SHA706E

SHA708EA

CHECKING PROCEDURE

NGHA0291S02

To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals or smoke in the vicinity of the vehicle. Perform the leak test in a calm area (low air/wind movement) so that the leaking refrigerant is not dispersed. 1. Turn engine off. 2. Connect a suitable A/C manifold gauge set to the A/C service ports. 3. Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm2, 50 psi) above 16°C (61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant. Refer to “HFC-134a (R-134a) Service Procedure”, HA-64. NOTE: At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.52 kg/cm2, 50 psi). 4. Conduct the leak test from the high side (compressor discharge a to evaporator f) to the low side (evaporator drain hose g to compressor suction k). Refer to “Refrigerant Lines”, HA-77. 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. 쐌 Compressor Check the fitting of high and low pressure hoses, relief valve and shaft seal. 쐌 Liquid tank Check the pressure switch, tube fitting, weld seams and the fusible plug mounts. 쐌 Service valves Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks).

HA-80

SERVICE PROCEDURE Electronic Refrigerant Leak Detector (Cont’d)

NOTE: After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any false readings by leak detector. 쐌 Cooling unit (Evaporator) With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended procedure for actual wait time) before inserting the leak detector probe into the drain hose. (keep the probe inserted for at least ten seconds.) Use caution not to contaminate the probe tip with water or dirt that may be in the drain hose. 5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat check as outlined above. 6. Do not stop when one leak is found. Continue to check for additional leaks at all system components and connection. If no leaks are found, perform steps 7 through 10. 7. Start engine. 8. Set the heater A/C control as follows: a. A/C switch ON b. Face mode c. Recirculation switch ON d. Max cold temperature e. Fan speed high 9. Run engine at 1,500 rpm for at least 2 minutes. 10. Turn engine off and perform leak check again following steps 4 through 6 above.

GI MA EM LC EC FE CL MT AT TF PD AX

Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector at the compressor. The pressure on the high pressure side will gradually drop after refrigerant circulation stops and pressure on the low pressure side will gradually rise, as shown in the graph. Some leaks are more easily detected when pressure is high.

SU BR ST RS

SHA839E

11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover refrigerant from equipment lines and then check refrigerant purity. 12. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. Refer to “Contaminated Refrigerant”, HA-3. 13. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier. Refer to “Contaminated Refrigerant”, HA-3. 14. Discharge A/C system using approved refrigerant recovery equipment. Refer to “Discharging Refrigerant”, HA-64. Repair

HA-81

BT

SC EL IDX

SERVICE PROCEDURE Electronic Refrigerant Leak Detector (Cont’d)

the leaking fitting or component as necessary. 15. Evacuate and recharge A/C system. Refer to “Evacuating System and Charging Refrigerant”, HA-64. Perform the leak test to confirm no refrigerant leaks. 16. Conduct A/C performance test to ensure system works properly.

Fluorescent Dye Leak Detector PRECAUTIONS FOR FLUORESCENT DYE LEAK DETECTION 쐌

쐌 쐌

2.

3. 4. 5.

NGHA0292S04

The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector (J-41995) to pinpoint refrigerant leaks. For your safety and your customer’s satisfaction, read and follow all manufacturer’s operating instructions and precautions prior to performing the work. Refer to “Precautions for Leak Detection Dye”, HA-4 .

CHECKING SYSTEM FOR LEAKS USING THE FLUORESCENT LEAK DETECTOR 1.

NGHA0292

NGHA0292S01

Check A/C system for leaks using the UV lamp and safety glasses (J-42220) in a low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly (tubes, core or TXV) leak. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or cloth, then check the cloth with the UV lamp for dye residue. Confirm any suspected leak areas with an approved electronic refrigerant leak detector. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiagnosis. Perform a system performance check and verify the leak repair with an approved electronic refrigerant leak detector.

DYE INJECTION

NGHA0292S02

(This procedure is only necessary when re-charging the system or when the compressor has seized and was replaced.) Refer to “Precautions for Leak Detection Dye”, HA-4 . 1. Check A/C system static (at rest) Pressure. Pressure must be at least 345 kPa (3.52 kg/cm2, 50 psi). 2. Pour one bottle (1/4 ounce /7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459). 3. Connect the injector tool to the A/C LOW PRESSURE side service fitting. 4. Start engine and switch A/C ON. 5. When the A/C operating (compressor running), inject one bottle (1/4 ounce /7.4 cc) of fluorescent dye through the lowpressure service valve using dye injector tool J-41459 (refer to the manufacturer’s operating instructions).

HA-82

SERVICE PROCEDURE Fluorescent Dye Leak Detector (Cont’d)

6.

With the engine still running, disconnect the injector tool from the service fitting. CAUTION: Be careful not to allow dye to spray or drip when disconnecting the injector from the system. NOTE: If repairing the A/C system or replacing a component, pour the dye directly into the open system connection and proceed with the service procedures. 7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to penetrate a leak and become visible.

GI MA EM LC EC FE CL MT

In-cabin Microfilter FUNCTION

NGHA0294

AT

NGHA0294S01

Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing in-cabin microfilter into blower unit.

TF PD AX

WHA337

REPLACEMENT TIMING

NGHA0294S02

Replace in-cabin microfilter. Refer to “SCHEDULE 1”, MA-8 or “SCHEDULE 2”, MA-8. Caution label is affixed inside the glove box.

SU BR ST RS

WHA338

REPLACEMENT PROCEDURES 1. 2. 3. 4. 5.

NGHA0294S03

Remove glove box assembly. Refer to “INSTRUMENT PANEL”, BT-20.. Remove in-cabin microfilter cover. Take out the in-cabin microfilter from blower unit. Replace with new in-cabin microfilter and reinstall cover on blower unit. Reinstall glove box assembly.

BT

SC EL

WHA339

HA-83

IDX

SERVICE PROCEDURE Belt

Belt TENSION ADJUSTMENT 쐌

NGHA0103

Refer to MA-16 (KA24DE models) or MA-26 (VG33E and VG33ER models), “Checking Drive Belts”.

IACV-FICD Solenoid Valve INSPECTION 쐌

NGHA0104

Refer to EC-592 (KA24DE models) EC-1165 (VG33E models), or EC-1197 (VG33ER models), “Component Description”.

Heater Core

NGHA0171

AHA563A

REMOVAL 1.

NGHA0171S01

Drain cooling system. Refer to MA-17, (KA24DE models) or MA-28 (VG33E and VG33ER models), “Changing Engine Coolant”.

HA-84

SERVICE PROCEDURE Heater Core (Cont’d)

2. 3. 4. 5. 6.

Disconnect the two heater hoses from the engine compartment side. Remove the cooling unit. Refer to “Evaporator Core”, HA-85. Remove the steering member assembly. Refer to “Removal and Installation”, BT-20. Remove the heater unit. Remove the heater core.

INSTALLATION

GI MA EM

NGHA0171S02

Installation is the reverse order of removal. Inspect system for coolant leaks. Refer to MA-17 (KA24DE models) or MA-28 (VG33E and VG33ER models), “Changing Engine Coolant”.

LC EC FE CL MT

Evaporator Core

NGHA0172

AT TF PD AX SU BR ST

AHA536A

REMOVAL 1. 2. 쐌 3.

AHA125A

4. 5.

NGHA0172S01

Discharge the A/C system. Refer to “Discharging Refrigerant”, HA-64. Disconnect the two evaporator core refrigerant lines from the engine compartment side. Cap the refrigerant lines to prevent moisture from entering the system. Remove the glove box and mating trim. Refer to BT-20, “Removal and Installation”. Disconnect the thermal amp. connector. Remove the cooling unit.

HA-85

RS BT

SC EL IDX

SERVICE PROCEDURE Evaporator Core (Cont’d)

6.

Separate the cooling unit case, and remove the evaporator.

INSTALLATION

NGHA0172S02

Installation is the reverse order of removal. Recharge the A/C system. Inspect system for refrigerant leaks. Refer to “Checking Refrigerant Leaks”, HA-79.

HA-86

SERVICE DATA AND SPECIFICATIONS (SDS) Manual

Manual GENERAL SPECIFICATIONS Compressor

=NGHA0169

GI

NGHA0169S01

Model

DKV-14C

Type

Vane rotary

Displacement cm3 (cu in)/rev.

140 (8.54)

Direction of rotation

MA EM

Clockwise (Viewed from drive end)

Drive belt

LC

A type

Lubricant

NGHA0169S02

Model

ZEXEL make DKV-14C

Name

Nissan A/C System Lubricant PAG Type R

Part No.*

FE CL

KLH00–PAGR0

Capacity (total in system) m
(US fl oz, Imp fl oz)

EC

200 (6.8, 7.0)

MT

*: Always check with the Parts Department for the latest parts information.

Refrigerant

NGHA0169S03

Type kg (lb)

0.60 - 0.70 (1.32 - 1.54)

g (oz)

600 - 700 (21.16 - 24.69)

TF

Capacity

PD

INSPECTION AND ADJUSTMENT Engine Idling Speed (When A/C is ON) 쐌

NGHA0170 NGHA0170S01

RefertoEC-59(KA24DEmodels),EC-648(VG33Emodels),orEC-1197(VG33ERmodels)“IdleSpeed/Ignition Timing/Idle Mixture Ratio Adjustment”.

Belt Tension 쐌

AT

R-134a

NGHA0170S02

Refer to MA-16 (KA24DE models) or MA-26 (VG33E or VG33ER models), “Checking Drive Belts”.

Magnet Clutch

NGHA0170S03

Model

AX SU BR

DKV-14C

Clutch disc-pulley clearance mm (in)

0.3 - 0.6 (0.012 - 0.024)

ST RS BT

SC EL

HA-87

IDX

NOTES

STARTING & CHARGING SYSTEM SECTION

SC

GI MA EM LC EC

CONTENTS PRECAUTIONS ...............................................................2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 Wiring Diagrams and Trouble Diagnosis.....................2 PREPARATION ...............................................................3 Special Service Tool ....................................................3 BATTERY.........................................................................4 How to Handle Battery ................................................4 METHODS OF PREVENTING OVER-DISCHARGE ......4 CHECKING ELECTROLYTE LEVEL ............................4 SPECIFIC GRAVITY CHECK ......................................5 CHARGING THE BATTERY ........................................6 Trouble Diagnoses with Battery/Starting/Charging System Tester ..............................................................7 DIAGNOSTIC RESULT ITEM CHART ..........................9 STARTING SYSTEM .....................................................10 System Description....................................................10 KA24DE MODELS ...................................................10 VG33E AND VG33ER M/T MODELS .........................11 VG33E AND VG33ER A/T MODELS ..........................12 Wiring Diagram - START -.........................................13 KA24DE MODELS ...................................................13 VG33E AND VG33ER M/T MODELS .........................14 VG33E AND VG33ER A/T MODELS ..........................15 Trouble Diagnoses with Battery/Starting/Charging System Tester ............................................................16 DIAGNOSTIC RESULT ITEM CHART ........................17 WORK FLOW ..........................................................18 DIAGNOSTIC PROCEDURE 1 ..................................19 DIAGNOSTIC PROCEDURE 2 ..................................21 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE ......................................................22

Construction...............................................................23 KA24DE MODELS ...................................................23 VG33E AND VG33ER MODELS ................................24 Removal and Installation ...........................................25 KA24DE MODELS ...................................................25 VG33E AND VG33ER MODELS ................................25 Pinion/Clutch Check ..................................................25 CHARGING SYSTEM ....................................................26 System Description....................................................26 Wiring Diagram - CHARGE -.....................................27 KA24DE MODELS ...................................................27 VG33E AND VG33ER MODELS ................................28 Trouble Diagnoses with Battery/Starting/Charging System Tester ............................................................29 DIAGNOSTIC RESULT ITEM CHART ........................31 WORK FLOW ..........................................................32 DIAGNOSTIC PROCEDURE 1 ..................................33 DIAGNOSTIC PROCEDURE 2 ..................................34 DIAGNOSTIC PROCEDURE 3 ..................................35 MALFUNCTION INDICATOR ....................................36 Construction...............................................................37 KA24DE MODELS ...................................................37 VG33E AND VG33ER MODELS ................................38 Removal and Installation ...........................................38 KA24DE MODELS ...................................................38 VG33E AND VG33ER MODELS ................................39 SERVICE DATA AND SPECIFICATIONS (SDS) .........40 Battery........................................................................40 Starter ........................................................................40 Generator...................................................................40

FE CL MT AT TF PD AX SU BR ST RS BT HA

EL IDX

PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGSC0001

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 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), 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 this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the following: 쐌 GI-10, “HOW TO READ WIRING DIAGRAMS” 쐌 EL-12, “POWER SUPPLY ROUTING” for power distribution circuit When you perform trouble diagnosis, refer to the following: 쐌 GI-33, “How To Follow Test Group In Trouble Diagnoses” 쐌 GI-22, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”

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NGSC0002

PREPARATION Special Service Tool

Special Service Tool Tool number Tool name

NGSC0018

GI

Description

J-44373 Model 620 Battery/Starting/Charging system tester

MA EM LC EC FE CL MT

SEL403X

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BATTERY How to Handle Battery

How to Handle Battery

NGSC0003

CAUTION: 쐌 If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt booster battery. 쐌 After connecting battery cables, ensure that they are tightly clamped to battery terminals for good contact. 쐌 Never add distilled water through the hole used to check specific gravity.

METHODS OF PREVENTING OVER-DISCHARGE

NGSC0003S01

The following precautions must be taken to prevent over-discharging a battery. 쐌 The battery surface (particularly its top) should always be kept clean and dry. 쐌 The terminal connections should be clean and tight. 쐌 At every routine maintenance, check the electrolyte level. This also applies to batteries designated as “low maintenance” and “maintenance-free”. MEL040F

쐌

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.)

쐌

Check the charge condition of the battery. Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent over-discharge.

MEL041F

MEL042F

CHECKING ELECTROLYTE LEVEL

NGSC0003S02

WARNING: Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touching a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If acid contacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.

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BATTERY How to Handle Battery (Cont’d)

쐌 쐌

Remove the cell plug using a suitable tool. Add distilled water up to the MAX level.

GI MA EM LC

MEL043F

Sulphation

SEL709E

NGSC0003S0201

A battery will be completely discharged if it is left unattended for a long time and the specific gravity will become less than 1.100. This may result in sulphation on the cell plates. To determine if a battery has been “sulphated”, note its voltage and current when charging it. As shown in the figure, less current and higher voltage are observed in the initial stage of charging sulphated batteries. A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test.

SPECIFIC GRAVITY CHECK 1.

NGSC0003S03

Read hydrometer and thermometer indications at eye level.

EC FE CL MT AT TF PD AX

MEL042FA

2.

Use the chart below to correct your hydrometer reading according to electrolyte temperature.

Hydrometer Temperature Correction

NGSC0003S0301

Battery electrolyte temperature °C (°F)

Add to specific gravity reading

71 (160)

0.032

66 (150)

0.028

60 (140)

0.024

54 (129)

0.020

49 (120)

0.016

43 (110)

0.012

38 (100)

0.008

32 (90)

0.004

27 (80)

0

21 (70)

−0.004

16 (60)

−0.008

10 (50)

−0.012

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SU BR ST RS BT HA

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BATTERY How to Handle Battery (Cont’d) Battery electrolyte temperature °C (°F)

Add to specific gravity reading

4 (39)

−0.016

−1 (30)

−0.020

−7 (20)

−0.024

−12 (10)

−0.028

−18 (0)

−0.032

Corrected specific gravity

Approximate charge condition

1.260 - 1.280

Fully charged

1.230 - 1.250

3/4 charged

1.200 - 1.220

1/2 charged

1.170 - 1.190

1/4 charged

1.140 - 1.160

Almost discharged

1.110 - 1.130

Completely discharged

CHARGING THE BATTERY

NGSC0003S04

CAUTION: 쐌 Do not “quick charge” a fully discharged battery. 쐌 Keep the battery away from open flame while it is being charged. 쐌 When connecting the charger, connect the leads first, then turn on the charger. Do not turn on the charger first, as this may cause a spark. 쐌 If battery electrolyte temperature rises above 60°C (140°F), stop charging. Always charge battery at a temperature below 60°C (140°F).

Charging Rates

NGSC0003S0401

Amps

Time

50

1 hour

25

2 hours

10

5 hours

5

10 hours

Do not charge at more than 50 ampere rate. NOTE: The ammeter reading on your battery charger will automatically decrease as the battery charges. This indicates that the voltage of the battery is increasing normally as the state of charge improves. The charging amps indicated above refer to initial charge rate. 쐌 If, after charging, the specific gravity of any two cells varies more than .050, the battery should be replaced.

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BATTERY Trouble Diagnoses with Battery/Starting/Charging System Tester

Trouble Diagnoses with Battery/Starting/Charging System Tester

NGSC0019

CAUTION: When working with batteries, always wear appropriate eye protection. NOTE: 쐌 To ensure a complete and thorough diagnosis, the battery, starter and generator test segments must be done as a set from start to finish. 쐌 If battery surface charge is detected while testing, the tester will prompt you to turn on the headlights to remove the surface charge. 쐌 If necessary, the tester will prompt you to determine if the battery temperature is above or below 0°C (32°F). Choose the appropriate selection by pressing the up or down arrow button, then press “ENTER” to make the selection.

GI MA EM LC EC FE CL MT

1.

SEL404X

Turn off all loads on the vehicle electrical system. Clean or repair as necessary. 2. Visually inspect the battery, battery terminals and cable ends with ignition switch in “OFF” position. NOTE: The contact surface between the battery terminals, cable ends and tester leads must be clean for a valid test. A poor connection will prevent testing and a “CHECK CONNECTION” message will appear during the test procedures. If this occurs, clean the battery post and terminals, reconnect them and restart the test. 3. Connect the red tester lead clamp to the positive battery terminal, and the black to the negative terminal.

AT TF PD AX SU BR ST RS

4.

The tester will turn on automatically. Using the arrow keys, select “IN-VEHICLE” on the tester and then press the “ENTER” key.

BT HA

EL SEL405X

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BATTERY Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

5.

SEL406X

Locate the battery type and rating stamped or written on the top case of the battery to be tested. NOTE: The battery type and rating will have either of the following. CCA: Cold Cranking Amps (490 CCA, 550 CCA, etc.) JIS: Japanese Industrial Standard. Battery is stamped with a number such as: 80D26L: 80 (rank of output), D (physical size-depth), 26 (width in cm). The last character L (post configuration) is not input into the tester. The tester requires the rating for the battery be entered exactly as it is written or stamped on the battery. Do not attempt a CCA conversion for JIS stamped batteries. JIS must be input directly. 6. Using the arrow and “ENTER” keys alternately, select the battery type and rating. NOTE: The tester lists five choices; CCA, JIS, IEC, DIN, and EN. Only use CCA or JIS.

7.

Press “ENTER” to begin the test. Diagnosis results are displayed on the tester. Refer to “DIAGNOSTIC RESULT ITEM CHART”, SC-9.

SEL407X

8.

SEL576X

Press “ENTER”, then test output code is displayed. Record the test output code on the repair order. 9. Toggle back to the “DIAGNOSTIC SCREEN” for test results. NOTE: 쐌 If necessary, the tester will ask the user to determine if the battery has just been charged. Choose the appropriate selection by pressing the up or down arrow button and then press the “ENTER” button to make the selection. 쐌 When testing a battery installed in a vehicle that has recently been driven, select “BEFORE CHARGE”. 쐌 If the battery has just been slow charged due to a “CHARGE & RETEST” decision by the tester, and the tester asks the user “BEFORE CHARGE/AFTER CHARGE”, select “AFTER CHARGE”.

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BATTERY Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC RESULT ITEM CHART Diagnostic item

NGSC0019S01

Service procedure

GOOD BATTERY

Battery is OK. Refer to “Trouble Diagnoses with Battery/Starting/Charging System Tester”, SC-16.

REPLACE BATTERY

Replace battery. Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again with Battery/Starting/Charging system tester. If second test result is “Replace Battery”, then do so. Perform battery test again to confirm repair.

BAD CELL-REPLACE

Replace the battery. Perform battery test again with Battery/Starting/Charging system tester to confirm repair.

GOOD-RECHARGE

Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester.

CHARGE & RETEST

Perform the slow battery charging. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester to confirm repair. NOTE: If the tester asks the user “BEFORE CHARGE/AFTER CHARGE”, select “AFTER CHARGE”.

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STARTING SYSTEM System Description

System Description KA24DE MODELS

NGSC0004 NGSC0004S01

Power is supplied at all times 쐌 through 40A fusible link (letter e, located in the fuse and fusible link box) 쐌 to ignition switch terminal B. With the ignition switch in the START position, power is supplied 쐌 through ignition switch terminal ST 쐌 to clutch interlock relay terminal 5. With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 11, located in the fuse block (J/B)] 쐌 to clutch interlock relay terminal 2. With the clutch pedal depressed, ground is supplied 쐌 to clutch interlock relay terminal 1 쐌 through clutch interlock switch terminal 1 쐌 through clutch interlock switch terminal 2 쐌 through body grounds M14 and M68. The clutch interlock relay is energized and power is supplied 쐌 through clutch interlock relay terminal 3 쐌 to starter motor windings terminal S. The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates.

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STARTING SYSTEM System Description (Cont’d)

VG33E AND VG33ER M/T MODELS

=NGSC0004S02

Power is supplied at all times 쐌 through 40A fusible link (letter e, located in the fuse and fusible link box) 쐌 to ignition switch terminal B. With the ignition switch in the START position, power is supplied 쐌 through ignition switch terminal ST 쐌 to clutch interlock relay terminal 5. With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 11, located in the fuse block (J/B)] 쐌 to clutch interlock relay terminal 2 and 쐌 through 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 to vehicle security relay terminal 2 (models with vehicle security system). If the vehicle security system is not activated (models with vehicle security system) and clutch pedal is depressed, ground is supplied 쐌 to clutch interlock relay terminal 1 쐌 through vehicle security relay terminals 3, 4 (models with vehicle security system) and 쐌 through clutch interlock switch terminal 1 쐌 through clutch interlock switch terminal 2 쐌 through body grounds M14 and M68. The clutch interlock relay is energized and power is supplied 쐌 through clutch interlock relay terminal 3 쐌 to starter motor windings terminal S. The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates. If the vehicle security system is activated (models with vehicle security system), ground is supplied to vehicle security relay terminal 1 through smart entrance control unit terminal 40, disengaging the clutch interlock relay and preventing starter motor operation.

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STARTING SYSTEM System Description (Cont’d)

VG33E AND VG33ER A/T MODELS

=NGSC0004S03

Power is supplied at all times 쐌 through 40A fusible link (letter e, located in the fuse and fusible link box) 쐌 to ignition switch terminal B. With the ignition switch in the START position, power is supplied 쐌 through ignition switch terminal ST 쐌 to park/neutral position (PNP) relay terminal 5. With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 12, located in the fuse block (J/B)] 쐌 to PNP switch terminal 1 and 쐌 through 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 to vehicle security relay terminal 2 (models with vehicle security system). With the selector lever in the P or N position, power is supplied 쐌 through PNP switch terminal 2 쐌 to PNP relay terminal 2. If the vehicle security system is not activated (models with vehicle security system), ground is supplied 쐌 to PNP relay terminal 1 쐌 through body grounds E12 and E54 (models without vehicle security system) or 쐌 through vehicle security relay terminals 3, 4 (models with vehicle security system) and 쐌 through body grounds M14 and M68. The PNP relay is energized and power is supplied 쐌 through PNP relay terminal 3 쐌 to starter motor windings terminal S. The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates. If the vehicle security system is activated (models with vehicle security system), ground is supplied to vehicle security relay terminal 1 through smart entrance control unit terminal 40, disengaging the PNP relay and preventing starter motor operation.

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STARTING SYSTEM Wiring Diagram — START —

Wiring Diagram — START — KA24DE MODELS

NGSC0005 NGSC0005S01

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA

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STARTING SYSTEM Wiring Diagram — START — (Cont’d)

VG33E AND VG33ER M/T MODELS

NGSC0005S02

WSC059

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STARTING SYSTEM Wiring Diagram — START — (Cont’d)

VG33E AND VG33ER A/T MODELS

NGSC0005S03

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA

WSC060

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EL IDX

STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester

Trouble Diagnoses with Battery/Starting/Charging System Tester

NGSC0020

NOTE: To ensure a complete and thorough diagnosis, the battery, starter and generator test segments must be done as a set from start to finish.

1. 2.

3.

Turn off all loads on the vehicle electrical system. Perform battery test with Battery/Starting/Charging system tester. Refer to “Trouble Diagnoses with Battery/Starting/ Charging System Tester”, SC-7. Press “ENTER” to begin the starting system test.

4.

Start the engine.

SEL408X

SEL409X

5.

Diagnosis result is displayed on the tester. Refer to “DIAGNOSTIC RESULT ITEM CHART”, SC-17. NOTE: 쐌 If the starter performs normally but the engine does not start, perform engine diagnosis. 쐌 For intermittent “NO CRANK” or “NO STARTER OPERATION” incidents, refer to “DIAGNOSTIC PROCEDURE 2”, SC-21.

SEL410X

SC-16

STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC RESULT ITEM CHART Diagnostic item

NGSC0020S01

Service procedure

GI

CRANKING VOLTAGE NORMAL

Go to “WORK FLOW”, SC-18.

CRANKING VOLTAGE LOW

Go to “WORK FLOW”, SC-18.

MA

CHARGE BATTERY

Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester. Refer to “Trouble Diagnoses with Battery/Starting/Charging System Tester”, SC-7.

EM

REPLACE BATTERY

Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again with Battery/Starting/Charging system tester. Refer to “Trouble Diagnoses with Battery/Starting/Charging System Tester”, SC-7. If second test result is “REPLACE BATTERY”, then do so. Perform battery test again to confirm repair.

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STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

WORK FLOW

NGSC0020S02

SEL411X

*1 *2

SC-7 SC-22

*3

SC-19

*4

SC-18

SC-21

STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 1 Check “B” Terminal Circuit 1

NGSC0020S03 NGSC0020S0301

GI

CHECK POWER SUPPLY FOR STARTER MOTOR “B” TERMINAL

1. 2. 3. 4.

Remove the fuel pump fuse. Crank or start the engine (where possible) until the fuel pressure is released. Turn the ignition switch OFF. Check that the starter motor terminal “B” [E210, (B/Y) for KA24DE models or E203, (B/L) for VG33E and VG33ER models] connection is clean and tight. 5. Check voltage between starter motor terminal “B” [E210, (B/Y) for KA24DE models or E203, (B/L) for VG33E and VG33ER models] and ground using a digital circuit tester.

MA EM LC EC FE CL

LSC037

MT

OK or NG OK

䊳

GO TO 2.

NG

䊳

Check harness between the battery and the starter motor for open circuit.

2

AT

CHECK BATTERY CABLE CONNECTION QUALITY (VOLTAGE DROP TEST)

TF

1. Check voltage between starter motor terminal “B” [E210, (B/Y) for KA24DE models or E203, (B/L) for VG33E and VG33ER models] and battery positive terminal using a digital circuit tester.

PD AX SU BR LSC038

OK or NG OK

䊳

GO TO 3.

NG

䊳

Check harness between the battery and the starter motor for poor continuity.

ST RS BT HA

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STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

3

CHECK STARTER MOTOR GROUND CIRCUIT (VOLTAGE DROP TEST)

1. Check voltage between starter motor case and battery negative terminal using a digital circuit tester.

LSC039

OK or NG OK

䊳

Starter motor “B” terminal circuit is OK. Further inspection necessary. Refer to “WORK FLOW”, SC-18.

NG

䊳

Check the starter motor case and ground for poor continuity.

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STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 2 Check “S” Terminal Circuit 1

=NGSC0020S04 NGSC0020S0401

GI

CHECK POWER SUPPLY FOR STARTER MOTOR “S” TERMINAL

1. 2. 3. 4.

Remove the fuel pump fuse. Crank or start the engine (where possible) until the fuel pressure is released. Turn the ignition OFF. Disconnect starter motor terminal “S” [E209 (B/R) for KA24DE models or E202 (B/R) for VG33E and VG33ER models] connector. 5. Check voltage between starter motor terminal “S” [E209, (B/R) for KA24DE models or E202, (B/R) for VG33E and VG33ER models] and ground using a digital circuit tester.

MA EM LC EC FE CL

LSC040

MT

OK or NG OK

䊳

GO TO 2.

NG

䊳

Check the following. 쐌 40A fusible link (letter e, located in fuse and fusible link box) 쐌 Clutch interlock relay 쐌 Park/neutral position relay 쐌 Harness for open or short

2

AT TF PD

CHECK “S” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

1. Connect starter motor terminal “S” [E209, (B/R) for KA24DE models or E202, (B/R) for VG33E and VG33ER models] connector. 2. Check voltage between starter motor terminal “S” [E209, (B/R) for KA24DE models or E202, (B/R) for VG33E and VG33ER models] and battery positive terminal using a digital tester.

AX SU BR ST RS

LSC041

OK or NG OK

䊳

Starter motor “S” terminal circuit is OK. Further inspection necessary. Refer to “WORK FLOW”, SC-18.

NG

䊳

Check harness between the battery and the starter motor “S” terminal for poor continuity.

BT HA

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STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE =NGSC0020S05 Voltage V Engine coolant temperature KA24DE

VG33E and VG33ER

−30°C to −20°C (−22°F to −4°F)

8.0

8.6

−19°C to −10°C (−2°F to 14°F)

9.0

9.3

−9°C to 0°C (16°F to 32°F)

9.9

9.5

More than 1°C (More than 34°F)

10.2

10.2

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STARTING SYSTEM Construction

Construction

=NGSC0006

KA24DE MODELS

NGSC0006S01

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

WSC077

1. 2. 3. 4. 5. 6.

Gear case Shift lever Plate Packing Adjusting plate Magnetic switch assembly

7. 8. 9. 10. 11.

Pinion stopper set Pinion assembly Internal gear Pinion shaft Planetary gear

12. 13. 14. 15. 16.

Packing Yoke Armature Brush holder assembly Rear cover

BT HA

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STARTING SYSTEM Construction (Cont’d)

VG33E AND VG33ER MODELS

NGSC0006S02

WSC078

1. 2. 3. 4. 5. 6.

Gear case Shift lever Plate Packing Adjusting plate Magnetic switch assembly

7. 8. 9. 10. 11.

Pinion stopper set Pinion assembly Internal gear Pinion shaft Planetary gear

SC-24

12. 13. 14. 15. 16.

Packing Yoke Armature Brush holder assembly Rear cover

STARTING SYSTEM Removal and Installation

Removal and Installation KA24DE MODELS Removal 1. 2.

NGSC0007 NGSC0007S01

Remove engine under cover. Remove two bolts and starter.

Installation

GI

NGSC0007S0101

MA NGSC0007S0102

To install, reverse the removal procedure.

EM LC

MEL271H

VG33E AND VG33ER MODELS Removal 1. 2.

NGSC0007S02 NGSC0007S0201

Remove engine under cover. Remove two bolts and starter.

Installation

EC FE

NGSC0007S0202

To install, reverse the removal procedure.

CL MT

WSC069

Pinion/Clutch Check 1. 쐌 2. 쐌 3. 쐌

NGSC0008

Inspect pinion teeth. Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.) Inspect reduction gear teeth. Replace reduction gear if teeth are worn or damaged. (Also check condition of armature shaft gear teeth.) Check to see if pinion locks in one direction and rotates smoothly in the opposite direction. If it locks or rotates in both directions, or unusual resistance is evident, replace.

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SC-25

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CHARGING SYSTEM System Description

System Description

NGSC0009

The generator provides DC voltage to operate the vehicle’s electrical system and to keep the battery charged. The voltage output is controlled by the IC regulator. Power is supplied at all times to generator terminal S through: 쐌 80A fusible link [letter a, located in the fuse and fusible link box (with KA24DE engine)] or 쐌 100A fusible link [letter a, located in the fuse and fusible link box (with VG33E and VG33ER engine)] and 쐌 7.5A fuse (No. 36, located in the fuse and fusible link box). Generator terminal B supplies power to charge the battery and operate the vehicle’s electrical system. Output voltage is controlled by the IC regulator at generator terminal S detecting the input voltage. The charging circuit is protected by the 80A fusible link (with KA24DE engine) or the 100A fusible link (with VG33E and VG33ER engine). Ground is supplied to generator terminal E through body ground E203 (with KA24DE engine) or body ground A1 (with VG33E and VG33ER engine). With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 11, located in the fuse block (J/B)] 쐌 to combination meter terminal 17 for the charge warning lamp. Ground is supplied to combination meter terminal 43 through generator terminal L. With power and ground supplied, the charge warning lamp will illuminate. When the generator is providing sufficient voltage with the engine running, the ground is opened and the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a fault is indicated.

SC-26

CHARGING SYSTEM Wiring Diagram — CHARGE —

Wiring Diagram — CHARGE — KA24DE MODELS

NGSC0010 NGSC0010S01

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CHARGING SYSTEM Wiring Diagram — CHARGE — (Cont’d)

VG33E AND VG33ER MODELS

NGSC0010S02

WSC057

SC-28

CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester

Trouble Diagnoses with Battery/Starting/Charging System Tester

NGSC0021

NOTE: To ensure a complete and thorough diagnosis, the battery, starter and generator test segments must be done as a set from start to finish.

GI MA EM LC

1. 2. 3. 4.

Turn off all loads on the vehicle electrical system. Perform battery and starting system test with Battery/Starting/ Charging system tester. Press “ENTER” to begin the charging system test. Start engine.

EC FE CL MT

SEL417X

5.

SEL418X

Press “ENTER” until “LOADS OFF REV ENGINE 5 SEC” is displayed. 6. Raise and hold the engine speed at 1,500 to 2,000 rpm for about 5 seconds, then return the engine to idle. Once the increase in engine rpm is detected, press “ENTER” to continue. NOTE: 쐌 If after 30 seconds an increase in engine idle speed is not detected, “RPM NOT DETECTED” will display. 쐌 Some engines may have a higher idle initially after starting, particularly when the engine is cold. The tester may detect this without any other action being taken. If this occurs, continue on with the testing process. The final results will not be affected.

AT TF PD AX SU BR ST RS

7.

The tester now checks the engine at idle and performs the DIODE/RIPPLE check. 8. When complete, the tester will prompt you to turn on the following electrical loads. 쐌 Heater fan set to highest speed. Do not run the A/C or windshield defroster. 쐌 Headlamp high beam 쐌 Rear window defogger NOTE: Do not run the windshield wipers or any other cyclical loads.

BT HA

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SEL419X

SC-29

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CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

9.

Press “ENTER” to continue.

SEL420X

10. Raise and hold the engine speed at 1,500 to 2,000 rpm for about 5 seconds, then return the engine to idle. Once the increase in engine rpm is detected, press “ENTER” to continue. NOTE: If after 30 seconds an increase in engine idle speed is not detected, “RPM NOT DETECTED” will be displayed. Press “ENTER” to restart the test.

SEL421X

11. Diagnostic result is displayed on the tester. Refer to “DIAGNOSTIC RESULT ITEM CHART”, SC-31.

SEL422X

12. Press “ENTER” then test output code is displayed. Record the test output code on the repair order. 13. Toggle back to the “DIAGNOSTIC SCREEN” for test results.

SEL577X

SC-30

CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC RESULT ITEM CHART Diagnostic item

NGSC0021S01

Service procedure

CHARGING SYSTEM NORMAL

Charging system is normal and will also show DIODE RIPPLE test result.

NO CHARGING VOLTAGE

Go to “WORK FLOW”, SC-32.

LOW CHARGING VOLTAGE

Go to “WORK FLOW”, SC-32.

HIGH CHARGING VOLTAGE

Go to “WORK FLOW”, SC-32.

DIODE RIPPLE NORMAL

Diode ripple is OK and will also show CHARGING VOLTAGE test result.

EXCESS RIPPLE DETECTED

Replace the generator. Perform “DIODE RIPPLE” test again using Battery/Starting/ Charging system tester to confirm repair.

DIODE RIPPLE NOT DETECTED

Go to “WORK FLOW”, SC-32.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA

EL

SC-31

IDX

CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

WORK FLOW

NGSC0021S02

LSC047

SC-32

CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 1 Check “L” Terminal Circuit 1

NGSC0021S03 NGSC0021S0301

GI

CHECK “L” TERMINAL CONNECTION

Check to see if “L” terminal is clean and tight.

MA

OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair “L” terminal connection. Confirm repair by performing complete Battery/Starting/ Charging system test.

EM LC

2

CHECK “L” TERMINAL CIRCUIT

1. Disconnect E207 for KA24DE models or A8 for VG33E and VG33ER models connector from generator. 2. Apply ground to terminal “L” [E207, (Y/B) for KA24DE models or A8, (Y/B) for VG33E and VG33ER models] with the ignition switch in the ON position.

EC FE CL MT AT

LSC042

OK or NG OK

䊳

Replace the generator. Confirm repair by performing complete Battery/Starting/Charging system test.

NG

䊳

Check the following. 쐌 10A fuse [No. 11, located in fuse block (J/B)] 쐌 CHARGE lamp 쐌 Harness for open or short between combination meter and fuse 쐌 Harness for open or short between combination meter and generator

TF PD AX SU BR ST RS BT HA

EL

SC-33

IDX

CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 2 Check “B” Terminal Circuit 1

=NGSC0021S04 NGSC0021S0401

CHECK “B” TERMINAL CONNECTION

Check to see if “B” terminal is clean and tight. OK or NG OK

䊳

GO TO 2. Confirm repair by performing complete Battery/Starting/Charging system test.

NG

䊳

Repair “B” terminal connection.

2

CHECK GENERATOR “B” TERMINAL CIRCUIT

Check voltage between generator terminal “B” [E208, (W) for KA24DE models or A6, (W) for VG33E and VG33ER models] and ground using a digital circuit tester.

LSC043

OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following. 쐌 80A fusible link (letter a, located in fuse and fusible link box) for KA24DE models 쐌 100A fusible link (letter a, located in fuse and fusible link box) for VG33E and VG33ER models 쐌 Harness for open or short between generator and fusible link

3

CHECK “B” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

Check voltage between generator terminal “B” [E208, (W) for KA24DE models or A6, (W) for VG33E and VG33ER models] and battery positive terminal using a digital tester.

LSC044

OK or NG OK

䊳

Replace the generator. Confirm repair by performing complete Battery/Starting/Charging system test.

NG

䊳

Check harness between the battery and the generator for poor continuity.

SC-34

CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 3 Check “S” Terminal Circuit 1

=NGSC0021S05 NGSC0021S0501

GI

CHECK “S” TERMINAL CONNECTION

Check to see if “S” terminal is clean and tight.

MA

OK or NG OK

䊳

GO TO 2.

NG

䊳

Repair “S” terminal connection. Confirm repair by performing complete Battery/Starting/ Charging system test.

EM LC

2

CHECK GENERATOR “S” TERMINAL CIRCUIT

Check voltage between generator terminal “S” [E207, (G/B) for KA24DE models or A8, (G/B) for VG33E and VG33ER models] and ground using a digital circuit tester.

EC FE CL MT

LSC045

AT

OK or NG

TF

OK

䊳

GO TO 3.

NG

䊳

Check the following. 쐌 7.5A fuse (No. 36, located in fuse and fusible link box) 쐌 Harness for open or short between generator and fuse

3

PD AX

CHECK “S” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

Check voltage between generator terminal “S” [E207, (G/B) for KA24DE models or A8, (G/B) for VG33E and VG33ER models] and battery positive terminal using a digital tester.

SU BR ST RS

LSC046

OK or NG OK

䊳

Replace the generator. Confirm repair by performing complete Battery/Starting/Charging system test.

NG

䊳

Check harness between the battery and the generator for poor continuity.

BT HA

EL

SC-35

IDX

CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

MALFUNCTION INDICATOR

=NGSC0021S06

The IC regulator warning function activates to illuminate “CHARGE” warning lamp, if any of the following symptoms occur while generator is operating: 쐌 Excessive voltage is produced. 쐌 No voltage is produced.

SC-36

CHARGING SYSTEM Construction

Construction

=NGSC0012

KA24DE MODELS

NGSC0012S01

GI MA EM LC EC FE CL MT AT TF

ASC013

PD 1. 2. 3. 4.

Pulley assembly Front cover Front bearing Retainer

5. 6. 7. 8.

Rotor Slip ring Stator Fan guide

9. 10. 11. 12.

IC regulator assembly Diode assembly Packing Rear cover

AX SU BR ST RS BT HA

EL

SC-37

IDX

CHARGING SYSTEM Construction (Cont’d)

VG33E AND VG33ER MODELS

NGSC0012S02

LSC054

1. 2. 3. 4.

Pulley assembly Front cover Front bearing Retainer

5. 6. 7. 8.

Rotor Slip ring Stator Fan guide

9. 10. 11. 12.

IC regulator assembly Diode assembly Packing Rear cover

Removal and Installation KA24DE MODELS Removal 1. 2. 3. 4. 5. AEL676B

NGSC0013 NGSC0013S01 NGSC0013S0101

Remove engine undercover. Remove RH side splash shield. Disconnect harness connectors. Loosen adjustment bolt, remove belt. Remove two generator bolts and generator.

Installation To install, reverse the removal procedure.

SC-38

NGSC0013S0102

CHARGING SYSTEM Removal and Installation (Cont’d)

VG33E AND VG33ER MODELS Removal 1. 2. 3. 4.

NGSC0013S02 NGSC0013S0201

Disconnect harness connectors. Remove engine undercover. Loosen adjustment bolt, remove belt. Remove 3 generator bolts and generator.

Installation To install, reverse the removal procedure.

GI MA

NGSC0013S0202

EM LC

ASC012

EC FE CL MT AT TF PD AX SU BR ST RS BT HA

EL

SC-39

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) Battery

Battery Applied area Type Capacity

USA

Canada

55D23R

65D26R

12-60

12-65

356

413

V-AH

Cold cranking current (For reference value)

NGSC0014

A

Starter Engine

NGSC0015

KA24DE

VG33E and VG33ER

M000T87381ZC

M000T87481ZC

Type

MITSUBISHI make Reduction gear type

System voltage

12 V Terminal voltage

No-load

11.0 V

Current

Less than 90 A

Revolution

More than 2,500 rpm

Minimum diameter of commutator

28.8 mm (1.134 in)

Minimum length of brush

7.0 mm (0.276 in)

Brush spring tension

5.8 - 21.6 N (0.59 - 2.20 kg, 1.30 - 4.86 lb)

Clearance of bearing metal and armature shaft

Less than 0.2 mm (0.008 in)

Clearance between pinion front edge and pinion stopper

0.5 - 2.0 mm (0.02 - 0.079 in)

Generator Engine

NGSC0016

KA24DE

VG33E and VG33ER

LR170-757B

LR180-756B

Type HITACHI make Nominal rating

12 V-70 A

Ground polarity

Negative

Minimum revolution under no-load (When 13.5 volts are applied) Hot output current (When 13.5 volts are applied)

12 V-80 A

Less than 1,000 rpm More than 17 A/1,300 rpm More than 54 A/2,500 rpm More than 72 A/5,000 rpm

More than 23 A/1,300 rpm More than 65 A/2,500 rpm More than 77 A/5,000 rpm

Regulated output voltage

14.1 - 14.7 V

Minimum length of brush

6.0 mm (0.236 in)

Brush spring pressure

1.000 - 2.452 N (102 - 250 g, 3.60 - 8.82 oz)

Slip ring minimum outer diameter Rotor (Field coil) resistance

26.0 mm (1.024 in) 2.6 Ω

SC-40

2.7 Ω

ELECTRICAL SYSTEM SECTION

EL

GI MA EM LC EC

CONTENTS PRECAUTIONS ...............................................................4 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............4 Wiring Diagrams and Trouble Diagnosis.....................4 PREPARATION ...............................................................5 Special Service Tools ..................................................5 HARNESS CONNECTOR................................................6 Description ...................................................................6 STANDARDIZED RELAY................................................8 Description ...................................................................8 POWER SUPPLY ROUTING.........................................10 Circuit Diagram ..........................................................10 Wiring Diagram - POWER - ......................................12 Inspection...................................................................17 GROUND........................................................................18 Ground Distribution....................................................18 COMBINATION SWITCH ..............................................32 Check.........................................................................32 Replacement..............................................................33 STEERING SWITCH......................................................34 Check.........................................................................34 HEADLAMP (FOR USA) ...............................................35 System Description....................................................35 Wiring Diagram - H/LAMP -.......................................36 Trouble Diagnoses.....................................................37 Bulb Replacement .....................................................38 Aiming Adjustment .....................................................38 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM - ......................................................................40 System Description (For Canada) .............................40 Circuit Diagram ..........................................................42 Wiring Diagram - DTRL -...........................................43 Trouble Diagnoses.....................................................46 Bulb Replacement .....................................................47 Aiming Adjustment .....................................................47 PARKING, LICENSE AND TAIL LAMPS .....................48 Wiring Diagram - TAIL/L -..........................................48 STOP LAMP ..................................................................49 Wiring Diagram - STOP/L - .......................................49

BACK-UP LAMP............................................................50 Wiring Diagram - BACK/L - .......................................50 FRONT FOG LAMP.......................................................51 System Description....................................................51 Wiring Diagram - F/FOG - .........................................52 Aiming Adjustment .....................................................53 Removal and Installation ...........................................54 Bulb and Lens Replacement .....................................54 TURN SIGNAL AND HAZARD WARNING LAMPS .....55 System Description....................................................55 Wiring Diagram - TURN - ..........................................57 Trouble Diagnoses.....................................................59 Electrical Components Inspection .............................59 TRAILER TOW...............................................................60 System Description....................................................60 Wiring Diagram - T/TOW -.........................................61 Trouble Diagnoses.....................................................62 ILLUMINATION..............................................................63 System Description....................................................63 Wiring Diagram - ILL - ...............................................64 INTERIOR ROOM LAMP...............................................66 Component Parts and Harness Connector Location .....................................................................66 System Description....................................................67 Wiring Diagram - ROOM/L - ......................................69 Trouble Diagnosis ......................................................72 METERS AND GAUGES...............................................75 Component Parts and Harness Connector Location .....................................................................75 System Description....................................................76 Combination Meter ....................................................78 Wiring Diagram - METER - .......................................80 Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode ..........................81 Trouble Diagnoses.....................................................82 Electrical Components Inspection .............................89 COMPASS AND THERMOMETER ...............................90 System Description....................................................90 Wiring Diagram - COMPAS -.....................................91

FE CL MT AT TF PD AX SU BR ST RS BT HA SC

IDX

CONTENTS Trouble Diagnoses.....................................................92 Calibration Procedure for Compass ..........................93 WARNING LAMPS ........................................................94 Circuit Diagram ..........................................................94 Wiring Diagram - WARN - .........................................95 Electrical Components Inspection ...........................102 WARNING CHIME .......................................................103 Component Parts and Harness Connector Location ...................................................................103 System Description..................................................103 Wiring Diagram - CHIME - ......................................106 Trouble Diagnoses...................................................108 FRONT WIPER AND WASHER ..................................118 System Description..................................................118 Wiring Diagram - WIPER - ......................................120 Removal and Installation .........................................122 Washer Nozzle Adjustment .....................................123 Washer Tube Layout ...............................................123 REAR WIPER AND WASHER ....................................124 System Description..................................................124 Wiring Diagram - WIP/R -........................................125 Removal and Installation .........................................126 Washer Nozzle Adjustment .....................................127 Washer Tube Layout ...............................................128 Check Valve.............................................................128 HORN ...........................................................................129 Wiring Diagram - HORN - .......................................129 CIGARETTE LIGHTER................................................130 Wiring Diagram - CIGAR -.......................................130 REAR WINDOW DEFOGGER.....................................131 Component Parts and Harness Connector Location ...................................................................131 System Description..................................................132 Wiring Diagram - DEF -...........................................134 Trouble Diagnoses...................................................136 Electrical Components Inspection ...........................141 Filament Check........................................................142 Filament Repair .......................................................143 AUDIO ..........................................................................144 System Description..................................................144 Schematic - With Audio Amplifier ............................145 Wiring Diagram - AUDIO -.......................................146 Trouble Diagnoses...................................................150 Inspection.................................................................151 AUDIO ANTENNA .......................................................153 Location of Antenna.................................................153 Fixed Antenna Rod Replacement............................153 DOOR MIRROR ...........................................................154 Wiring Diagram - MIRROR - ...................................154 AUTOMATIC SPEED CONTROL DEVICE (ASCD) ...155 Component Parts and Harness Connector Location ...................................................................155

(Cont’d)

System Description..................................................157 Circuit Diagram ........................................................159 Wiring Diagram - ASCD - ........................................160 Fail-safe System ......................................................163 Trouble Diagnoses...................................................164 Electrical Component Inspection .............................172 ASCD Wire Adjustment ...........................................174 POWER WINDOW .......................................................176 System Description..................................................176 Circuit Diagram ........................................................179 Wiring Diagram - WINDOW - ..................................180 Trouble Diagnoses...................................................184 POWER DOOR LOCK.................................................186 Component Parts and Harness Connector Location ...................................................................186 System Description..................................................187 Circuit Diagram ........................................................190 Wiring Diagram - D/LOCK -.....................................191 Trouble Diagnoses...................................................195 REMOTE KEYLESS ENTRY SYSTEM.......................202 Component Parts and Harness Connector Location ...................................................................202 System Description..................................................203 Circuit Diagram ........................................................205 Wiring Diagram - MULTI - .......................................206 Trouble Diagnoses...................................................209 ID Code Entry Procedure ........................................218 Keyfob Battery Replacement...................................219 VEHICLE SECURITY (THEFT WARNING) SYSTEM.......................................................................220 Component Parts and Harness Connector Location ...................................................................220 System Description..................................................222 Circuit Diagram ........................................................225 Wiring Diagram - VEHSEC - ...................................226 Trouble Diagnoses...................................................229 Electrical Components Inspection ...........................241 SMART ENTRANCE CONTROL UNIT .......................242 Description ...............................................................242 Circuit Diagram ........................................................243 Smart Entrance Control Unit Inspection Table ........245 ELECTRICAL UNITS LOCATION...............................247 Engine Compartment...............................................247 Passenger Compartment.........................................248 HARNESS LAYOUT ....................................................250 How to Read Harness Layout .................................250 Outline......................................................................251 Main Harness...........................................................252 Engine Room Harness ............................................255 Engine Control Harness ..........................................261 Engine No. 2 Harness .............................................267 Body Harness ..........................................................270

EL-2

CONTENTS Body No. 2 and Chassis Harness ...........................271 Room Lamp Harness...............................................272 Front Door Harness .................................................273 Rear Door Harness..................................................274 Back Door Harness .................................................275

(Cont’d)

BULB SPECIFICATIONS ............................................276 Headlamp.................................................................276 Exterior Lamp ..........................................................276 Interior Lamp............................................................276 WIRING DIAGRAM CODES (CELL CODES).............277

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-3

IDX

PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NGEL0001

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 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), 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 this Service Manual. WARNING: 쐌 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. 쐌 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. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.

Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the following: 쐌 GI-10, “HOW TO READ WIRING DIAGRAMS” 쐌 EL-10, “POWER SUPPLY ROUTING” for power distribution circuit. When you perform trouble diagnosis, refer to the following: 쐌 GI-33, “How to Follow Test Groups in Trouble Diagnoses”. 쐌 GI-22, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”. Check for any Service bulletins before servicing the vehicle.

EL-4

NGEL0002

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 (Kent-Moore No.) Tool name

NGEL0217

GI

Description

MA Used to test keyfobs

(J-43241) Remote keyless entry tester

EM LC LEL946A

EC

*: Special tool or commercial equivalent

FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-5

IDX

HARNESS CONNECTOR Description

Description HARNESS CONNECTOR (TAB-LOCKING TYPE) 쐌 쐌

NGEL0003 NGEL0003S01

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 EL-7 for description of the slide-locking type connector. CAUTION: Do not pull the harness when disconnecting the connector. [Example]

SEL769D

EL-6

HARNESS CONNECTOR Description (Cont’d)

HARNESS CONNECTOR (SLIDE-LOCKING TYPE) 쐌

=NGEL0003S02

A new style slide-locking connector is used on certain systems and components, especially those related to OBD. 쐌 The slide-locking type connectors help prevent incomplete locking and accidental looseness or disconnection. 쐌 The slide-locking type connectors are disconnected by pushing or pulling 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.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR

AEL299C

ST RS BT HA SC

EL-7

IDX

STANDARDIZED RELAY Description

Description

NGEL0004

NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS

NGEL0004S01

Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.

SEL881H

TYPE OF STANDARDIZED RELAYS

NGEL0004S02

1M

1 Make

2M

2 Make

1T

1 Transfer

1M·1B

1 Make 1 Break

SEL882H

EL-8

STANDARDIZED RELAY Description (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC GEL264

EL-9

IDX

POWER SUPPLY ROUTING Circuit Diagram

Circuit Diagram

NGEL0005

NOTE: For detailed ground distribution information, refer to “Ground Distribution”, EL-18.

WEL812A

EL-10

POWER SUPPLY ROUTING Circuit Diagram (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL108B

EL-11

IDX

POWER SUPPLY ROUTING Wiring Diagram — POWER —

Wiring Diagram — POWER — BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION

=NGEL0006 NGEL0006S01

NOTE: For detailed ground distribution information, refer to “Ground Distribution”, EL-18.

WEL157B

EL-12

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL808A

EL-13

IDX

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)

ACCESSORY POWER SUPPLY — IGNITION SW. IN ACC OR ON

=NGEL0006S02

NOTE: For detailed ground distribution information, refer to “Ground Distribution”, EL-18.

WEL809A

EL-14

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)

IGNITION POWER SUPPLY — IGNITION SW. IN ON AND/OR START

=NGEL0006S03

NOTE: For detailed ground distribution information, refer to “Ground Distribution”, EL-18.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

WEL109B

EL-15

IDX

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)

WEL811A

EL-16

POWER SUPPLY ROUTING Inspection

Inspection FUSE 쐌 쐌 쐌 쐌

NGEL0007 NGEL0007S01

If fuse is blown, be sure to eliminate cause of problem before installing new fuse. Use fuse of specified rating. Never use fuse of more than specified rating. Do not partially install fuse; always insert it into fuse holder properly. Remove fuse for “ELECTRICAL PARTS (BAT)” if vehicle is not used for a long period of time.

CEL083

FUSIBLE LINK

MEL944F

GI MA EM LC

NGEL0007S02

A melted fusible link can be detected either by visual inspection or by feeling with fingertip. If its condition is questionable, use circuit tester or test lamp. CAUTION: 쐌 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. 쐌 Never wrap outside of fusible link with vinyl tape. Important: Never let fusible link touch any other wiring harness, vinyl or rubber parts.

EC FE CL MT AT TF PD AX

CIRCUIT BREAKER

NGEL0007S03

For example, when current is 30A, the circuit is broken within 8 to 20 seconds. Circuit breakers are used in the following systems. 쐌 power window 쐌 power door lock 쐌 remote keyless entry

SU BR ST RS

SBF284E

BT HA SC

EL-17

IDX

GROUND Ground Distribution

Ground Distribution MAIN HARNESS

NGEL0171 NGEL0171S01

WEL818A

EL-18

GROUND Ground Distribution (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT WEL819A

HA SC

EL-19

IDX

GROUND Ground Distribution (Cont’d)

ENGINE ROOM HARNESS KA24DE

NGEL0171S02 NGEL0171S0201

WEL820A

EL-20

GROUND Ground Distribution (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT WEL898A

HA SC

EL-21

IDX

GROUND Ground Distribution (Cont’d)

VG33E and VG33ER

NGEL0171S0202

WEL821A

EL-22

GROUND Ground Distribution (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT WEL822A

HA SC

EL-23

IDX

GROUND Ground Distribution (Cont’d)

ENGINE NO. 2 HARNESS KA24DE

NGEL0171S08 NGEL0171S0801

AEL710C

EL-24

GROUND Ground Distribution (Cont’d)

GENERATOR HARNESS VG33E and VG33ER

NGEL0171S03 NGEL0171S0301

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA

AEL697C

EL-25

SC

IDX

GROUND Ground Distribution (Cont’d)

ENGINE CONTROL HARNESS KA24DE

NGEL0171S04 NGEL0171S0401

WEL110B

EL-26

GROUND Ground Distribution (Cont’d)

VG33E and VG33ER

NGEL0171S0402

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL111B

EL-27

IDX

GROUND Ground Distribution (Cont’d)

WEL825A

EL-28

GROUND Ground Distribution (Cont’d)

BODY HARNESS

NGEL0171S05

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA LEL734

SC

EL-29

IDX

GROUND Ground Distribution (Cont’d)

BODY NO. 2 HARNESS

NGEL0171S06

WEL826A

EL-30

GROUND Ground Distribution (Cont’d)

BACK DOOR NO. 2 HARNESS

NGEL0171S07

GI MA EM LC EC FE CL MT AT TF PD LEL736

AX SU BR ST RS BT HA SC

EL-31

IDX

COMBINATION SWITCH Check

Check

NGEL0009

WEL112B

EL-32

COMBINATION SWITCH Replacement

Replacement

NGEL0010

For removal and installation of spiral cable, refer to RS-16, “Driver Air Bag Module and Spiral Cable”. 쐌 Each switch can be replaced without removing combination switch base.

GI MA EM LC

SEL865L

쐌

To remove combination switch base, remove base attaching screws.

EC FE CL MT

MEL205B

쐌

Before installing the steering wheel, align the turn signal cancel tab with the notch of the combination switch. Refer to RS-16, “Driver Air Bag Module and Spiral Cable”.

AT TF PD AX SU BR ST RS

ARS152

BT HA SC

EL-33

IDX

STEERING SWITCH Check

Check

NGEL0011

WEL113B

EL-34

HEADLAMP (FOR USA) System Description

System Description

NGEL0012

The headlamps are controlled by the lighting switch which is built into the combination switch. Power is supplied at all times 쐌 through 15A fuse (No. 37, located in the fuse and fusible link box) 쐌 to lighting switch terminal 5 and 쐌 through 15A fuse (No. 38, located in the fuse and fusible link box) 쐌 to lighting switch terminal 8.

LOW BEAM OPERATION

GI MA EM NGEL0012S01

With the lighting switch in the headlamp ON (2ND) position and LOW BEAM (B) position, power is supplied 쐌 from lighting switch terminal 10 쐌 to headlamp LH terminal D and 쐌 from lighting switch terminal 7 쐌 to headlamp RH terminal D. Ground is supplied to headlamp LH/RH terminal E through body grounds E12 and E54. With power and ground supplied, the low beams illuminate.

HIGH BEAM OPERATION/FLASH-TO-PASS OPERATION

LC EC FE

NGEL0012S02

With the lighting switch in the FLASH-TO-PASS (C) position or the headlamp ON (2ND) position and HIGH BEAM (A) position, power is supplied 쐌 from lighting switch terminal 6 쐌 to headlamp RH terminal M and 쐌 from lighting switch terminal 9 쐌 to headlamp LH terminal M and 쐌 to combination meter terminal 11 for the high beam indicator. Ground is supplied to terminal 10 of the combination meter through body grounds M14 and M68. Ground is supplied to headlamp LH/RH terminal E through body grounds E12 and E54. With power and ground supplied, the high beams and the high beam indicator illuminate.

CL

VEHICLE SECURITY SYSTEM

PD

NGEL0012S03

The vehicle security system will flash the high beams if the system is triggered. Refer to “System Description”, EL-222.

MT AT TF

AX SU BR ST RS BT HA SC

EL-35

IDX

HEADLAMP (FOR USA) Wiring Diagram — H/LAMP —

Wiring Diagram — H/LAMP —

NGEL0013

WEL114B

EL-36

HEADLAMP (FOR USA) Trouble Diagnoses

Trouble Diagnoses Symptom

Possible cause

NGEL0014

Repair order

Neither headlamp LH nor headlamp 1. Lighting switch RH operate.

1. Check lighting switch.

Headlamp LH does not operate, but headlamp RH operates properly.

1. Check bulb. 2. Check continuity between headlamp LH terminal E and grounds E12 and E54. 3. Check 15A fuse (No. 38, located in fuse and fusible link box). Verify battery positive voltage is present at terminal 8 of lighting switch. 4. Check lighting switch.

Headlamp RH does not operate, but headlamp LH operates properly.

1. 2. 3. 4.

1. 2. 3. 4.

MA

Bulb Headlamp LH ground circuit 15A fuse Lighting switch

Bulb Headlamp RH ground circuit 15A fuse Lighting switch

1. Check bulb. 2. Check continuity between headlamp RH terminal E and grounds E12 and E54. 3. Check 15A fuse (No. 37, located in fuse and fusible link box). Verify battery positive voltage is present at terminal 5 of lighting switch. 4. Check lighting switch.

1. Bulb 2. Open in high beam LH circuit 3. Lighting switch

1. Check bulb. 2. Check R/G wire between lighting switch terminal 9 and headlamp LH terminal M for an open circuit. 3. Check lighting switch.

Low beam LH does not operate, but high beam LH operates.

1. Bulb 2. Open in low beam LH circuit 3. Lighting switch

1. Check bulb. 2. Check R wire between lighting switch terminal 10 and headlamp LH terminal D for an open circuit. 3. Check lighting switch.

High beam RH does not operate, but low beam RH operates.

1. Bulb 2. Open in high beam RH circuit 3. Lighting switch

1. Check bulb. 2. Check R/W wire between lighting switch terminal 6 and headlamp RH terminal M for an open circuit. 3. Check lighting switch.

High beam LH does not operate, but low beam LH operates.

Low beam RH does not operate, but high beam RH operates.

GI

1. Bulb 2. Open in low beam RH circuit 3. Lighting switch

High beam indicator does not work. 1. Bulb 2. High beam indicator ground circuit 3. Open in high beam circuit

1. Check bulb. 2. Check R/B wire between lighting switch terminal 7 and headlamp RH terminal D for an open circuit. 3. Check lighting switch. 1. Check bulb in combination meter. 2. Check continuity between combination meter terminal 10 and grounds M14 and M68. 3. Check R/G wire between lighting switch terminal 9 and combination meter terminal 11 for an open circuit.

EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-37

IDX

HEADLAMP (FOR USA) Bulb Replacement

Bulb Replacement

=NGEL0015

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. 쐌 Grasp only the plastic base when handling the bulb. Never touch the glass envelope. 1. Disconnect the battery cable. 2. Disconnect the harness connector from the back side of the bulb. 3. Remove bulb retaining ring. 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.

WEL790A

Aiming Adjustment

NGEL0208

When performing headlamp aiming adjustment, use an aiming wall screen. For details, refer to the regulations in your own country. Before performing aiming adjustment, check the following. 1) Keep all tires inflated to correct pressures. 2) Place vehicle on flat surface. 3) See that the 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 the driver’s seat.

LOW BEAM

NGEL0208S01

NOTE: The horizontal headlamp aim cannot be adjusted. Only vertical aim is adjustable. 1. Turn headlamp low beam on.

2. 쐌 쐌

Use adjusting screw to adjust the vertical aim of the lamp. Cover the opposite lamp and ensure fog lamps, if equipped, are turned off. Adjust beam pattern until cut-off line (top edge of illumination area) is positioned at same height off ground as bulb center (on H-line). Measure cut-off line within distance A on H-line. See aiming chart following.

WEL918A

EL-38

HEADLAMP (FOR USA) Aiming Adjustment (Cont’d)

GI MA EM LC EC FE CL MT AT WEL536A

If the vehicle front body has been repaired and/or the headlamp assembly has been replaced, check aiming. Use the aiming chart shown in the figure. 쐌 Basic illuminating area (shaded) for adjustment should be within the range shown on the aiming chart. Adjust headlamps accordingly.

TF PD AX SU BR ST RS BT HA SC

EL-39

IDX

HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — System Description (For Canada)

System Description (For Canada)

NGEL0017

The headlamp system for Canada vehicles contains a daytime light control unit that activates the high beam headlamps at approximately half illumination whenever the engine is running. If the parking brake is applied before the engine is started the daytime lights will not be illuminated. The daytime lights will illuminate once the parking brake is released. Thereafter, the daytime lights will continue to operate when the parking brake is applied. If the daytime light control unit receives a ground signal from the generator, the daytime lights will not be illuminated. The daytime lights will illuminate once a battery positive voltage signal is sent to the daytime light control unit from the generator. Power is supplied at all times 쐌 through 15A fuse (No. 38, located in the fuse and fusible link box) 쐌 to daytime light control unit terminal 3 and 쐌 to lighting switch terminal 8. Power is also supplied at all times 쐌 through 15A fuse (No. 37, located in the fuse and fusible link box) 쐌 to daytime light control unit terminal 2 and 쐌 to lighting switch terminal 5. With the ignition switch in the ON or START position, power is supplied 쐌 through 7.5A fuse [No. 5, located in the fuse block (J/B)] 쐌 to daytime light control unit terminal 12. With the ignition switch in the START position, power is supplied 쐌 through 7.5A fuse [No. 7, located in the fuse block (J/B)] 쐌 to daytime light control unit terminal 1. Ground is supplied to daytime light control unit terminal 9 through body grounds E12 and E54.

HEADLAMP OPERATION Low Beam Operation

NGEL0017S01 NGEL0017S0101

When the lighting switch is turned to the headlamp ON (2ND) position, LOW BEAM (B), power is supplied 쐌 from lighting switch terminal 7 쐌 to headlamp RH terminal D and 쐌 to daytime light control unit terminal 4. Ground is supplied to headlamp RH terminal E through body grounds E12 and E54. Also, when the lighting switch is turned to the headlamp ON (2ND) position, LOW BEAM (B), power is supplied 쐌 from lighting switch terminal 10 쐌 to headlamp LH terminal D. Ground is supplied 쐌 to headlamp LH terminal E 쐌 from daytime light control unit terminal 7 쐌 through daytime light control unit terminal 9 쐌 through body grounds E12 and E54. With power and ground supplied, the low beam headlamps illuminate.

High Beam Operation/Flash-to-pass Operation

NGEL0017S0102

When the lighting switch is turned to the headlamp ON (2ND) position, HIGH BEAM (A) or FLASH-TO-PASS (C) position, power is supplied 쐌 from lighting switch terminal 6 쐌 to headlamp RH terminal M and 쐌 to daytime light control unit terminal 8. Also, when the lighting switch is turned to the headlamp ON (2ND) position, HIGH BEAM (A) or FLASH-TOPASS (C) position, power is supplied 쐌 from lighting switch terminal 9 쐌 to combination meter terminal 11 for the high beam indicator and 쐌 to daytime light control unit terminal 5 쐌 through daytime light control unit terminal 6

EL-40

HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — System Description (For Canada) (Cont’d)

쐌 to headlamp LH terminal M. Ground is supplied in the same manner as low beam operation. Ground is supplied to combination meter terminal 10 through body grounds M14 and M68. With power and ground supplied, the high beam headlamps and HI BEAM indicator illuminate.

GI

DAYTIME LIGHT OPERATION

NGEL0017S02

With the engine running, the lighting switch in the OFF or 1ST position and parking brake released, power is supplied 쐌 through daytime light control unit terminal 6 쐌 to headlamp LH terminal M 쐌 through headlamp LH terminal E 쐌 to daytime light control unit terminal 7 쐌 through daytime light control unit terminal 8 쐌 to headlamp RH terminal M. Ground is supplied to headlamp RH terminal E through body grounds E12 and E54. Because the high beam headlamps are now wired in series, they operate at half illumination.

OPERATION (FOR CANADA)

MA EM LC EC FE

NGEL0017S03

After starting the engine with the lighting switch in the OFF or parking lamp (1ST) position, the headlamp high beams automatically turn on. Lighting switch operations other than the above are the same as conventional light systems. Engine

With engine stopped OFF

1ST

MT

With engine running 2ND

OFF

1ST

2ND

Lighting switch A

B

C

A

B

C

A

B

C

A

B

C

A

B

C

A

B

C

High beam

X

X

O

X

X

O

O

X

O

왕*

왕*

O

왕*

왕*

O

O

X

O

Low beam

X

X

X

X

X

X

X

O

X

X

X

X

X

X

X

X

O

X

Clearance and tail lamp

X

X

X

O

O

O

O

O

O

X

X

X

O

O

O

O

O

O

License and instrument illumination lamp

X

X

X

O

O

O

O

O

O

X

X

X

O

O

O

O

O

O

Headlamp

CL

AT TF PD

A: HIGH BEAM position B: LOW BEAM position C: FLASH-TO-PASS position O : Lamp ON X : Lamp OFF 왕 : Lamp dims. (Added functions) *: When starting the engine with the parking brake released, the daytime lights will come ON. When starting the engine with the parking brake pulled, the daytime lights won’t come ON.

AX SU BR ST RS BT HA SC

EL-41

IDX

HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Circuit Diagram

Circuit Diagram

NGEL0019

LEL714A

EL-42

HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Wiring Diagram — DTRL —

Wiring Diagram — DTRL —

NGEL0020

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL657A

EL-43

IDX

HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Wiring Diagram — DTRL — (Cont’d)

LEL658A

EL-44

HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Wiring Diagram — DTRL — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL659A

EL-45

IDX

HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Trouble Diagnoses

Trouble Diagnoses

NGEL0021

DAYTIME LIGHT CONTROL UNIT INSPECTION TABLE NGEL0021S01 Terminal No.

Wire color

Item

1

L/OR

Ignition switch start signal

Condition

Voltage (Approx.)

Ignition switch in START position

12

All other conditions

0

2

Y/G

Power source for headlamp RH

—

12

3

Y/B

Power source for headlamp LH

—

12

4

R/B

Lighting switch headlamp RH low beam output

5

6

R/G

R/Y

Lighting switch headlamp LH high beam output

Headlamp LH high beam

Lighting switch in the headlamp ON (2ND) position and LOW BEAM (B) position

12

All other conditions

0

Lighting switch in the FLASH-TO-PASS (C) position or headlamp ON (2ND) position and HIGH BEAM (A) position

12

All other conditions

0

Lighting switch in the FLASH-TO-PASS (C) position or headlamp ON (2ND) position and HIGH BEAM (A) position

12

With parking brake released, engine running and lighting switch in OFF or parking and tail lamp ON (1ST) positions CAUTION: Block wheels and ensure selector lever is in P or N position.

7

8

B/W

R/W

Headlamp LH control (ground)

Lighting switch headlamp RH high beam output

All other conditions

0

Lighting switch in the FLASH-TO-PASS (C) position or headlamp ON (2ND) position

0

All other conditions

6

Lighting switch in the FLASH-TO-PASS (C) position or headlamp ON (2ND) position and HIGH BEAM (A) position

12

With parking brake released, engine running and lighting switch in OFF or parking and tail lamp ON (1ST) positions CAUTION: Block wheels and ensure selector lever is in P or N position. All other conditions 9

B

Ground

10

Y

Parking brake switch

11

Y/B

Generator (L terminal)

12

6

0 —

—

Parking brake released

12

Parking brake set

0

When engine is running

12

All other conditions

0

EL-46

HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Trouble Diagnoses (Cont’d) 12

G/W

Ignition switch on signal

Ignition switch OFF, ACC positions

0

Ignition switch ON, START positions

12

GI MA EM LC

Bulb Replacement

NGEL0022

Refer to “Bulb Replacement”, EL-38.

EC FE CL MT

Aiming Adjustment Refer to “Aiming Adjustment”, EL-38.

NGEL0023

AT TF PD AX SU BR ST RS BT HA SC

EL-47

IDX

PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L —

Wiring Diagram — TAIL/L —

NGEL0024

WEL144B

EL-48

STOP LAMP Wiring Diagram — STOP/L —

Wiring Diagram — STOP/L —

NGEL0025

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL661A

EL-49

IDX

BACK-UP LAMP Wiring Diagram — BACK/L —

Wiring Diagram — BACK/L —

NGEL0026

WEL662A

EL-50

FRONT FOG LAMP System Description

System Description

NGEL0027

Power is supplied at all times 쐌 through 15A fuse (No. 40, located in the fuse and fusible link box) 쐌 to front fog lamp relay terminal 5 and 쐌 through 15A fuse (No. 37, located in the fuse and fusible link box) 쐌 to lighting switch terminal 5. With the lighting switch in the headlamp ON (2ND) position and LOW BEAM (B) position, power is supplied 쐌 through lighting switch terminal 7 쐌 to front fog lamp switch terminal 1.

GI MA EM LC

FRONT FOG LAMP OPERATION

NGEL0027S01

The front fog lamp switch is built into the combination switch. The lighting switch must be in the headlamp ON (2ND) position and LOW BEAM (B) position for front fog lamp operation. With the front fog lamp switch in the ON position: 쐌 power is supplied to front fog lamp relay terminal 2 쐌 through front fog lamp switch terminal 2 쐌 through front fog lamp switch terminal 1. The front fog lamp relay is energized and power is supplied 쐌 through front fog lamp relay terminal 3 쐌 to front fog lamp LH/RH terminal 1. Ground is supplied to front fog lamp LH/RH terminal 2 and front fog lamp relay terminal 1 through body grounds E12 and E54. With power and ground supplied, the front fog lamps illuminate.

EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-51

IDX

FRONT FOG LAMP Wiring Diagram — F/FOG —

Wiring Diagram — F/FOG —

NGEL0028

WEL663A

EL-52

FRONT FOG LAMP Aiming Adjustment

Aiming Adjustment

NGEL0029

Before performing aiming adjustment, make sure of the following. 1) Keep all tires inflated to correct pressure. 2) Place vehicle on level ground. 3) See 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. Loosen front fog lamp adjusting nuts and adjust aiming by moving front fog lamps.

GI MA EM LC

LEL384A

1. 2.

Set the distance between the screen and the center of the front fog lamp lens as shown at left. Turn front fog lamps ON.

EC FE CL MT

MEL327G

3. 쐌 4.

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. Tighten the front fog lamp adjusting nuts.

AT TF PD AX SU BR ST RS

MEL328G

BT HA SC

EL-53

IDX

FRONT FOG LAMP Removal and Installation

Removal and Installation 1. 2. 3. 4.

Bulb and Lens Replacement 1. 2. 3. 4. 5. 6.

=NGEL0184

Disconnect front fog lamp harness connector. Remove mounting bolt and remove lens and housing assembly from front bumper cover. Install in reverse order of removal. Ensure top of lens faces up. Tighten mounting bolt. : 5 – 6 N·m (0.51 – 0.61 kg-m, 44.3 – 53.1 in-lb)

NGEL0185

Remove front fog lamp. Refer to “Removal and Installation”, EL-54. Remove bulb cover. Release the spring retainer. Disconnect fog lamp bulb connector. Remove fog lamp bulb. Install in reverse order of removal. Ensure top of lens faces up. DO NOT TOUCH BULB.

LEL380A

EL-54

TURN SIGNAL AND HAZARD WARNING LAMPS System Description

System Description TURN SIGNAL OPERATION

NGEL0030 NGEL0030S01

With the hazard switch in the OFF position and the ignition switch in the ON or START position, power is supplied 쐌 through 7.5A fuse [No. 2, located in the fuse block (J/B)] 쐌 to hazard switch terminal 2 쐌 through the hazard switch terminal 1 쐌 to combination flasher unit terminal B 쐌 through combination flasher unit terminal L 쐌 to turn signal switch terminal 1. Ground is supplied to combination flasher unit terminal E through body grounds M14 and M68.

LH Turn

NGEL0030S0101

With the turn signal switch in the LH position, power is supplied from turn signal switch terminal 3 to 쐌 front combination lamp LH terminal 1 쐌 combination meter terminal 11 and 쐌 rear combination lamp LH terminal 3. Ground is supplied to front combination lamp LH terminal 2 through body grounds E12 and E54. Ground is supplied to rear combination lamp LH terminal 2 through body grounds B6 and B10. Ground is supplied to combination meter terminal 36 through body grounds M14 and M68. With power and ground supplied, the combination flasher unit controls the flashing of the LH turn signal lamps.

RH Turn

GI MA EM LC EC FE CL MT

NGEL0030S0102

With the turn signal switch in the RH position, power is supplied from turn signal switch terminal 2 to 쐌 front combination lamp RH terminal 1 쐌 combination meter terminal 28 and 쐌 rear combination lamp RH terminal 3. Ground is supplied to the front combination lamp RH terminal 2 through body grounds E12 and E54. Ground is supplied to the rear combination lamp RH terminal 2 through body grounds B106 and B116. Ground is supplied to combination meter terminal 36 through body grounds M14 and M68. With power and ground supplied, the combination flasher unit controls the flashing of the RH turn signal lamps.

AT

HAZARD LAMP OPERATION

AX

TF PD

NGEL0030S02

Power is supplied at all times to hazard switch terminal 3 through: 쐌 10A fuse [No. 17, located in the fuse block (J/B)]. With the hazard switch in the ON position, power is supplied 쐌 through hazard switch terminal 1 쐌 to combination flasher unit terminal B 쐌 through combination flasher unit terminal L 쐌 to hazard switch terminal 4. Ground is supplied to combination flasher unit terminal E through body grounds M14 and M68. Power is supplied through hazard switch terminal 5 to 쐌 front combination lamp LH terminal 1 쐌 combination meter terminal 11 and 쐌 rear combination lamp LH terminal 3. Power is supplied through hazard switch terminal 6 to 쐌 front combination lamp RH terminal 1 쐌 combination meter terminal 28 and 쐌 rear combination lamp RH terminal 3. Ground is supplied to front combination lamp LH/RH terminal 2 through body grounds E12 and E54. Ground is supplied to rear combination lamp LH terminal 2 through body grounds B6 and B10. Ground is supplied to rear combination lamp RH terminal 2 through body grounds B106 and B116. Ground is supplied to combination meter terminal 36 through body grounds M14 and M68. With power and ground supplied, the combination flasher unit controls the flashing of the hazard warning lamps.

EL-55

SU BR ST RS BT HA SC

IDX

TURN SIGNAL AND HAZARD WARNING LAMPS System Description (Cont’d)

REMOTE KEYLESS ENTRY SYSTEM OPERATION

NGEL0030S04

Power is supplied at all times to smart entrance control unit terminal 49 쐌 through 9.5A fuse [No. 28, located in the fuse block (J/B)]. Ground is supplied to smart entrance control unit terminals 43 and 64. Refer to “REMOTE KEYLESS ENTRY SYSTEM”, EL-203. When smart entrance control unit receives LOCK or UNLOCK signal from key fob with all doors closed, power is supplied through smart entrance control unit terminal 47 쐌 to front combination lamp LH terminal 1 쐌 to combination meter terminal 11 쐌 to rear combination lamp LH terminal 3. Power is supplied through smart entrance control unit terminal 48 쐌 to front combination lamp RH terminal 1 쐌 to combination meter terminal 28 쐌 to rear combination lamp RH terminal 3. Ground is supplied to terminal 2 of each front combination lamp through body grounds E12 and E54. Ground is supplied to terminal 2 of rear combination lamp LH through body grounds B6 and B10. Ground is supplied to terminal 2 of rear combination lamp RH through body grounds B106 and B116. Ground is supplied to combination meter terminal 36 through body grounds M14 and M68. With power and ground supplied, the smart entrance control unit controls the flashing of the hazard warning lamps.

EL-56

TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN —

Wiring Diagram — TURN —

NGEL0032

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL664A

EL-57

IDX

TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — (Cont’d)

WEL665A

EL-58

TURN SIGNAL AND HAZARD WARNING LAMPS Trouble Diagnoses

Trouble Diagnoses Symptom Turn signal and hazard warning lamps do not operate.

Turn signal lamps do not operate but hazard warning lamps operate.

Possible cause 1. 2. 3. 4. 5.

1. 2. 3. 4.

NGEL0033

GI

Repair order

1. Check 7.5A fuse [No. 2, located in fuse block (J/B)]. 7.5A fuse 10A fuse Turn ignition switch ON and verify battery positive Hazard switch voltage is present at terminal 2 of hazard switch. Combination flasher unit 2. Check 10A fuse [No. 17, located in fuse block Open in combination flasher unit (J/B)]. Verify battery positive voltage is present at circuit terminal 3 of hazard switch. 3. Check hazard switch. 4. Refer to combination flasher unit check. 5. Check wiring to combination flasher unit for open circuit. 1. Check 7.5A fuse [No. 2, located in fuse block (J/B)]. 7.5A fuse Hazard switch Turn ignition switch ON and verify battery positive Turn signal switch voltage is present at terminal 2 of hazard switch. Open in turn signal switch circuit 2. Check hazard switch. 3. Check turn signal switch. 4. Check G wire between combination flasher unit and turn signal switch for open circuit. Check the harness between turn signal switch and front combination lamp for an open circuit.

Hazard warning lamps do not oper- 1. 10A fuse ate but turn signal lamps operate. 2. Hazard switch 3. Open in hazard switch circuit

MA EM LC EC FE CL

1. Check 10A fuse [No. 17, located in fuse block (J/B)]. Verify battery positive voltage is present at terminal 3 of hazard switch. 2. Check hazard switch. 3. Check G wire between combination flasher unit and hazard switch for open circuit.

MT

TF

Front turn signal lamp LH or RH does not operate.

1. Bulb 2. Front turn signal lamp ground circuit

1. Check bulb. 2. Check front turn signal lamp ground circuit.

Rear turn signal lamp LH does not operate.

1. Bulb 2. Rear turn signal lamp LH ground circuit

1. Check bulb. 2. Check rear turn signal lamp LH ground circuit.

Rear turn signal lamp RH does not operate.

1. Bulb 2. Rear turn signal lamp RH ground circuit

1. Check bulb. 2. Check rear turn signal lamp RH ground circuit.

LH and RH turn indicators do not operate.

1. Ground circuit

1. Check ground circuit.

LH or RH turn indicator does not operate.

1. Bulb 2. Turn indicator circuit

1. Check bulb in cluster lid A. 2. Check continuity between combination meter terminals 12, 14 and 13.

AT

PD AX SU BR ST RS

Electrical Components Inspection COMBINATION FLASHER UNIT CHECK 쐌 쐌

NGEL0034

BT

NGEL0034S01

Before checking, ensure that bulbs meet specifications. Connect a battery and test lamp to the combination flasher unit, as shown. Combination flasher unit is properly functioning if it blinks when power is supplied to the circuit.

HA SC

SEL122E

EL-59

IDX

TRAILER TOW System Description

System Description

NGEL0161

Power is supplied at all times 쐌 through 15A fuse [No. 22, located in the fuse block (J/B)] 쐌 to trailer tow control unit terminal 6. Ground is supplied 쐌 to trailer tow control unit terminal 7 and 쐌 to trailer harness connector terminal 1 쐌 through body grounds B106 and B116.

TRAILER TAIL LAMP OPERATION

NGEL0161S01

With the lighting switch in the parking and tail lamp ON (1ST) or headlamp ON (2ND) position, power is supplied 쐌 from lighting switch terminal 12 쐌 to trailer harness connector terminal 2.

TRAILER STOP, TURN SIGNAL AND HAZARD LAMP OPERATION

NGEL0161S02

The trailer stop, turn signal and hazard lamps are all controlled by the trailer tow control unit. The trailer tow control unit regulates the amount of voltage supplied to the trailer lamps. If either turn signal or the hazard lamps are turned on and the trailer tow control unit gets a brake lamp input, the trailer tow control unit supplies more voltage to the trailer lamps to make them illuminate brighter. Power is supplied to trailer tow control unit terminal 6 through 15A fuse (No. 22, located in the fuse block) at all times. Stop lamp input is supplied to trailer tow control unit terminal 3. Left turn signal and hazard lamp input is supplied to trailer tow control unit terminal 4. Right turn signal and hazard lamp input is supplied to trailer tow control unit terminal 1. Based on the stop lamp, turn signal lamp and hazard lamp inputs to the trailer tow control unit, power is supplied to trailer stop/turn lamp LH 쐌 from trailer tow control unit terminal 8 쐌 to trailer harness connector terminal 3. Power is also supplied to trailer stop/turn lamp RH 쐌 from trailer tow control unit terminal 5 쐌 to trailer harness connector terminal 4.

EL-60

TRAILER TOW Wiring Diagram — T/TOW —

Wiring Diagram — T/TOW —

NGEL0162

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL666A

EL-61

IDX

TRAILER TOW Trouble Diagnoses

Trouble Diagnoses

NGEL0163

TRAILER TOW CONTROL UNIT INSPECTION TABLE NGEL0163S01 Terminal No.

Wire color

1

G/R

3

BR/R

Condition

Voltage (Approx.)

When RH turn lamps or hazard lamps operate

12 (intermittently)

Item

RH turn lamps input All other conditions

0

When brake pedal is depressed

12

When brake pedal is released

0

Stop lamps signal input When LH turn lamps or hazard lamps operate

4

5

G/Y

G

Stop/RH turn lamp (output)

All other conditions

0

When brake pedal is depressed

12

When RH turn lamps or hazard lamps operate All other conditions

6

R/B

7

B

Y

12 (intermittently) 0

Power supply

—

12

Ground

—

—

When brake pedal is depressed 8

12 (intermittently)

LH turn lamps input

Stop/LH turn lamp (output)

When LH turn lamps or hazard lamps operate All other conditions

EL-62

12 12 (intermittently) 0

ILLUMINATION System Description

System Description

NGEL0035

Power is supplied at all times 쐌 through 15A fuse (No. 39, located in the fuse and fusible link box) 쐌 to lighting switch terminal 11. The lighting switch must be in the parking and tail lamps ON (1ST) or headlamps ON (2ND) position for illumination. The illumination control switch controls the amount of current to the illumination system. As the amount of current increases, the illumination becomes brighter. The following chart shows the power and ground connector terminals for the components included in the illumination system. Component

Connector No.

Power terminal

Ground terminal

Illumination control switch

M28

1

5

Air control

M95

10

9

Audio unit

M51

8

7

Hazard switch

M53

7

8

Rear wiper switch

M89

4

5

R5

3

4

M39

30, 32

42

D7

3

8

M35

4

3

Compass and thermometer Combination meter Main power window and door lock/unlock switch A/T device

GI MA EM LC EC FE CL MT AT

The ground for all of the components are controlled through terminals 4 and 5 of the illumination control switch and body grounds M14 and M68.

TF PD AX SU BR ST RS BT HA SC

EL-63

IDX

ILLUMINATION Wiring Diagram — ILL —

Wiring Diagram — ILL —

NGEL0037

WEL667A

EL-64

ILLUMINATION Wiring Diagram — ILL — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL115B

EL-65

IDX

INTERIOR ROOM LAMP Component Parts and Harness Connector Location

Component Parts and Harness Connector Location

NGEL0194

WEL116B

EL-66

INTERIOR ROOM LAMP System Description

System Description MODELS WITHOUT POWER DOOR LOCKS Room Lamp

NGEL0038 NGEL0038S01

GI

NGEL0038S0106

Power is supplied at all times 쐌 through 7.5A fuse [No. 26, located in the fuse block (J/B)] 쐌 to front room lamp terminal + and 쐌 to rear room lamp terminal +. With the front/rear room lamp switch in the ON position, ground is supplied through the case of the front/rear room lamp. With one or more doors open, with the front/rear room lamp switch in the DOOR position, ground is supplied 쐌 to front/rear room lamp terminal DR 쐌 through front door switch LH terminal 1 and/or 쐌 through front door switch RH, rear door switch LH/RH and/or back door switch terminal +. Ground is supplied to back door switch terminal – through body grounds D402 and D404.

MA EM LC EC FE

MODELS WITH POWER DOOR LOCKS Room Lamp

NGEL0038S06 NGEL0038S0601

Power is supplied at all times 쐌 through 7.5A fuse [No. 28, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 49. With the front/rear room lamp or map lamp switches in the ON position, ground is supplied 쐌 through the case of the front/rear room lamp or 쐌 through body grounds M14 and M68 쐌 to map lamp terminal –. Power is also supplied 쐌 to front/rear room lamp or map lamp terminal + 쐌 from smart entrance control unit terminal 50. With the front door LH open and the front/rear room lamp switch in the DOOR position, ground is supplied 쐌 to front/rear room lamp terminal DR 쐌 through front door switch LH terminal 1 and 쐌 to smart entrance control unit terminal 1 쐌 through front door switch LH terminal 2 쐌 through body grounds B6 and B10. With the front door RH open and the front/rear room lamp switch in the DOOR position, ground is supplied 쐌 to smart entrance control unit terminal 2 쐌 through front door switch RH terminal + and 쐌 to front/rear room lamp terminal DR 쐌 through smart entrance control unit terminal 31 쐌 through smart entrance control unit terminal 43 and 64 쐌 through body grounds M14 and M68. With rear door LH/RH and/or back door open and the front/rear room lamp switch in the DOOR position, ground is supplied 쐌 to smart entrance control unit terminal 3 (with vehicle security system) or terminal 2 (without vehicle security system) 쐌 through rear door switch LH/RH and/or back door switch terminal + and 쐌 to front/rear room lamp terminal DR 쐌 through smart entrance control unit terminal 31 쐌 through smart entrance control unit terminal 43 and 64 쐌 through body grounds M14 and M68.

EL-67

CL MT AT TF PD AX SU BR ST RS BT HA SC

IDX

INTERIOR ROOM LAMP System Description (Cont’d)

Room Lamp Timer Operation

=NGEL0038S0603

When the room lamp switch is in the DOOR position, the smart entrance control unit keeps the room lamp illuminated for about 30 seconds when: 쐌 unlock signal is supplied from driver door lock and unlock switch while all doors are closed and key is removed from ignition key cylinder 쐌 unlock signal is supplied from key fob while all doors are closed and driver door is locked 쐌 key is removed from ignition key cylinder while driver door is closed 쐌 driver door is opened and then closed while key is removed from ignition key cylinder. (However, if the driver door is closed with the key inserted in the ignition key cylinder after the driver door is opened with key removed, the timer is operated.) The timer is canceled when: 쐌 driver door is locked, or 쐌 driver door is opened or 쐌 ignition switch is turned ON.

ON-OFF CONTROL

NGEL0038S0602

When the driver door, front passenger door, rear LH, RH door or back door is opened, the interior room lamp turns on while the room lamp switch is in the “DOOR” position.

BATTERY SAVER

NGEL0038S0604

The lamp turns off automatically when front/rear room lamp, map lamp is illuminated with the ignition key in the OFF position, if the lamp remains lit by the door switch open signal or if the lamp switch is in ON position for more than 30 minutes. After lamps turn OFF by the battery saver system, the lamps illuminate again when: 쐌 driver door is locked or unlocked, 쐌 door is opened or closed, 쐌 key is inserted in or removed from ignition key cylinder.

EL-68

INTERIOR ROOM LAMP Wiring Diagram — ROOM/L —

Wiring Diagram — ROOM/L — MODELS WITHOUT POWER DOOR LOCKS

NGEL0040 NGEL0040S01

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

WEL669A

EL-69

IDX

INTERIOR ROOM LAMP Wiring Diagram — ROOM/L — (Cont’d)

MODELS WITH POWER DOOR LOCKS

NGEL0040S02

WEL670A

EL-70

INTERIOR ROOM LAMP Wiring Diagram — ROOM/L — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL117B

EL-71

IDX

INTERIOR ROOM LAMP Trouble Diagnosis

Trouble Diagnosis

NGEL0207

SYMPTOM: Front and rear room lamp does not turn on or off properly.

MODELS WITHOUT POWER DOOR LOCKS 1

NGEL0207S01

CHECK FRONT AND REAR ROOM LAMP FUSE

Check 7.5 A fuses [No. 26 located in fuse block (J/B)]. OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace fuse and check harness for short between fuse and front and rear room lamps.

2

CHECK FRONT AND REAR ROOM LAMP SWITCH SIGNALS

1. Close all doors, turn ON front and rear room lamp switches. Do front and rear room lamps turn on? 2. Turn off front and rear room lamp switches. Do front and rear room lamps turn off? OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following. 쐌 Front or rear room lamp switch 쐌 Front or rear room lamp switch ground circuit 쐌 Harness for open or short between front or rear room lamp switch and front door switch LH, front door switch RH, rear door switch LH, rear door switch RH or back door switch

3

CHECK FRONT AND REAR ROOM LAMP POWER SUPPLY

Check voltage between front room lamp connector R2, or rear room lamp connector R3 terminal + (R/G) and ground.

LEL341A

OK or NG OK

䊳

GO TO 4.

NG

䊳

Check harness for open between fuse and front or rear room lamps.

4

CHECK INTERIOR ROOM LAMP BULB

Check interior room lamp bulb. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace bulb.

EL-72

INTERIOR ROOM LAMP Trouble Diagnosis (Cont’d)

5

CHECK KEY SWITCH (INSERTED) AND IGNITION ON SIGNAL

1. Insert key into ignition key cylinder. 2. Open front door LH. Does warning chime sound? 3. Turn ignition key to ON position. Does warning chime stop sounding?

GI MA YES or NO

YES

䊳

Check harness for open or short between front or rear room lamp switch and front door switch LH, front door switch RH, rear door switch LH, rear door switch RH or back door switch.

NO

䊳

Check “WARNING CHIME” system, refer to EL-103.

MODELS WITH POWER DOOR LOCKS 1

NGEL0207S02

EM LC EC

CHECK FRONT AND REAR ROOM LAMP FUSE

FE

Check 7.5 A fuses [No. 28 located in fuse block (J/B)]. OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace fuse and check harness for short between fuse and front and rear room lamps.

CL MT

2

CHECK FRONT AND REAR ROOM LAMP SWITCH SIGNALS

1. Close all doors, turn ON front and rear room lamp switches. Do front and rear room lamps turn on? 2. Turn off front and rear room lamp switches. Do front and rear room lamps turn off?

AT TF

OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following. 쐌 Front or rear room lamp switch 쐌 Front or rear room lamp switch ground circuit 쐌 Harness for open or short between front or rear room lamp switch and smart entrance control unit

PD AX SU

3

CHECK FRONT AND REAR ROOM LAMP POWER SUPPLY

Check voltage between front room lamp connector R2, or rear room lamp connector R3 terminal + (R/G) and ground.

BR ST RS BT

LEL341A

HA

OK or NG OK

䊳

GO TO 4.

NG

䊳

Check harness for open between fuse and front or rear room lamps.

SC

EL-73

IDX

INTERIOR ROOM LAMP Trouble Diagnosis (Cont’d)

4

CHECK INTERIOR ROOM LAMP BULB

Check interior room lamp bulb. OK or NG OK

䊳

GO TO 5.

NG

䊳

Replace bulb.

5

CHECK KEY SWITCH (INSERTED) AND IGNITION ON SIGNAL

1. Insert key into ignition key cylinder. 2. Open front door LH. Does warning chime sound? 3. Turn ignition key to ON position. Does warning chime stop sounding? YES or NO YES

䊳

GO TO 6.

NO

䊳

Check “WARNING CHIME” system, refer to EL-103.

6

CHECK DOOR SWITCH INPUT SIGNAL

Unlock doors using LH door key cylinder Do the doors unlock? YES or NO YES

䊳

Replace smart entrance control unit.

NO

䊳

Refer to “DOOR KEY CYLINDER SWITCH CHECK”, EL-200.

EL-74

METERS AND GAUGES Component Parts and Harness Connector Location

Component Parts and Harness Connector Location

NGEL0041

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

WEL916A

EL-75

IDX

METERS AND GAUGES System Description

System Description UNIFIED CONTROL METER 쐌 쐌 쐌 쐌

NGEL0042 NGEL0042S06

Speedometer, odo/trip meter, tachometer, fuel gauge and water temperature gauge are controlled totally by unified meter control unit combined with speedometer and odo/trip meter. 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.

HOW TO CHANGE THE DISPLAY FOR ODO/TRIP METER

NGEL0042S07

SEL253V

NOTE: Turn ignition switch ON to operate odo/trip meter.

POWER SUPPLY AND GROUND CIRCUIT

NGEL0042S08

Power is supplied at all times 쐌 through 7.5A fuse [No. 28, located in the fuse block (J/B)] 쐌 to combination meter terminal 31. With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 11, located in the fuse block (J/B)] 쐌 to combination meter terminal 32. Ground is supplied 쐌 to combination meter terminal 33 쐌 through body grounds M14 and M68.

FUEL GAUGE

NGEL0042S03

The fuel gauge indicates the approximate fuel level in the fuel tank. The reading on the gauge is based on the resistance of the fuel level sensor unit. The fuel gauge is regulated by a variable ground signal supplied 쐌 to combination meter terminal 47 for the fuel gauge 쐌 through fuel level sensor unit terminal 2 쐌 through fuel level sensor unit terminal 4 쐌 through body grounds B106 and B116.

EL-76

METERS AND GAUGES System Description (Cont’d)

WATER TEMPERATURE GAUGE

NGEL0042S01

The water temperature gauge indicates the engine coolant temperature. The reading on the gauge is based on the resistance of the thermal transmitter. The water temperature gauge is regulated by a variable ground signal supplied 쐌 to combination meter terminal 46 쐌 through thermal transmitter terminal 1. As the temperature of the coolant increases, the resistance of the thermal transmitter decreases and the needle on the gauge moves from C to H.

TACHOMETER

GI MA EM

NGEL0042S02

The tachometer indicates engine speed in revolutions per minute (rpm). The tachometer is regulated by a signal 쐌 to combination meter terminal 48 for the tachometer 쐌 from ECM terminal 3.

SPEEDOMETER

LC EC NGEL0042S04

The vehicle speed sensor provides a voltage signal to the combination meter for the speedometer. The voltage is supplied 쐌 to combination meter terminals 34 and 35 for the speedometer 쐌 from vehicle speed sensor terminals 1 and 2. The unified meter control unit converts the voltage to the vehicle speed and displays it on the speedometer.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-77

IDX

METERS AND GAUGES Combination Meter

Combination Meter

NGEL0043

LEL894A

EL-78

METERS AND GAUGES Combination Meter (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL118B

EL-79

IDX

METERS AND GAUGES Wiring Diagram — METER —

Wiring Diagram — METER —

NGEL0045

WEL119B

EL-80

METERS AND GAUGES Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode

Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode DIAGNOSIS FUNCTION 쐌 쐌

2.

GI

NGEL0151S01

Odo/trip meter segment can be checked in diagnosis mode. Meters/gauges can be checked in diagnosis mode.

HOW TO ALTERNATE DIAGNOSIS MODE 1.

NGEL0151

NGEL0151S02

Turn ignition switch ON while pressing and holding trip reset switch for 0.8 second. Push trip reset switch 3 times within 7 seconds.

3. All odo/trip meter segments should be turned on. NOTE: If some segments are not turned on, speedometer (unified meter control unit) with odo/trip meter should be replaced. At this point, the unified meter control unit is in diagnosis mode.

MA EM LC EC FE CL MT

SEL110V

4.

Push odo/trip meter switch. Indication of each meter/gauge should be as shown in figure at left while pushing odo/trip meter switch if it is not malfunctioning. NOTE: It takes about 1 minute for indication of fuel gauge to become stable.

AT TF PD AX

WEL900A

SU BR ST RS BT HA SC

EL-81

IDX

METERS AND GAUGES Trouble Diagnoses

Trouble Diagnoses

NGEL0046

PRELIMINARY CHECK

NGEL0046S04

WEL835A

*1: EL-81

*2: EL-84

*3: EL-83

EL-82

METERS AND GAUGES Trouble Diagnoses (Cont’d)

SYMPTOM CHART Symptom Speedometer and odo/trip meter are malfunctioning.

Possible causes

=NGEL0046S05

Repair order

쐌 Signal - Speedometer, Odo/Trip meter 쐌 Unified meter control unit

GI

1. Check vehicle speed sensor. Refer to INSPECTION/VEHICLE SPEED SENSOR, EL-85. 2. Replace combination meter.

MA

Multiple meters/gauges 쐌 Unified meter control unit are malfunctioning (except speedometer, odo/trip meter).

쐌 Replace combination meter.

EM

쐌 Unified meter control unit

1. Replace combination meter.

One gauge (tachometer, fuel gauge or water temp. gauge) is malfunctioning.

LC EC

Before starting trouble diagnoses above, refer to “PRELIMINARY CHECK”, EL-82.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-83

IDX

METERS AND GAUGES Trouble Diagnoses (Cont’d)

POWER SUPPLY AND GROUND CIRCUIT CHECK=NGEL0046S07 Power Supply Circuit Check NGEL0046S0701 Terminals (+)

Ignition switch position (−)

Connector

Terminal (wire color)

M39

31 (R/Y)

Ground

Battery voltage

Battery voltage

Battery voltage

M39

32 (W/B)

Ground

0V

0V

Battery voltage

WEL791A

If NG, check the following. 쐌 7.5A fuse [No. 28, located in fuse block (J/B)] 쐌 10A fuse [No. 11, located in fuse block (J/B)] 쐌 Harness for open or short between fuse and combination meter

Ground Circuit Check

NGEL0046S0702

Terminals (+)

Continuity (–)

Connector

Terminal (wire color)

M39

33 (B/R)

Ground

WEL792A

EL-84

Yes

METERS AND GAUGES Trouble Diagnoses (Cont’d)

INSPECTION/VEHICLE SPEED SENSOR 1

=NGEL0046S03

CHECK VEHICLE SPEED SENSOR OUTPUT

GI

1. Remove vehicle speed sensor from transmission. 2. Check voltage between combination meter connector M39 terminal 34 (BR/W) and terminal 35 (SB) while quickly turning speed sensor pinion.

MA EM LC EC

WEL793A

FE

Voltage: Approx. 0.5V OK or NG OK

䊳

Vehicle speed sensor is OK.

NG

䊳

GO TO 2.

2

CL MT

CHECK VEHICLE SPEED SENSOR

AT

Check resistance between vehicle speed sensor terminals 1 and 2.

TF PD AX WEL120B

SU

Resistance: Approx. 285Ω OK or NG OK

䊳

Check harness and connector between speedometer and vehicle speed sensor.

NG

䊳

Replace vehicle speed sensor.

BR ST RS BT HA SC

EL-85

IDX

METERS AND GAUGES Trouble Diagnoses (Cont’d)

INSPECTION/ENGINE REVOLUTION SIGNAL 1

NGEL0046S02

CHECK ECM OUTPUT

1. Start engine. 2. Check voltage between combination meter connector M39 terminal 48 (P/L) and terminal 33 (B/R) at idle and 2,000 rpm.

WEL795A

OK or NG OK

䊳

Engine revolution signal is OK.

NG

䊳

Check harness for open or short between ECM and combination meter.

EL-86

METERS AND GAUGES Trouble Diagnoses (Cont’d)

INSPECTION/FUEL LEVEL SENSOR UNIT 1

=NGEL0046S08

CHECK GROUND CIRCUIT FOR FUEL LEVEL SENSOR UNIT

GI

Check harness continuity between fuel level sensor unit harness connector B108 terminal 4 (B) and ground.

MA EM LC LEL004A

Yes

䊳

GO TO 2.

No

䊳

Repair harness or connector.

2

EC FE CL

CHECK FUEL LEVEL SENSOR UNIT

Refer to “FUEL LEVEL SENSOR UNIT CHECK”, EL-89.

MT

OK or NG OK

䊳

GO TO 3.

NG

䊳

Replace fuel level sensor unit.

3

AT

CHECK HARNESS FOR OPEN OR SHORT

TF

1. Disconnect combination meter harness connector M39, fuel level sensor unit harness connector B108 and ECM connector F29. 2. Check continuity between combination meter harness connector M39 terminal 47 (OR/B) and fuel level sensor unit harness connector B108 terminal 2 (OR/B). Continuity should exist. 3. Check continuity between combination meter harness connector M39 terminal 47 (OR/B) and ground. Continuity should not exist.

PD AX SU BR ST RS

WEL796A

OK or NG OK

䊳

Fuel level sensor unit is OK.

NG

䊳

Repair harness or connector.

BT HA SC

EL-87

IDX

METERS AND GAUGES Trouble Diagnoses (Cont’d)

INSPECTION/THERMAL TRANSMITTER 1

NGEL0046S09

CHECK THERMAL TRANSMITTER

Refer to “THERMAL TRANSMITTER CHECK”, EL-89. OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace thermal transmitter.

2

CHECK HARNESS FOR OPEN OR SHORT

1. Disconnect combination meter harness connector M39 and thermal transmitter harness connector. 2. Check continuity between combination meter harness connector M39 terminal 46 (GY) and thermal transmitter harness connector terminal 1. Continuity should exist. 3. Check continuity between combination meter harness connector M39 terminal 46 (GY) and ground. Continuity should not exist.

WEL797A

OK or NG OK

䊳

Thermal transmitter is OK.

NG

䊳

Repair harness or connector.

EL-88

METERS AND GAUGES Electrical Components Inspection

Electrical Components Inspection

NGEL0047

FUEL LEVEL SENSOR UNIT CHECK

=NGEL0047S01

쐌 For removal, refer to FE-4, “Removal and Installation”. Check the resistance between fuel level sensor unit terminals 2 and 4. Ohmmeter Float position (+)

MEL827F

2

Resistance value (Ω)

mm (in)

(−)

4

*1

Full

96 (3.78)

Approx. 4 - 6

*2

1/2

188 (7.40)

30 - 34

*3

Empty

257 (10.12)

80 - 83

GI MA EM LC EC

*1 and *3: When float rod is in contact with stopper.

FE CL MT THERMAL TRANSMITTER CHECK

NGEL0047S02

Check the resistance between thermal transmitter terminal 1 and body ground. Water temperature

Resistance

60°C (140°F)

Approx. 170 - 210Ω

100°C (212°F)

Approx. 47 - 53Ω

AT TF PD AX

MEL424F

VEHICLE SPEED SENSOR SIGNAL CHECK 1. 2.

NGEL0047S03

Remove vehicle speed sensor from transmission. Turn vehicle speed sensor pinion quickly and measure voltage across 1 and 2.

SU BR ST RS

WEL121B

BT HA SC

EL-89

IDX

COMPASS AND THERMOMETER System Description

System Description

NGEL0209

WEL901A

This unit displays following items: 쐌 Earth magnetism and heading direction of vehicle. 쐌 Outside air temperature. 쐌 Caution for frozen road surfaces.

OUTSIDE TEMPERATURE DISPLAY

NGEL0209S01

Push the switch when the ignition key is in the “ACC” or “ON” position. The outside temperature will be displayed in “°F”. 쐌 Selecting the indication range Push the switch to change from “°F” to “°C”. 쐌 The indicated temperature on the thermometer is not readily affected by engine heat. It changes only when one of the following conditions is present. a) The temperature detected by the ambient air temperature sensor is lower than the indicated temperature on the thermometer. b) The vehicle speed is greater than 20 km/h (13 MPH). (This is to prevent the indicated temperature from being affected by engine heat during low-speed driving.) c) The ignition key has been turned to the “OFF” position for more than 2 hours. (The engine is cold.)

DIRECTION DISPLAY

NGEL0209S02

Push the switch when the ignition key is in the “ACC” or “ON” position. The direction will be displayed.

EL-90

COMPASS AND THERMOMETER Wiring Diagram — COMPAS —

Wiring Diagram — COMPAS —

NGEL0210

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL122B

EL-91

IDX

COMPASS AND THERMOMETER Trouble Diagnoses

Trouble Diagnoses

NGEL0211

PRELIMINARY CHECK FOR THERMOMETER 1

NGEL0211S01

COOL DOWN CHECK

1. Turn the ignition key switch to the “ACC” position. 2. Cool down the ambient air temperature sensor with water or ice, so that the indicated temperature falls. Does the indicated temperature fall? Yes

䊳

GO TO 2.

No

䊳

The system is malfunctioning. Check the system following “INSPECTION/COMPASS AND THERMOMETER”.

2

WARM UP CHECK

1. Leave the vehicle for 10 minutes, so that the indicated temperature rises. 2. With the ignition key in the “ACC” position, disconnect and reconnect the ambient air temperature sensor connector. Does the indicated temperature rise? Yes

䊳

The system is OK.

No

䊳

The system is malfunctioning. Check the system following “INSPECTION/COMPASS AND THERMOMETER”.

NOTE: 쐌 The indicated temperature on the thermometer is not readily affected by engine heat. It changes only when one of the following conditions is present. a) The temperature detected by the ambient air temperature sensor is lower than the indicated temperature on the thermometer. b) The vehicle speed is greter than 20 km/h (13 MPH). (This is to prevent the indicated temperature from being affected by engine heat during low-speed driving.) c) The ignition key has been turned to the “OFF” position for more than 2 hours. (The engine is cold.)

INSPECTION/COMPASS AND THERMOMETER Symptom

NGEL0211S02

Possible causes

Repair order

No display at all

1. 10A fuse 2. Ground circuit 3. Compass and thermometer

1. Check 10A fuse [No. 11, located in fuse block (J/B)]. Turn the ignition switch ON and verify that battery positive voltage is at terminal 7 of compass and thermometer. 2. Check ground circuit for compass and thermometer. 3. Replace compass and thermometer.

Forward direction indication slips off the mark or incorrect.

1. In manual correction mode (Bar and display vanish.) 2. Zone variation change is not done.

1. Drive the vehicle and turn at an angle of 90°. 2. Perform the zone variation change.

Compass reading remains unchanged.

1. Vehicle speed signal is not entered. 1. Check harness for open or short between combination meter 2. Compass and thermometer terminal 2 and compass and thermometer terminal 1. 2. Replace compass and thermometer.

Displays wrong temperature when ambient temperature is between −40°C (−40°F) and 55°C (130°F). (See NOTE above.)

1. Check operation 2. Ambient air temperature sensor circuit 3. Vehicle speed signal is not entered. 4. Ambient air temperature sensor 5. Compass and thermometer

1. Perform preliminary check shown above. 2. Check harness for open or short between ambient air temperature sensor and compass and thermometer. 3. Check harness for open or short between combination meter terminal 2 and compass and thermometer terminal 1. 4. Replace ambient air temperature sensor. 5. Replace compass and thermometer.

Displays SC or OC.

1. Ambient air temperature sensor circuit. 2. Ambient air temperature sensor. 3. Compass and thermometer.

1. Check harness for open or short between ambient air temperature sensor and compass and thermometer. 2. Replace ambient air temperature sensor. 3. Replace compass and thermometer.

EL-92

COMPASS AND THERMOMETER Calibration Procedure for Compass

Calibration Procedure for Compass

=NGEL0212

The difference between magnetic North and geographical North can sometimes be great enough to cause false compass readings. In order for the compass to operate accurately in a particular zone, it must be calibrated using the following procedure.

GI MA EM LC EC FE CL MT AT TF PD

WEL859A

AX CORRECTION FUNCTIONS OF COMPASS

NGEL0212S01

The direction display is equipped with automatic correction function. If the direction is not shown correctly, carry out initial correction.

SU BR

INITIAL CORRECTION PROCEDURE FOR COMPASS NGEL0212S02 1.

WEL902A

Pushing the “Mode” switch for about 10 seconds will enter the initial correction mode. The “CAL” icon will illuminate. 2. Turn the vehicle slowly in an open, safe place. The initial correction is completed in one or two turns. NOTE: In places where the terrestrial magnetism is extremely disturbed, the initial correction may start automatically.

ST RS BT HA SC

EL-93

IDX

WARNING LAMPS Circuit Diagram

Circuit Diagram

NGEL0049

WEL158B

EL-94

WARNING LAMPS Wiring Diagram — WARN —

Wiring Diagram — WARN —

NGEL0050

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL123B

EL-95

IDX

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

MODELS WITHOUT POWER DOOR LOCKS

NGEL0050S01

WEL677A

EL-96

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

MODELS WITH POWER DOOR LOCKS

NGEL0050S02

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL678A

EL-97

IDX

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

WEL159B

EL-98

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL160B

EL-99

IDX

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

WEL124B

EL-100

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL682A

EL-101

IDX

WARNING LAMPS Electrical Components Inspection

Electrical Components Inspection

NGEL0051

FUEL WARNING LAMP SENSOR CHECK 1)

NGEL0051S01

Turn ignition switch OFF.

LEL005A

2) 3)

Disconnect fuel level sensor unit harness connector B108. Connect a resistor (80 Ω) between fuel level sensor unit harness connector B108 terminals 2 (OR/B) and 4 (B). 4) Turn ignition switch ON. The fuel warning lamp should come on. NOTE: ECM might store the 1st tip DTC P0180 during this inspection. If the DTC is stored in ECM memory, erase the DTC after reconnecting the fuel level sensor unit harness connector. Refer to EC-86 (KA24DE), EC-673 (VG33E), or EC-1197 (VG33ER), “ HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.

OIL PRESSURE SWITCH CHECK

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 oil pressure switch terminal 1 and body ground.

DIODE CHECK 쐌 쐌

SEL901F

NGEL0051S02

NGEL0051S03

Check continuity using an ohmmeter. Diode is functioning properly if test results are as shown in the figure at left. 쐌 Check diodes at the combination meter harness connector instead of the combination meter assembly. Refer to “Wiring Diagrams —WARN—”, EL-95. NOTE: Specification may vary depending on the type of tester. Before performing this inspection, be sure to refer to the instruction manual of the tester to be used.

EL-102

WARNING CHIME Component Parts and Harness Connector Location

Component Parts and Harness Connector Location

NGEL0052

GI MA EM LC EC FE CL MT AT TF PD

WEL125B

System Description MODELS WITHOUT POWER DOOR LOCKS

NGEL0053

NGEL0053S0401

With the key switch in the INSERTED (key is in the ignition key cylinder) position, the ignition switch in the OFF or ACC position and the front door LH open, the warning chime will sound. A battery positive voltage is supplied 쐌 from key switch terminal 2 쐌 to warning chime unit terminal 5.

EL-103

SU

NGEL0053S04

The warning chime is integral with the warning chime unit, which controls its operation. Power is supplied at all times 쐌 through 7.5A fuse [No. 28, located in the fuse block (J/B)] 쐌 to key switch terminal 1. Power is supplied at all times 쐌 through 15A fuse (No. 39, located in the fuse and fusible link box) 쐌 to lighting switch terminal 11. With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 to warning chime unit terminal 1. Ground is supplied to warning chime unit terminal 8 through body grounds M14 and M68. When a signal, or combination of signals, is received by the warning chime unit, the warning chime will sound.

Ignition Key Warning Chime

AX

BR ST RS BT HA SC

IDX

WARNING CHIME System Description (Cont’d)

Ground is supplied 쐌 to warning chime unit terminal 7 쐌 through front door switch LH terminal 2. Front door switch LH terminal 3 is grounded through body grounds B6 and B10.

Light Warning Chime

NGEL0053S0402

With the ignition switch in the OFF or ACC position, front door LH open and lighting switch in the parking and tail lamps ON (1ST) or headlamps ON (2ND) position, the warning chime will sound. A battery positive voltage is supplied 쐌 from lighting switch terminal 12 쐌 to warning chime unit terminal 4. Ground is supplied 쐌 to warning chime unit terminal 7 쐌 through front door switch LH terminal 2. Front door switch LH terminal 3 is grounded through body grounds B6 and B10.

Seat Belt Warning Chime

NGEL0053S0403

The warning chime will sound for approximately 6 seconds when the ignition switch is turned from OFF to ON with the driver’s seat belt unfastened (seat belt buckle switch ON). Ground is supplied 쐌 to warning chime unit terminal 2 쐌 through seat belt buckle switch terminal 1. Seat belt buckle switch terminal 2 is grounded through body grounds M14 and M68.

MODELS WITH POWER DOOR LOCKS

NGEL0053S05

The warning chime is controlled by the smart entrance control unit. Power is supplied at all times 쐌 through 7.5A fuse [No. 28, located in the fuse block (J/B)] 쐌 to key switch terminal 1, and 쐌 to smart entrance control unit terminal 49. Power is supplied at all times 쐌 through 15A fuse (No. 39, located in the fuse and fusible link box) 쐌 to lighting switch terminal 11. With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 27. Ground is supplied to smart entrance control unit terminals 43 and 64 through body grounds M14 and M68. When a signal, or combination of signals, is received by the smart entrance control unit, the warning chime will sound.

Ignition Key Warning Chime

NGEL0053S0501

With the key switch in the INSERTED (key is in the ignition key cylinder) position, the ignition switch in the OFF or ACC position and the front door LH open, the warning chime will sound. Power is supplied 쐌 from key switch terminal 2 쐌 to smart entrance control unit terminal 25. Ground is supplied 쐌 to smart entrance control unit terminal 1 쐌 through front door switch LH terminal 2. Front door switch LH terminal 3 is grounded through body grounds B6 and B10.

Light Warning Chime

NGEL0053S0502

With the ignition switch the OFF or ACC position, front door LH open and lighting switch in parking and tail lamps ON (1ST) or headlamps ON (2ND) position, the warning chime will sound. Power is supplied 쐌 from lighting switch terminal 12 쐌 to smart entrance control unit terminal 58. Ground is supplied

EL-104

WARNING CHIME System Description (Cont’d)

쐌 to smart entrance control unit terminal 1 쐌 through front door switch LH terminal 2. Front door switch LH terminal 3 is grounded through body grounds B6 and B10.

Seat Belt Warning Chime

GI NGEL0053S0503

The warning chime will sound for approximately 6 seconds when the ignition switch is turned from OFF to ON with the driver’s seat belt unfastened (seat belt buckle switch ON). Ground is supplied 쐌 to smart entrance control unit terminal 28 쐌 through seat belt buckle switch terminal 1. Seat belt buckle switch terminal 2 is grounded through body grounds M14 and M68.

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-105

IDX

WARNING CHIME Wiring Diagram — CHIME —

Wiring Diagram — CHIME — MODELS WITHOUT POWER DOOR LOCKS

NGEL0054 NGEL0054S01

LEL683A

EL-106

WARNING CHIME Wiring Diagram — CHIME — (Cont’d)

MODELS WITH POWER DOOR LOCKS

NGEL0054S02

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL684A

EL-107

IDX

WARNING CHIME Trouble Diagnoses

Trouble Diagnoses

NGEL0055

SYMPTOM CHART Without power door locks

109

111

112

114

116

With power door locks

109

111

113

115

117

SYMPTOM

POWER SUPPLY AND GROUND CIRCUIT CHECK

LIGHTING SWITCH INPUT SIGNAL CHECK

KEY SWITCH (INSERTED) CHECK

SEAT BELT BUCKLE SWITCH CHECK

FRONT DOOR SWITCH LH CHECK

NGEL0055S01

Light warning chime does not activate.

X

X

Ignition key warning chime does not activate.

X

Seat belt warning chime does not activate.

X

All warning chimes do not activate.

X

REFERENCE PAGE (EL-

)

X: Applicable

EL-108

X X

X X

WARNING CHIME Trouble Diagnoses (Cont’d)

POWER SUPPLY AND GROUND CIRCUIT CHECK=NGEL0055S02 Main Power Supply Circuit Check NGEL0055S0201 쐌

Models without power door locks Terminals

AEL617C

GI

Ignition switch position

(+)

(–)

OFF

ACC

ON

1

Ground

0V

0V

Battery voltage

If NG, check the following 쐌 15A fuse (No. 39, located in fuse and fusible link box) 쐌 Harness for open or short between warning chime unit and fuse.

MA EM LC EC FE CL MT

쐌

Models with power door locks Terminals

AT

Ignition switch position

(+)

TF

Terminal (wire color)

(−)

OFF

ACC

ON

Connector M111

27 (G/W)

Ground

0V

0V

Battery voltage

PD

M112

49 (G)

Ground

Battery voltage

Battery voltage

Battery voltage

AX

LEL007A

If NG, check the following 쐌 7.5A fuse [No. 28, located in fuse block (J/B)] 쐌 10A fuse [No. 5, located in fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse.

SU BR ST RS

Ground Circuit Check 쐌

NGEL0055S0202

BT

Models without power door locks Terminals

Continuity

8 - Ground

Yes

HA SC

AEL619C

EL-109

IDX

WARNING CHIME Trouble Diagnoses (Cont’d)

쐌

Models with power door locks Terminals (+)

Continuity (−)

Connector

Terminal (wire color)

M111

43 (B)

Ground

M112

64 (B)

Ground

Yes

LEL008A

EL-110

WARNING CHIME Trouble Diagnoses (Cont’d)

LIGHTING SWITCH INPUT SIGNAL CHECK Models without Power Door Locks 1

=NGEL0055S03 NGEL0055S0301

GI

CHECK LIGHTING SWITCH INPUT SIGNAL

Check voltage between warning chime unit terminal 4 and ground.

MA EM LC AEL372B

Voltage [V]: Condition of lighting switch: 1ST or 2ND Approx. 12 Condition of lighting switch: OFF 0

FE CL

OK or NG OK

䊳

Lighting switch is OK.

NG

䊳

Check the following. 쐌 15A fuse (No. 39, located in the fuse and fusible link box) 쐌 Harness for open or short between warning chime unit and lighting switch

Models with Power Door Locks 1

EC

MT AT NGEL0055S0302

CHECK LIGHTING SWITCH INPUT SIGNAL

TF

Check voltage between smart entrance control unit connector M112 terminal 58 (L/R) and ground.

PD AX SU LEL009A

BR

OK or NG

ST

OK

䊳

Lighting switch is OK.

NG

䊳

Check the following. 쐌 15A fuse (No. 39, located in the fuse and fusible link box) 쐌 Harness for open or short between smart entrance control unit and lighting switch

RS BT HA SC

EL-111

IDX

WARNING CHIME Trouble Diagnoses (Cont’d)

KEY SWITCH (INSERTED) CHECK Models without Power Door Locks 1

NGEL0055S04 NGEL0055S0401

CHECK KEY SWITCH INPUT SIGNAL

Check voltage between warning chime unit terminal 5 and ground.

AEL374B

Voltage [V]: Condition of key switch: Key is INSERTED. Approx. 12 Condition of key switch: Key is REMOVED. 0 OK or NG OK

䊳

Key switch is OK.

NG

䊳

GO TO 2.

2

CHECK KEY SWITCH (INSERTED)

Check continuity between terminals 1 and 2.

AEL416B

Continuity: Condition of key switch: Key is INSERTED. Yes Condition of key switch: Key is REMOVED. No OK or NG OK

䊳

Check the following. 쐌 7.5A fuse [No. 28, located in fuse block (J/B)] 쐌 Harness for open or short between key switch and fuse 쐌 Harness for open or short between warning chime unit and key switch

NG

䊳

Replace key switch.

EL-112

WARNING CHIME Trouble Diagnoses (Cont’d)

Models with Power Door Locks 1

NGEL0055S0402

CHECK KEY SWITCH INPUT SIGNAL

GI

Check voltage between smart entrance control unit connector M111 terminal 25 (W/G) and ground.

MA EM LC LEL010A

EC

OK or NG OK

䊳

Key switch is OK.

NG

䊳

GO TO 2.

FE CL

2

CHECK KEY SWITCH (INSERTED)

MT

Check continuity between terminals 1 and 2.

AT TF

AEL416B

Continuity: Condition of key switch: Key is INSERTED. Yes Condition of key switch: Key is REMOVED. No

PD AX SU

OK or NG OK

䊳

Check the following. 쐌 7.5A fuse [No. 28, located in fuse block (J/B)] 쐌 Harness for open or short between key switch and fuse 쐌 Harness for open or short between smart entrance control unit and key switch

NG

䊳

Replace key switch.

BR ST RS BT HA SC

EL-113

IDX

WARNING CHIME Trouble Diagnoses (Cont’d)

SEAT BELT BUCKLE SWITCH CHECK Models without Power Door Locks 1

=NGEL0055S05 NGEL0055S0501

CHECK SEAT BELT BUCKLE SWITCH INPUT SIGNAL

1. Turn ignition switch ON. 2. Check voltage between warning chime unit terminal 2 and ground.

AEL376B

Voltage [V]: Condition of seat belt buckle switch: FASTENED Approx. 12 Condition of seat belt buckle switch: UNFASTENED 0 OK or NG OK

䊳

Seat belt buckle switch is OK.

NG

䊳

GO TO 2.

2

CHECK SEAT BELT BUCKLE SWITCH

Check continuity between terminals 1 and 2 when seat belt is fastened and unfastened.

AEL381B

Continuity: Seat belt is fastened. No Seat belt is unfastened. Yes OK or NG OK

䊳

Check the following. 쐌 Seat belt buckle switch ground circuit 쐌 Harness for open or short between warning chime unit and seat belt buckle switch

NG

䊳

Replace seat belt buckle switch.

EL-114

WARNING CHIME Trouble Diagnoses (Cont’d)

Models with Power Door Locks 1

NGEL0055S0502

CHECK SEAT BELT BUCKLE SWITCH INPUT SIGNAL

GI

1. Turn ignition switch ON. 2. Check voltage between smart entrance control unit connector M111 terminal 28 (B/P) and ground.

MA EM LC EC LEL011A

FE

OK or NG OK

䊳

Seat belt buckle switch is OK.

NG

䊳

GO TO 2.

2

CL

CHECK SEAT BELT BUCKLE SWITCH

MT

Check continuity between terminals 1 and 2 when seat belt is fastened and unfastened.

AT TF PD AEL381B

Continuity: Seat belt is fastened. No Seat belt is unfastened. Yes

SU OK or NG

OK

NG

䊳

䊳

AX

Check the following. 쐌 Seat belt buckle switch ground circuit 쐌 Harness for open or short between smart entrance control unit and seat belt buckle switch Replace seat belt buckle switch.

BR ST RS BT HA SC

EL-115

IDX

WARNING CHIME Trouble Diagnoses (Cont’d)

FRONT DOOR SWITCH LH CHECK Models without Power Door Locks 1

NGEL0055S06 NGEL0055S0601

CHECK FRONT DOOR SWITCH LH INPUT SIGNAL

Check voltage between warning chime unit terminal 7 and ground.

AEL378B

Voltage [V]: Condition of front door LH: CLOSED Approx. 12 Condition of front door LH: OPEN 0 OK or NG OK

䊳

Front door switch LH is OK.

NG

䊳

GO TO 2.

2

CHECK FRONT DOOR SWITCH LH

Check continuity between front door switch LH connector B4 terminals 2 and 3.

LEL319A

OK or NG OK

䊳

Check the following. 쐌 Front door switch LH ground circuit 쐌 Harness for open or short between warning chime unit and front door switch LH

NG

䊳

Replace front door switch LH.

EL-116

WARNING CHIME Trouble Diagnoses (Cont’d)

Models with Power Door Locks 1

NGEL0055S0602

CHECK FRONT DOOR SWITCH LH INPUT SIGNAL

GI

Check voltage between smart entrance control unit connector M110 terminal 1 (G/R) and ground.

MA EM LC LEL012A

EC

OK or NG OK

䊳

Front door switch LH is OK.

NG

䊳

GO TO 2.

FE CL

2

CHECK FRONT DOOR SWITCH LH

MT

Check continuity between front door switch LH connector B4 terminals 2 and 3.

AT TF PD LEL319A

OK or NG OK

NG

䊳

Check the following. 쐌 Front door switch LH ground circuit 쐌 Harness for open or short between smart entrance control unit and front door switch LH

䊳

Replace front door switch LH.

AX SU BR ST RS BT HA SC

EL-117

IDX

FRONT WIPER AND WASHER System Description

System Description WIPER OPERATION Models without Intermittent Wipers

NGEL0057 NGEL0057S01 NGEL0057S0104

The front wiper switch is controlled by a lever built into the combination switch. There are two front wiper switch positions: 쐌 LO speed 쐌 HI speed With the ignition switch in the ON or START position, power is supplied 쐌 through 20A fuse [No. 6, located in the fuse block (J/B)] 쐌 to front wiper motor terminal B. Low and High Speed Wiper Operation Ground is supplied to front wiper switch terminal 17 through body grounds E12 and E54. With the front wiper switch in the LO position, ground is supplied 쐌 to front wiper motor terminal L 쐌 through front wiper switch terminal 14. With power and ground supplied, the front wiper motor operates at low speed. With the front wiper switch in the HI position, ground is supplied 쐌 to front wiper motor terminal H 쐌 through front wiper switch terminal 16. With power and ground supplied, the front wiper motor operates at high speed. Auto Stop Operation When the front wiper switch is turned OFF, the front wiper motor will continue to operate at low speed until wiper blades reach windshield base. When wiper blades are not located at base of windshield with front wiper switch OFF, ground is supplied 쐌 to front wiper motor terminal L 쐌 through front wiper switch terminal 14 쐌 through front wiper switch terminal 13 쐌 through front wiper motor terminal P. Ground is supplied to front wiper motor terminal E through body grounds E12 and E54.

Models with Intermittent Wipers

NGEL0057S0105

The front wiper switch is controlled by a lever built into the combination switch. There are three front wiper switch positions: 쐌 LO speed 쐌 HI speed 쐌 INT (Intermittent) With the ignition switch in the ON or START position, power is supplied 쐌 through 20A fuse [No. 6, located in the fuse block (J/B)] 쐌 to front wiper motor terminal B and 쐌 to front wiper switch terminal 15. Low and High Speed Wiper Operation Ground is supplied to front wiper switch terminal 17 through body grounds E12 and E54 With the front wiper switch in the LO position, ground is supplied 쐌 to front wiper motor terminal L 쐌 through front wiper switch terminal 14. With power and ground supplied, the front wiper motor operates at low speed. With the front wiper switch in the HI position, ground is supplied 쐌 to front wiper motor terminal H 쐌 through front wiper switch terminal 16. With power and ground supplied, the front wiper motor operates at high speed. Auto Stop Operation When the front wiper switch is turned OFF, the front wiper motor will continue to operate at low speed until wiper blades reach windshield base. When wiper blades are not located at base of windshield with front wiper switch OFF, ground is supplied

EL-118

FRONT WIPER AND WASHER System Description (Cont’d)

쐌 to front wiper motor terminal L 쐌 through front wiper switch terminal 14 쐌 through front wiper switch terminal 13 쐌 through front wiper motor terminal P 쐌 through front wiper motor terminal E 쐌 through body grounds E12 and E54. When wiper blades reach base of windshield, front wiper motor terminals B and P are connected instead of terminals P and E. Battery power is then supplied 쐌 through front wiper motor terminal P 쐌 to front wiper switch terminal 13. With battery voltage supplied to front wiper switch terminal 13, the front wiper switch will stop the front wiper motor with the wiper blades at the PARK position. Intermittent Operation The wiper blades perform a single wiping operation, followed by a delay interval which is adjustable from approximately 3 to 13 seconds, after which the cycle repeats. This feature is controlled by the front wiper switch. When the front wiper switch is placed in the INT position, ground is supplied intermittently 쐌 to front wiper motor terminal L 쐌 through front wiper switch terminal 14 쐌 through front wiper switch terminal 17 쐌 through body grounds E12 and E54. The delay interval time is controlled by the wiper switch. Ground is supplied to front wiper switch terminal 17 through body grounds E12 and E54. The wiper motor operates at low speed at the desired delay interval.

WASHER OPERATION

NGEL0057S02

With the ignition switch in the ON or START position, power is supplied 쐌 through 20A fuse [No. 6, located in the fuse block (J/B)] 쐌 to front washer motor terminal +. When the lever is pulled to the WASH position, ground is supplied 쐌 to front washer motor terminal – 쐌 from front wiper switch terminal 18 쐌 through front wiper switch terminal 17, and 쐌 through body grounds E12 and E54. With power and ground supplied, the front washer motor operates.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR

Models with Intermittent Wipers

NGEL0057S0201

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 wiper switch in the same manner as the intermittent operation.

ST RS BT HA SC

EL-119

IDX

FRONT WIPER AND WASHER Wiring Diagram — WIPER —

Wiring Diagram — WIPER — MODELS WITHOUT INTERMITTENT WIPERS

NGEL0058 NGEL0058S01

WEL685A

EL-120

FRONT WIPER AND WASHER Wiring Diagram — WIPER — (Cont’d)

MODELS WITH INTERMITTENT WIPERS

NGEL0058S02

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL686A

EL-121

IDX

FRONT WIPER AND WASHER Removal and Installation

Removal and Installation WIPER ARMS 1. 2.

3. 4. SEL543TA

쐌

쐌

NGEL0060 NGEL0060S01

Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it “OFF” (Auto Stop). Lift the blade up and then set it down onto glass surface to set the blade center to clearance “L1” and “L2” immediately before tightening nut. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it “OFF”. Ensure that wiper blades stop within clearance “L1” and “L2”. Clearance “L1”: 25 mm (.98 in) Clearance “L2”: 25 mm (.98 in) Tighten wiper arm nuts to specified torque. Front wiper: 13 - 18 N·m (1.3 - 1.8 kg-m, 9 - 13 ft-lb)

Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness.

SEL024J

WIPER LINKAGE

NGEL0060S02

MEL840F

EL-122

FRONT WIPER AND WASHER Removal and Installation (Cont’d)

Removal 1. 2. 3. Be

NGEL0060S0201

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 쐌 1.

GI MA NGEL0060S0202

Grease ball joint portion before installation. Installation is the reverse order of removal.

EM LC

Washer Nozzle Adjustment 쐌

NGEL0061

Adjust washer nozzle with suitable tool as shown in the figure at left. Adjustable range: ±10°

EC FE CL MT

SEL241P

Unit: mm (in) *1

390 (15.35)

*5

145 (5.71)

*2

160 (6.30)

*6

143 (5.63)

*3

379 (14.92)

*7

225 (8.86)

*4

140 (5.51)

*8

535 (21.06)

AT TF PD

*: The diameters of these circles are less than 80 mm (3.15 in).

AX SEL544T

Washer Tube Layout

NGEL0062

SU BR ST RS BT HA SC

AEL440C

EL-123

IDX

REAR WIPER AND WASHER System Description

System Description POWER SUPPLY AND GROUND

NGEL0063 NGEL0063S03

With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 10, located in the fuse block (J/B)] 쐌 to rear wiper motor terminal +A and 쐌 to rear washer motor terminal +. Ground is supplied 쐌 to rear wiper switch terminal 3 쐌 through body grounds M14 and M68. Ground is also supplied 쐌 to rear wiper motor terminal E 쐌 through body grounds D402 and D404.

WIPER OPERATION

NGEL0063S01

With the rear wiper switch WIPER in the ON position, ground is supplied 쐌 to rear wiper motor terminal I 쐌 through rear wiper switch terminal 1.

WASHER OPERATION

NGEL0063S02

With the rear wiper switch WASHER in the ON position, ground is supplied 쐌 to rear washer motor terminal – and 쐌 to rear wiper motor terminal W 쐌 through rear wiper switch terminal 2. With power and ground supplied, the rear wiper motor and rear washer motor operate until the rear wiper switch WASHER is released from the ON position. If the switch is pressed momentarily, the rear wiper motor will cycle 2 times.

AUTO STOP OPERATION

NGEL0063S04

When the rear wiper switch is placed in the OFF position, the rear wiper motor will continue to operate until the rear wiper blade reaches the park position. The ground is supplied through rear wiper motor terminal E. This allows the rear wiper motor to operate until the rear wiper blade reached the park position. When the rear wiper blade reaches the park position, the rear wiper motor ground is interrupted and the rear wiper motor stops.

EL-124

REAR WIPER AND WASHER Wiring Diagram — WIP/R —

Wiring Diagram — WIP/R —

NGEL0065

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL687A

EL-125

IDX

REAR WIPER AND WASHER Removal and Installation

Removal and Installation

NGEL0067

AEL439C

LEL049A

1. 2. 3.

Rear wiper arm Pivot shaft cover Pivot shaft nut

4. 5. 6.

Outer collar Seal Rear wiper motor

EL-126

7. 8. 9.

Mounting bolts Back door Rear wiper blade

REAR WIPER AND WASHER Removal and Installation (Cont’d)

WIPER ARMS 1. 2.

NGEL0067S01

Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it “OFF” (Auto Stop). Install wiper arm so that wiper blade is parallel to the ground and tighten wiper arm nut to specification. : 13 - 18 N·m (1.3 - 1.8 kg-m, 9 - 13 ft-lb)

GI MA EM LC

쐌

Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness.

EC FE CL MT

SEL024J

Washer Nozzle Adjustment 쐌

NGEL0068

Adjust washer nozzle with suitable tool as shown in the figure at left. Adjustable range: ±10° (In any direction)

AT TF PD AX

SEL241P

SU BR ST RS WEL912A

BT HA SC

EL-127

IDX

REAR WIPER AND WASHER Washer Tube Layout

Washer Tube Layout

NGEL0069

AEL509C

Check Valve 쐌

NGEL0070

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

EL-128

HORN Wiring Diagram — HORN —

Wiring Diagram — HORN —

NGEL0071

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL126B

EL-129

IDX

CIGARETTE LIGHTER Wiring Diagram — CIGAR —

Wiring Diagram — CIGAR —

NGEL0156

WEL127B

EL-130

REAR WINDOW DEFOGGER Component Parts and Harness Connector Location

Component Parts and Harness Connector Location

NGEL0072

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

WEL128B

EL-131

IDX

REAR WINDOW DEFOGGER System Description

System Description MODELS WITHOUT POWER DOOR LOCKS

NGEL0073 NGEL0073S01

The rear window defogger system is controlled by the rear window defogger timer. The rear window defogger operates only for approximately 15 minutes. Power is supplied at all times 쐌 to rear window defogger relay terminal 5 and 쐌 through 20A fuse [No. 25, located in the fuse block (J/B)] and With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 to rear window defogger relay terminal 1 and 쐌 to rear window defogger timer terminal 1. Ground is supplied to air control (rear window defogger switch) terminal 8 and rear window defogger timer terminal 4 through body grounds M14 and M68. With the air control (rear window defogger switch) ON, ground is supplied 쐌 to rear window defogger timer terminal 3 쐌 through air control (rear window defogger switch) terminal 5. Rear window defogger timer terminal 2 then supplies ground to the rear window defogger relay terminal 2. With power and ground supplied, the rear window defogger relay is energized. Power is supplied 쐌 through terminal 3 of the rear window defogger relay 쐌 to rear window defogger terminal +. Rear window defogger terminal – is grounded through body grounds D402 and D404. With power and ground supplied, the rear window defogger filaments heat and defog the rear window. When the system is activated, the rear window defogger indicator illuminates in the air control (rear window defogger switch). Power is supplied 쐌 from rear window defogger relay terminal 3 쐌 to air control (rear window defogger switch) terminal 4. Air control (rear window defogger switch) terminal 8 is grounded through body grounds M14 and M68.

MODELS WITH POWER DOOR LOCKS

NGEL0073S02

The rear window defogger system is controlled by the smart entrance control unit. The rear window defogger operates only for approximately 15 minutes. Power is supplied at all times 쐌 to rear window defogger relay terminal 5 and 쐌 through 20A fuse [No. 25, located in the fuse block (J/B)] and 쐌 to smart entrance control unit terminal 49 쐌 through 7.5A fuse [No. 28, located in the fuse block (J/B)]. With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 to rear window defogger relay terminal 1 and 쐌 to smart entrance control unit terminal 27. Ground is supplied to air control (rear window defogger switch) terminal 8 and smart entrance control unit terminals 43 and 64 through body grounds M68 and M14. With the air control (rear window defogger switch) ON, ground is supplied 쐌 to smart entrance control unit terminal 14 쐌 through air control (rear window defogger switch) terminal 5. Smart entrance control unit terminal 37 then supplies ground to the rear window defogger relay terminal 2. With power and ground supplied, the rear window defogger relay is energized. Power is supplied 쐌 through terminal 3 of the rear window defogger relay 쐌 to rear window defogger terminal +.

EL-132

REAR WINDOW DEFOGGER System Description (Cont’d)

Rear window defogger terminal – is grounded through body grounds D402 and D404. With power and ground supplied, the rear window defogger filaments heat and defog the rear window. When the system is activated, the rear window defogger indicator illuminates in the air control (rear window defogger switch). Power is supplied 쐌 from rear window defogger relay terminal 3 쐌 to air control (rear window defogger switch) terminal 4. Air control (rear window defogger switch) terminal 8 is grounded through body grounds M14 and M68.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-133

IDX

REAR WINDOW DEFOGGER Wiring Diagram — DEF —

Wiring Diagram — DEF — MODELS WITHOUT POWER DOOR LOCKS

NGEL0074 NGEL0074S01

WEL691A

EL-134

REAR WINDOW DEFOGGER Wiring Diagram — DEF — (Cont’d)

MODELS WITH POWER DOOR LOCKS

NGEL0074S02

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL690A

EL-135

IDX

REAR WINDOW DEFOGGER Trouble Diagnoses

Trouble Diagnoses DIAGNOSTIC PROCEDURE

NGEL0075 NGEL0075S01

SYMPTOM: Rear window defogger does not activate, or does not turn off after activating.

Models without Power Door Locks 1

NGEL0075S0101

CHECK REAR WINDOW DEFOGGER OUTPUT SIGNAL

1. Turn ignition switch ON. 2. Check voltage between rear window defogger timer harness connector terminal 2 and ground.

AEL629C

Voltage [V]: Rear window defogger switch is OFF. Approx. 12 Rear window defogger switch is ON. 0 OK or NG OK

䊳

Check the following. 쐌 Rear window defogger relay Refer to “REAR WINDOW DEFOGGER RELAY”, EL-141. 쐌 Rear window defogger circuit 쐌 Rear window defogger filament Refer to “Filament Check”, EL-142.

NG

䊳

GO TO 2.

EL-136

REAR WINDOW DEFOGGER Trouble Diagnoses (Cont’d)

2

CHECK DEFOGGER RELAY COIL SIDE CIRCUIT

1. Disconnect rear window defogger timer harness connector. 2. Turn ignition switch ON. 3. Check voltage between rear window defogger timer harness connector terminal 2 and ground.

GI MA EM LC EC AEL630C

Does battery voltage exist?

FE

Yes

䊳

GO TO 3.

No

䊳

Check the following. 쐌 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 Rear window defogger relay. Refer to “REAR WINDOW DEFOGGER RELAY”, EL-141. 쐌 Harness for open or short between rear window defogger relay and rear window defogger timer 쐌 Harness for open or short between rear window defogger relay and fuse

3

CL MT AT

CHECK REAR WINDOW DEFOGGER SWITCH INPUT SIGNAL

TF

Check continuity between rear window defogger timer harness connector terminal 3 and ground.

PD AX SU AEL631C

Continuity: Rear window defogger switch is pressed. Yes Rear window defogger switch is released. No

BR ST

OK or NG OK

䊳

GO TO 4.

NG

䊳

Check the following. 쐌 Air control (rear window defogger switch) Refer to “REAR WINDOW DEFOGGER SWITCH”, EL-141 쐌 Harness for open or short between rear window defogger timer and air control (rear window defogger switch) 쐌 Air control (rear window defogger switch) ground circuit

RS BT HA SC

EL-137

IDX

REAR WINDOW DEFOGGER Trouble Diagnoses (Cont’d)

4

CHECK IGNITION INPUT SIGNAL

Check voltage between rear window defogger timer harness connector terminal 1 and ground.

AEL632C

Voltage [V]: Ignition switch is ON. Approx. 12 Ignition switch is OFF. 0 OK or NG OK

䊳

GO TO 5.

NG

䊳

Check the following. 쐌 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 Harness for open or short between rear window defogger timer and fuse

5

CHECK CONTROL UNIT GROUND CIRCUIT

Check continuity between rear window defogger timer harness connector terminal 4 and ground.

AEL633C

Does continuity exist? Yes

䊳

Replace rear window defogger timer.

No

䊳

Repair harness or connectors.

EL-138

REAR WINDOW DEFOGGER Trouble Diagnoses (Cont’d)

Models with Power Door Locks 1

NGEL0075S0102

CHECK REAR WINDOW DEFOGGER OUTPUT SIGNAL

GI

1. Turn ignition switch ON. 2. Check voltage between smart entrance control unit harness connector M111 terminal 37 (G/R) and ground.

MA EM LC EC LEL013A

FE

OK or NG OK

NG

䊳

䊳

Check the following. 쐌 Rear window defogger relay Refer to “REAR WINDOW DEFOGGER RELAY”, EL-141. 쐌 Rear window defogger circuit 쐌 Rear window defogger filament Refer to “Filament Check”, EL-142.

CL MT

GO TO 2.

AT 2

CHECK DEFOGGER RELAY COIL SIDE CIRCUIT

1. Disconnect smart entrance control unit harness connector. 2. Turn ignition switch ON. 3. Check voltage between smart entrance control unit harness connector M111 terminal 37 (G/R) and ground.

TF PD AX SU BR LEL014A

Does battery voltage exist? Yes

䊳

GO TO 3.

No

䊳

Check the following. 쐌 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 Rear window defogger relay Refer to “REAR WINDOW DEFOGGER RELAY”, EL-141. 쐌 Harness for open or short between rear window defogger relay and smart entrance control unit 쐌 Harness for open or short between rear window defogger relay and fuse

ST RS BT HA SC

EL-139

IDX

REAR WINDOW DEFOGGER Trouble Diagnoses (Cont’d)

3

CHECK REAR WINDOW DEFOGGER SWITCH INPUT SIGNAL

Check continuity between smart entrance control unit harness connector M110 terminal 14 (G/B) and ground.

LEL015A

OK or NG OK

䊳

GO TO 4.

NG

䊳

Check the following. 쐌 Air control (rear window defogger switch) Refer to “REAR WINDOW DEFOGGER SWITCH”, EL-141. 쐌 Harness for open or short between smart entrance control unit and air control (rear window defogger switch) 쐌 Air control (rear window defogger switch) ground circuit

4

CHECK IGNITION INPUT SIGNAL

Check voltage between smart entrance control unit harness connector M111 terminal 27 (G/W) and ground.

LEL016A

OK or NG OK

䊳

GO TO 5.

NG

䊳

Check the following. 쐌 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse

EL-140

REAR WINDOW DEFOGGER Trouble Diagnoses (Cont’d)

5

CHECK CONTROL UNIT GROUND CIRCUIT

Check continuity between smart entrance control unit harness connector M111 terminal 43 (B), connector M112 terminal 64 (B) and ground.

GI MA EM LC

LEL017A

EC

Does continuity exist? Yes

䊳

Replace smart entrance control unit.

No

䊳

Repair harness or connectors.

FE CL MT

Electrical Components Inspection

NGEL0076

REAR WINDOW DEFOGGER RELAY

AT

NGEL0076S01

Check continuity between terminals 3 and 5. Condition

Continuity

12V direct current supply between terminals 1 and 2

Yes

No current supply

No

TF PD AX

SEF090M

REAR WINDOW DEFOGGER SWITCH

NGEL0076S02

Check continuity between terminals when rear window defogger switch is pushed and released.

BR

Terminals (+) Connector

(–) Terminal

Connector

Condition

WEL129B

5

M95

Continuity

ST

Terminal Rear window defogger switch is pushed

M95

SU

Yes

8 Rear window defogger switch is released

RS BT

No

HA SC

EL-141

IDX

REAR WINDOW DEFOGGER Filament Check

Filament Check

NGEL0077

1.

Attach probe circuit tester (in volt range) to middle portion of each filament.

쐌

When measuring voltage, wrap tin foil around the top of the negative probe. Then press the foil against the wire with your finger.

2.

If a filament is burned out, circuit tester registers 0 or 12 volts.

3.

To locate burned out point, move probe to left and right along filament. Test needle will swing abruptly when probe passes the point.

SEL263

SEL122R

SEL265

SEL266

EL-142

REAR WINDOW DEFOGGER Filament Repair

Filament Repair REPAIR EQUIPMENT 1) 2) 3) 4) 5) 6)

NGEL0078 NGEL0078S01

Conductive silver composition (Dupont No. 4817 or equivalent) Ruler 30 cm (11.8 in) long Drawing pen Heat gun Alcohol Cloth

GI MA EM LC

REPAIRING PROCEDURE

NGEL0078S02

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. BE540

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.

EC FE CL MT

4.

AT TF PD AX

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.

SU BR ST RS

SEL013D

BT HA SC

EL-143

IDX

AUDIO System Description

System Description

NGEL0079

Refer to Owner’s Manual for audio system operating instructions.

MODELS WITHOUT AUDIO AMPLIFIER

NGEL0079S03

Power is supplied at all times 쐌 through 15A fuse (No. 41, located in the fuse and fusible link box) 쐌 to audio unit terminal 6. With the ignition switch in the ACC or ON position, power is supplied 쐌 through 10A fuse [No. 18, located in the fuse block (J/B)] 쐌 to audio unit terminal 10. Ground is supplied through the case of the audio unit. When the audio unit power knob is pushed to the ON position, audio signals are supplied 쐌 through audio unit terminals 2, 4, 14 and 16 쐌 to door speakers, pillar tweeters and rear speakers.

MODELS WITH AUDIO AMPLIFIER

NGEL0079S04

Power is supplied at all times 쐌 through 20A fuse (No. 33, located in the fuse and fusible link box) 쐌 to audio amplifier terminals 5 and 12 쐌 through 15A fuse (No. 41, located in the fuse and fusible link box) 쐌 to audio unit terminal 6. With the ignition switch in the ACC or ON position, power is supplied 쐌 through 10A fuse [No. 18, located in the fuse block (J/B)] 쐌 to audio unit terminal 10. Ground for the audio unit is supplied through the case of the audio unit. Ground for the audio amplifier is supplied to terminals 4 and 11 through body grounds M68 and M14. When the audio unit power knob is pushed to the ON position, audio signals are supplied 쐌 through audio unit terminals 1, 2, 3, 4, 13, 14, 15 and 16 쐌 to audio amplifier terminals 15, 16, 17, 20, 21, 22, 23, and 24 쐌 through audio amplifier terminals 1, 2, 3, and 9 쐌 to front door speakers, pillar tweeters and rear speakers When the steering switch is pushed, audio signals are supplied 쐌 through audio unit terminal 23 쐌 to steering wheel audio control switch terminal 15, and 쐌 through steering wheel audio control switch terminal 16 쐌 to audio unit terminal 24.

EL-144

AUDIO Schematic — With Audio Amplifier

Schematic — With Audio Amplifier

NGEL0213

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL130B

EL-145

IDX

AUDIO Wiring Diagram — AUDIO —

Wiring Diagram — AUDIO — WITHOUT AUDIO AMPLIFIER

NGEL0157 NGEL0157S01

WEL161B

EL-146

AUDIO Wiring Diagram — AUDIO — (Cont’d)

WITH AUDIO AMPLIFIER

NGEL0157S02

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEL693A

EL-147

IDX

AUDIO Wiring Diagram — AUDIO — (Cont’d)

LEL694A

EL-148

AUDIO Wiring Diagram — AUDIO — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL131B

EL-149

IDX

AUDIO Trouble Diagnoses

Trouble Diagnoses

NGEL0082

AUDIO UNIT (WITHOUT AUDIO AMPLIFIER) Symptom Audio unit inoperative (no digital display and no sound from speakers).

NGEL0082S01

Possible causes

Repair order

1. 10A fuse 2. Poor audio unit case ground 3. Audio unit

1. Check 10A fuse [No. 18, located in fuse block (J/B)]. Turn ignition switch ON and verify that battery positive voltage is present at terminal 10 of audio unit. 2. Check audio unit case ground. 3. Remove audio unit for repair.

Audio unit controls are 1. Audio unit output operational, but no sound 2. Audio unit is heard from any speaker.

1. Check audio unit output voltages. 2. Remove audio unit for repair.

Audio unit presets are lost 1. 15A fuse when ignition switch is 2. Audio unit turned OFF.

1. Check 15A fuse (No. 41, located in fuse and fusible link box) and verify that battery positive voltage is present at terminal 6 of audio unit. 2. Remove audio unit for repair.

Individual speaker is noisy 1. or inoperative. 2. 3. 4.

1. Check speaker. 2. Check audio unit output voltages. 3. Check wires for open or short between audio unit and speaker. 4. Remove audio unit for repair.

Audio unit stations are weak or noisy.

Speaker Audio unit output Speaker circuit Audio unit

1. Antenna 2. Poor audio unit ground 3. Audio unit

1. Check antenna. 2. Check audio unit ground. 3. Remove audio unit for repair.

Audio unit generates noise 1. Poor audio unit ground in AM and FM modes with 2. Loose or missing ground bonding straps engine running. 3. Ignition condenser or rear window defogger noise suppressor condenser 4. Alternator 5. Ignition coil or secondary wiring 6. Audio unit

1. Check audio unit ground. 2. Check ground bonding straps. 3. Replace ignition condenser or rear window defogger noise suppressor condenser. 4. Check alternator. 5. Check ignition coil and secondary wiring. 6. Remove audio unit for repair.

Audio unit generates noise in AM and FM modes with accessories on (switch pops and motor noise).

1. 2. 3. 4.

1. 2. 3. 4.

Poor audio unit ground Antenna Accessory ground Faulty accessory

Check audio unit ground. Check antenna. Check accessory ground. Replace accessory.

AUDIO UNIT (WITH AUDIO AMPLIFIER) Symptom Audio unit inoperative (no digital display and no sound from speakers).

NGEL0082S04

Possible causes

Repair order

1. 10A fuse 2. Poor audio unit case ground 3. Audio unit

1. Check 10A fuse [No. 18, located in fuse block (J/B)]. Turn ignition switch ON and verify that battery positive voltage is present at terminal 10 of audio unit. 2. Check audio unit case ground. 3. Remove audio unit for repair.

Audio unit controls are 1. 20A fuse operational, but no sound 2. Audio amplifier ground is heard from any speaker. 3. Audio amplifier

1. Check 20A fuse (No. 33, located in fuse and fusible link box). Verify battery positive voltage is present at terminals 5 and 12. 2. Check harness continuity between audio amplifier terminals 4 and 11, and ground. 3. Remove audio amplifier for repair.

Audio unit presets are lost 1. 15A fuse when ignition switch is 2. Audio unit turned OFF.

1. Check 15A fuse (No. 41, located in fuse and fusible link box) and verify that battery positive voltage is present at terminal 6 of audio unit. 2. Remove audio unit for repair.

EL-150

AUDIO Trouble Diagnoses (Cont’d) Symptom

Possible causes

Repair order

Individual speaker is noisy 1. Each speaker or inoperative. 2. Output circuit to each speaker

Audio unit stations are weak or noisy.

GI

1. Check speaker. 2. Check the output circuit to each speaker 쐌 between audio unit and audio amplifier 쐌 between audio amplifier and each speaker

1. Antenna 2. Poor audio unit ground 3. Audio unit

MA

1. Check antenna. 2. Check audio unit ground. 3. Remove audio unit for repair.

EM

Audio unit generates noise 1. Poor audio unit ground in AM and FM modes with 2. Loose or missing ground bonding straps engine running. 3. Ignition condenser or rear window defogger noise suppressor condenser 4. Generator 5. Ignition coil or secondary wiring 6. Audio unit

1. Check audio unit ground. 2. Check ground bonding straps. 3. Replace ignition condenser or rear window defogger noise suppressor condenser. 4. Check generator. 5. Check ignition coil and secondary wiring. 6. Remove audio unit for repair.

Audio unit generates noise in AM and FM modes with accessories on (switch pops and motor noise).

1. 2. 3. 4.

1. 2. 3. 4.

Poor audio unit ground Antenna Accessory ground Faulty accessory

CL

Inspection

NGEL0083S03

Disconnect speaker harness connector. Measure the resistance between speaker terminals + and –. The resistance should be 2 - 4Ω. Using jumper wires, momentarily connect a 9V battery between speaker terminals + and –. A momentary hum or pop should be heard.

PD AX

NGEL0083S02

1. Using a jumper wire, clip an auxiliary ground between antenna and body. 쐌 If reception improves, check antenna ground (at body surface). 쐌 If reception does not improve, check main feeder cable for short circuit or open circuit. NGEL0083S01

voltage inspections are made with: Ignition switch ON or ACC Audio unit ON Audio unit connected (If removed for inspection, supply a ground to the case using a jumper wire.)

AUDIO UNIT VOLTAGES

NGEL0083S04

Voltage (V)

SU BR

AUDIO UNIT

ST RS BT

Voltage (V)

Wire color

Base Audio System

Premium Audio System

Terminal

1

B/W

5 - 7.5

5 - 7.5

2

L

5 - 7.5

3

B/R

4

BR

Terminal

AT TF

ANTENNA

All 쐌 쐌 쐌

MT

NGEL0083

SPEAKER 1. 2. 쐌 3. 쐌

EC FE

Check audio unit ground. Check antenna. Check accessory ground. Replace accessory.

1. Check steering wheel audio control switch, refer to “STEERING WHEEL AUDIO CONTROL SWITCH RESISTANCE CHECK”, EL-152. 2. Check audio unit output voltage. 3. Check harness between audio unit and steering switch. 4. Remove audio unit for repair.

Steering wheel audio con- 1. Steering wheel audio control switch trol switch does not oper- 2. Audio unit output ate. 3. Steering wheel audio control switch circuit 4. Audio unit

LC

Wire color

Base Audio System

Premium Audio System

9

—

—

—

5 - 7.5

10

G/R

10.8 - 15.6

10.8 - 15.6

5 - 7.5

5 - 7.5

11

—

—

—

5 - 7.5

5 - 7.5

12

—

—

—

EL-151

HA SC

IDX

AUDIO Inspection (Cont’d) Voltage (V)

Voltage (V)

Wire color

Base Audio System

Premium Audio System

Terminal

5

—

—

—

6

R/Y

10.8 - 15.6

10.8 - 15.6

7

P/B

8

L/R

Terminal

0 - 12 (Illumination) 0 - 12 (Illumination) 0 (Illumination)

0 (Illumination)

Wire color

Base Audio System

Premium Audio System

13

B/Y

5 - 7.5

5 - 7.5

14

LG

5 - 7.5

5 - 7.5

15

B/P

5 - 7.5

5 - 7.5

16

OR

5 - 7.5

5 - 7.5

STEERING WHEEL AUDIO CONTROL SWITCH RESISTANCE

NGEL0083S05

WEL132B

Connector

M204

Terminal

15 - 16

Switch

Resistance Ω (Approx.)

VOLUME (down) sw

21.7 - 22.2

VOLUME (up) sw

69.3 - 70.7

PREVIOUS sw

108.9 - 111.1

NEXT sw

158.4 - 161.6

MODE sw

326.7 - 333.3

EL-152

AUDIO ANTENNA Location of Antenna

Location of Antenna

NGEL0196

GI MA EM LC EC FE CL AEL508C

MT

Fixed Antenna Rod Replacement REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

NGEL0192

Remove antenna rod. Remove rubber seal. Remove cowl screen top seal. Remove right wiper arm. Remove right cowl to grille. Remove antenna base bolts. Remove right fender splash shield. Remove audio unit. Disconnect antenna cable from audio unit. Remove attachment clip from fender apron. Remove antenna base and cable.

INSTALLATION

AT

NGEL0192S01

TF PD AX SU BR NGEL0192S02

Install in reverse order of removal. CAUTION: Always properly tighten the antenna rod during installation or the antenna rod may bend or break during vehicle operation.

ST RS

WEL191A

BT HA SC

EL-153

IDX

DOOR MIRROR Wiring Diagram — MIRROR —

Wiring Diagram — MIRROR —

NGEL0090

LEL696A

EL-154

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Component Parts and Harness Connector Location

Component Parts and Harness Connector Location

NGEL0094

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

WEL917A

EL-155

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Component Parts and Harness Connector Location (Cont’d)

WEL905A

EL-156

AUTOMATIC SPEED CONTROL DEVICE (ASCD) System Description

System Description

NGEL0095

Refer to Owner’s Manual for ASCD operating instructions.

POWER SUPPLY AND GROUND CIRCUIT

GI NGEL0095S07

Power is supplied at all times 쐌 through 15A fuse [No. 22, located in the fuse block (J/B)] 쐌 to the stop lamp switch terminal 1 When ignition switch is in the ON or START position, power is supplied 쐌 through 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 to ASCD control unit terminal 5. 쐌 through 10A fuse [No. 12, located in the fuse block (J/B)] 쐌 to park/neutral position switch terminal 1, 쐌 through 10A fuse [No. 11, located in the fuse block (J/B)] 쐌 to combination meter terminals 32 and 38. When park/neutral position switch (A/T) is in the P or N position, ground is supplied 쐌 to park/neutral position switch terminal 2 쐌 through ASCD relay terminal 1 to ASCD relay terminal 2 쐌 through body grounds M68 and M14. When ASCD ON쐌OFF switch is depressed (ON), ground is supplied 쐌 to ASCD control unit terminal 11 쐌 from ASCD steering switch terminal 14 쐌 from ASCD steering switch terminal 13 쐌 from ASCD control unit terminal 24. Then ASCD control unit illuminates CRUISE indicator. Ground is supplied 쐌 to combination meter terminal 36 쐌 from ASCD control unit terminal 15. Ground is supplied 쐌 to ASCD control unit terminal 17 쐌 through body grounds M14 and M68.

OPERATION Set Operation

MA EM LC EC FE CL MT AT TF PD AX NGEL0095S04 NGEL0095S0401

To activate the ASCD, all of following conditions must exist 쐌 ASCD control unit receives ASCD ON쐌OFF switch ON signal 쐌 Power supply to ASCD control unit terminal 8 [Brake and clutch pedal is released (M/T), and brake pedal is released and A/T selector lever is in other than P and N position. (A/T)] 쐌 Vehicle speed is between 40 km/h (25 MPH) and 144 km/h (89 MPH). (Signal from combination meter) When the COAST/SET switch is depressed, ground is supplied 쐌 to ASCD control unit terminal 11 쐌 from ASCD steering switch terminal 14 쐌 from ASCD steering switch terminal 13 쐌 from ASCD control unit terminal 24. Then ASCD motor actuator is activated to control throttle wire and ASCD control unit supplies ground 쐌 to combination meter terminal 37 to illuminate SET indicator.

A/T Overdrive Control During Cruise Control Driving (A/T Models)

BR ST RS BT HA

NGEL0095S0402

When the vehicle speed is approximately 5 km/h (3 MPH) below set speed, a signal is sent 쐌 from ASCD control unit terminal 10 쐌 to TCM terminal 24. When this occurs, the TCM cancels overdrive. When vehicle speed returns to approximately 0.6 km/h (0.4 MPH) below set speed, overdrive is reactivated.

EL-157

SU

SC

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD) System Description (Cont’d)

Coast Operation

NGEL0095S0403

When the COAST/SET switch is depressed during cruise control driving, ASCD motor actuator returns the throttle cable to decrease vehicle set speed until the switch is released. Then ASCD will keep the new set speed. If COAST/SET switch is pressed and released quickly during cruise control driving, vehicle set speed will be reduced by 1.6 km/h (1.0 MPH).

Accel Operation

NGEL0095S0404

When the RES/ACCEL switch is depressed, ground is supplied 쐌 to ASCD control unit terminal 11 쐌 from ASCD steering switch terminal 14 쐌 from ASCD steering switch terminal 13 쐌 from ASCD control unit terminal 24 If the RES/ACCEL switch is depressed during cruise control driving, ASCD motor actuator pulls the throttle cable to increase the vehicle speed until the switch is released or vehicle speed is reached to maximum controlled speed by the system. Then ASCD will keep the new set speed. If RES/ACCEL switch is pressed and released quickly during cruise control driving, vehicle set speed will be increased by 1.6 km/h (1.0 MPH).

Cancel Operation

NGEL0095S0405

When any of following conditions exist, cruise operation will be canceled 쐌 CANCEL switch is depressed. (Ground is supplied to ASCD control unit terminal 11.) 쐌 Brake pedal is depressed. (Power is supplied to ASCD control unit terminal 23 from stop lamp switch.) 쐌 Brake or clutch pedal is depressed (M/T), brake pedal is depressed or A/T selector lever is shifted to P or N position (A/T). (Power supply to ASCD control unit terminal 8 is interrupted.) If ON쐌OFF switch is turned to OFF when ASCD is activated, all of ASCD operation will be canceled and vehicle speed memory will be erased.

Resume Operation

NGEL0095S0406

When the RES/ACCEL switch is depressed, after cancel operation other than depressing ON쐌OFF switch is performed, vehicle speed will return to last set speed. To resume vehicle set speed, vehicle condition must meet following conditions: 쐌 Brake pedal is released. 쐌 Clutch pedal is released (M/T). 쐌 A/T selector lever is in other than P and N position (A/T). 쐌 Vehicle speed is between 40 km/h (25 MPH) and 144 km/h (89 MPH).

ASCD MOTOR ACTUATOR OPERATION

NGEL0095S05

When the ASCD activates, power is supplied 쐌 from terminal 7 of ASCD control unit 쐌 to ASCD motor actuator terminal 1, and 쐌 from terminal 12 of ASCD control unit 쐌 to ASCD motor actuator terminal 6. Ground is supplied 쐌 from ASCD control unit terminals 1, 13, and 14 쐌 to terminals 3, 5, and 2 of ASCD motor actuator. Power to the actuator motor is supplied constantly from the ASCD control unit. The ASCD control unit then switches the actuator motor ground signals ON and OFF to control actuator motor operation and vehicle speed.

EL-158

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Circuit Diagram

Circuit Diagram

NGEL0096

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL715A

EL-159

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Wiring Diagram — ASCD —

Wiring Diagram — ASCD — FIG. 1

NGEL0097 NGEL0097S01

WEL133B

EL-160

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Wiring Diagram — ASCD — (Cont’d)

FIG. 2

NGEL0097S02

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL134B

EL-161

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Wiring Diagram — ASCD — (Cont’d)

FIG. 3

NGEL0097S03

WEL699A

EL-162

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Fail-safe System

Fail-safe System

NGEL0098

DESCRIPTION

NGEL0098S01

When the fail-safe system senses a malfunction, it deactivates ASCD operation. The CRUISE indicator in the combination meter will then flash.

GI MA EM LC

CEL322

MALFUNCTION DETECTION CONDITIONS

ASCD operation during malfunction detection

Detection conditions 쐌 쐌 쐌 쐌 쐌

NGEL0098S02

ASCD steering (RES/ACCEL, CANCEL, COAST/SET) switch is stuck. ASCD motor actuator has internal malfunction. ASCD motor actuator ground circuit or power circuit is open or shorted. Vehicle speed sensor is faulty. ASCD control unit internal circuit is malfunctioning.

쐌 ASCD brake switch or stop lamp switch is faulty.

쐌 ASCD is deactivated. 쐌 Vehicle speed memory is canceled.

EC FE CL

쐌 ASCD is deactivated. 쐌 Vehicle speed memory is not canceled.

MT AT TF PD AX SU BR ST RS BT HA SC

EL-163

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Trouble Diagnoses

Trouble Diagnoses

=NGEL0203

SYMPTOM CHART

ASCD cannot be set. (“CRUISE” indicator lamp does not turn ON.)

X

ASCD cannot be set. (“SET” indicator lamp does not turn ON.) ASCD cannot be set. (“SET” indicator lamp blinks.★1)

X

168

169

169

171

ASCD MOTOR ACTUATOR CIRCUIT CHECK

ASCD MOTOR ACTUATOR CHECK

167

VEHICLE SPEED SENSOR CHECK

166

ASCD STEERING SWITCH CHECK

SYMPTOM

165

ASCD BRAKE/STOP LAMP SWITCH CHECK

)

POWER SUPPLY AND GROUND CIRCUIT CHECK

REFERENCE PAGE (EL-

Diagnostic procedure

FAIL-SAFE SYSTEM CHECK

PROCEDURE

NGEL0203S01

X★3 X

X

X

X

X

X

X

Vehicle speed does not decrease after COAST/SET switch has been pressed.

X

X

Vehicle speed does not return to the set speed after RES/ACCEL switch has been pressed.★2

X

X

Vehicle speed does not increase after RES/ACCEL switch has been pressed.

X

X

System is not released after CANCEL switch (steering) has been pressed.

X

X

Large difference between set speed and actual vehicle speed.

X

X

X

Deceleration is greatest immediately after ASCD has been set.

X

X

X

★1: It indicates that system is in fail-safe. After completing diagnostic procedures, perform “FAIL-SAFE SYSTEM CHECK”, (EL-165) to verify repairs. ★2: If vehicle speed is greater than 40 km/h (25 MPH) after system has been released, pressing RES/ACCL switch returns vehicle speed to the set speed previously achieved. However, doing so when the ON쐌OFF switch is turned to “OFF”, vehicle speed will not return to the set speed since the memory is canceled. ★3: Check only ON쐌OFF switch built into steering switch.

EL-164

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Trouble Diagnoses (Cont’d)

FAIL-SAFE SYSTEM CHECK 1. 2. 쐌

=NGEL0203S02

Turn ignition switch to ON position. Turn ON쐌OFF switch to ON and check if the “SET” indicator blinks. If the indicator lamp blinks, check the following. ASCD steering switch. Refer to “ASCD STEERING SWITCH CHECK”, EL-168.

GI MA EM LC

SEL417V

3.

SEL767P

Drive the vehicle at more than 40 km/h (25 MPH) and push COAST/SET switch. If the indicator lamp blinks, check the following. 쐌 Vehicle speed sensor. Refer to “VEHICLE SPEED SENSOR CHECK”, EL-169. 쐌 ASCD motor actuator circuit. Refer to “ASCD MOTOR ACTUATOR CIRCUIT CHECK”, EL-169. 쐌 Replace control unit. 4. Drive the vehicle at more than 20 km/h (12 MPH). If the indicator lamp blinks, check the following. 쐌 Replace ASCD motor actuator. 5. Depress brake pedal slowly (brake pedal should be depressed more than 5 seconds). If the indicator lamp blinks, check the following. 쐌 ASCD brake/stop lamp switch. Refer to “ASCD BRAKE/STOP LAMP SWITCH CHECK”, EL-167.

EC FE CL MT AT TF PD AX

SAT797A

6.

END. (System is OK.)

SU BR ST RS BT HA SC

EL-165

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Trouble Diagnoses (Cont’d)

POWER SUPPLY AND GROUND CIRCUIT CHECK=NGEL0203S03 1

CHECK POWER SUPPLY CIRCUIT FOR ASCD CONTROL UNIT

1. Disconnect ASCD control unit harness connector. 2. Turn ignition switch ON. 3. Check voltage between ASCD control unit harness connector M119 terminal 5 (G/W) and ground.

WEL018A

Refer to “Wiring Diagram —ASCD—”, EL-160. Yes

䊳

GO TO 2.

No

䊳

Check the following. 쐌 10A fuse (No. 5 located in the fuse block) 쐌 Harness for open or short

2

CHECK GROUND CIRCUIT FOR ASCD CONTROL UNIT

Check continuity between ASCD control unit harness connector M119 terminal 17 (B) and body ground.

WEL019A

Refer to “Wiring Diagram —ASCD—”, EL-160. Yes

䊳

Power supply and ground circuit is OK.

No

䊳

Repair harness.

EL-166

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Trouble Diagnoses (Cont’d)

ASCD BRAKE/STOP LAMP SWITCH CHECK 1

=NGEL0203S04

CHECK ASCD BRAKE SWITCH CIRCUIT

GI

1. Turn ignition switch OFF. 2. Disconnect ASCD control unit harness connector. 3. Check continuity between ASCD control unit harness connector M119 terminal 8 (L/Y) and terminal 5 (G/W).

MA EM LC EC WEL020A

FE

OK or NG OK

䊳

GO TO 2.

NG

䊳

Check the following. 쐌 ASCD brake switch Refer to “ASCD BRAKE SWITCH AND STOP LAMP SWITCH”, EL-172. 쐌 Park/neutral position switch (A/T) Refer to “PARK/NEUTRAL POSITION SWITCH (A/T)”, EL-172. 쐌 Park/neutral position relay (A/T) Refer to “ASCD RELAY (A/T MODELS)”, EL-173. 쐌 ASCD clutch switch (M/T) Refer to “ASCD CLUTCH SWITCH (M/T)”, EL-172. 쐌 Harness for open or short 쐌 ASCD control unit

2

CL MT AT TF PD

CHECK STOP LAMP SWITCH CIRCUIT

AX

1. Disconnect ASCD control unit harness connector. 2. Check voltage between ASCD control unit harness connector M119 terminal 23 (BR/R) and ground.

SU BR ST RS WEL035A

Refer to “Wiring Diagram —ASCD—”, EL-160.

BT OK or NG

OK

䊳

ASCD brake/stop lamp switch is OK.

NG

䊳

Check the following. 쐌 15A fuse [No. 22, located in the fuse block (J/B)] 쐌 Harness for open or short between ASCD control unit and stop lamp switch 쐌 Harness for open or short between fuse and stop lamp switch 쐌 Stop lamp switch Refer to “ASCD BRAKE SWITCH AND STOP LAMP SWITCH”, EL-172.

EL-167

HA SC

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Trouble Diagnoses (Cont’d)

ASCD STEERING SWITCH CHECK 1

=NGEL0203S05

CHECK ASCD STEERING SWITCH CIRCUIT FOR ASCD CONTROL UNIT

Check resistance between ASCD control unit harness connector M119 terminals 11 (G/OR) and 24 (LG/B).

WEL022A

Refer to “Wiring Diagram —ASCD—”, EL-160. OK or NG OK

䊳

ASCD steering switch is OK.

NG

䊳

GO TO 2.

2

CHECK CIRCUIT CONTINUITY

1. Disconnect ASCD steering switch and ASCD control unit connector. 2. Check continuity between ASCD steering switch connector M205 terminal 14 (G) and ASCD control unit connector M119 terminal 11 (G/OR). 3. Check continuity between ASCD steering switch connector M205 terminal 13 (L) and ASCD control unit connector M119 terminal 24 (LG/B).

LEL326A

Refer to “Wiring Diagram —ASCD—”, EL-160. OK or NG OK

䊳

Replace ASCD steering switch.

NG

䊳

Repair or replace harness or connectors.

EL-168

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Trouble Diagnoses (Cont’d)

VEHICLE SPEED SENSOR CHECK 1

=NGEL0203S06

CHECK SPEEDOMETER OPERATION

GI

Refer to “Wiring Diagram —ASCD—”, EL-160. Does speedometer operate normally?

MA

Yes

䊳

GO TO 2.

No

䊳

Check speedometer and vehicle speed sensor circuit. Refer to “Trouble Diagnoses”, EL-82.

2

EM LC

CHECK VEHICLE SPEED INPUT

1. Apply wheel chocks and jack up drive wheel. 2. Disconnect ASCD control unit harness connector. 3. Check voltage between control unit connector M119 terminal 22 (G/B) and ground while turning drive wheel slowly by hand.

EC FE CL MT AT

WEL023A

TF

Yes

䊳

Vehicle speed sensor is OK.

No

䊳

Check harness for open or short between ASCD control unit connector M119 terminal 22 (G/B) and combination meter connector M39 terminal 37 (G/B).

ASCD MOTOR ACTUATOR CIRCUIT CHECK 1

PD

NGEL0203S07

AX

CHECK ASCD MOTOR ACTUATOR (CLUTCH)

1. Disconnect ASCD motor actuator connector. 2. Measure resistance between ASCD motor actuator connector E80 terminals 1 and 4.

SU BR ST RS WEL024A

Refer to “Wiring Diagram —ASCD—”, EL-160. OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace ASCD motor actuator.

BT HA SC

EL-169

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Trouble Diagnoses (Cont’d)

2

CHECK ASCD MOTOR ACTUATOR (MOTOR)

1. Disconnect ASCD motor actuator connector. 2. Measure resistance between ASCD motor actuator connector E80 terminal 6 and terminals 2, 3, and 5.

WEL135B

OK or NG OK

䊳

Check the following. 쐌 Harness for open or short between ASCD motor actuator and ASCD control unit 쐌 ASCD motor actuator (clutch) ground circuit

NG

䊳

Replace ASCD motor actuator.

EL-170

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Trouble Diagnoses (Cont’d)

ASCD MOTOR ACTUATOR CHECK 1

=NGEL0203S08

CHECK ASCD WIRE

GI

Check wire for improper installation, rust formation or breaks.

MA EM LC EC LEL620

OK or NG OK

䊳

Replace ASCD motor actuator.

NG

䊳

Repair or replace wire. Refer to “ASCD Wire Adjustment”, EL-174.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-171

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Electrical Component Inspection

Electrical Component Inspection

=NGEL0204

ASCD STEERING SWITCH

NGEL0204S01

Check continuity between ASCD steering switch connector M205 terminals 14 and 13 by pushing each button. Button

Terminals

Resistance (kΩ)

CRUISE/ON쐌OFF

Approx. 0

COAST/SET

1.47 - 1.53 13 - 14

WEL136B

RES/ACCEL

3.24 - 3.36

CANCEL

5.00 - 5.20

ASCD BRAKE SWITCH AND STOP LAMP SWITCHNGEL0204S02 Continuity Condition

LEL524

ASCD brake switch connector M48

Stop lamp switch connector M26

When brake pedal is depressed

No

Yes

When brake pedal is released

Yes

No

Check brake pedal adjustment after checking each switch. Refer to BR-12, “Adjustment”.

ASCD CLUTCH SWITCH (M/T)

NGEL0204S03

Check continuity between clutch switch connector M4 terminals 1 and 2. Condition

Continuity

When clutch pedal is depressed

No

When clutch pedal is released

Yes

WEL800A

PARK/NEUTRAL POSITION SWITCH (A/T)

NGEL0204S04

Continuity A/T selector lever position Between terminals 1 and 2 “P”

Yes

“N”

Yes

Except “P” and “N”

No

WEL801A

EL-172

AUTOMATIC SPEED CONTROL DEVICE (ASCD) Electrical Component Inspection (Cont’d)

ASCD RELAY (A/T MODELS)

NGEL0204S05

Check continuity between ASCD relay terminals 3 and 4, 3 and 5.

GI

Condition

Continuity

12V direct current supply between terminals 1 and 2

Between terminals 3 and 5

MA

No current supply

Between terminals 3 and 4

EM LC

AEL553C

EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-173

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD) ASCD Wire Adjustment

ASCD Wire Adjustment WITH KA24DE

=NGEL0205 NGEL0205S01

WEL451A

WITH VG33E

NGEL0205S02

WEL450A

EL-174

AUTOMATIC SPEED CONTROL DEVICE (ASCD) ASCD Wire Adjustment (Cont’d)

WITH VG33ER

NGEL0205S03

GI MA EM LC EC FE CL MT AT LEL449A

CAUTION: 쐌 Be careful not to twist ASCD wire when removing it. 쐌 Do not tense ASCD wire excessively during adjustment. Adjust the tension of ASCD wire in the following manner. 1. Loosen lock nut and adjusting nut. 2. Make sure that accelerator wire is properly adjusted. Refer to FE-3, “Adjusting Accelerator Wire”. 3. Tighten adjusting nut just until throttle drum starts to move. 4. Loosen adjusting nut again 1/2 to 1 turn. 5. Tighten lock nut.

TF PD AX SU BR ST RS BT HA SC

EL-175

IDX

POWER WINDOW System Description

System Description

NGEL0102

Power is supplied at all times 쐌 from 40A fusible link (letter f, located in the fuse and fusible link box) 쐌 to circuit breaker terminal + 쐌 through circuit breaker terminal – 쐌 to power window relay terminal 3 쐌 through 7.5A fuse [No. 28, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 49 With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 27 쐌 through smart entrance control unit terminal 46 쐌 to power window relay terminal 2. Ground is supplied 쐌 to power window relay terminal 1 쐌 through body grounds M14 and M68. The power window relay is energized and power is supplied 쐌 through power window relay terminal 5 쐌 to main power window and door lock/unlock switch terminal 2 쐌 to front power window switch RH terminal 4 쐌 to rear power window switch LH terminal 2 쐌 to rear power window switch RH terminal 2 Ground is supplied 쐌 to main power window and door lock/unlock switch terminal 10 쐌 through body grounds M14 and M68. When the ignition switch is turned to the OFF position from the ON or START position, the power windows will still operate for approximately 45 seconds, unless either front door is opened.

MANUAL OPERATION

NGEL0102S01

NOTE: Numbers in parentheses are terminal numbers which apply with switch pressed in the UP and DOWN positions respectively.

Front Door LH

NGEL0102S0101

Power is supplied 쐌 through main power window and door lock/unlock switch terminal (12, 16) 쐌 to front power window motor LH terminal (UP, DN). Ground is supplied 쐌 to front power window motor LH terminal (DN, UP) 쐌 through main power window and door lock/unlock switch terminal (16, 12). Then, the motor raises or lowers the window until the switch is released or the window is fully closed or open.

Front Door RH

NGEL0102S0102

MAIN POWER WINDOW AND DOOR LOCK/UNLOCK SWITCH OPERATION With front RH switch pressed, power is supplied 쐌 through main power window and door lock/unlock switch (14, 13) 쐌 to front power window switch RH (5, 2). The following description is the same as the front power window switch RH description. FRONT POWER WINDOW SWITCH RH OPERATION Power is supplied 쐌 through front power window switch RH (6, 3) 쐌 to front power window motor RH (UP, DN). Ground is supplied 쐌 to front power window motor RH (DN, UP)

EL-176

POWER WINDOW System Description (Cont’d)

쐌 through front power window switch RH (3, 6) 쐌 to front power window switch RH (2, 5) 쐌 through main power window and door lock/unlock switch (13, 14). Then, the motor raises or lowers the window until the switch is released or the window is fully closed or open.

GI

Rear Door LH

MA NGEL0102S0103

MAIN POWER WINDOW AND DOOR LOCK/UNLOCK SWITCH OPERATION With rear LH switch pressed, power is supplied 쐌 through main power window and door lock/unlock switch (1, 6) 쐌 to rear power window switch LH (1, 3). The following description is the same as the rear power window switch LH description. REAR POWER WINDOW SWITCH LH OPERATION Power is supplied 쐌 through rear power window switch LH (4, 6) 쐌 to rear power window motor LH (UP, DN). Ground is supplied 쐌 to rear power window motor LH (DN, UP) 쐌 through rear power window switch LH (6, 4) 쐌 to rear power window switch LH (3, 1) 쐌 through main power window and door lock/unlock switch (6, 1). Then, the motor raises or lowers the window until the switch is released or the window is fully closed or open.

Rear Door RH

EM LC EC FE CL MT

NGEL0102S0104

MAIN POWER WINDOW AND DOOR LOCK/UNLOCK SWITCH OPERATION With rear RH switch pressed, power is supplied 쐌 through main power window and door lock/unlock switch (7, 9) 쐌 to rear power window switch RH (1, 3). The following description is the same as the rear power window switch RH description. REAR POWER WINDOW SWITCH RH OPERATION Power is supplied 쐌 through rear power window switch RH (4, 6) 쐌 to rear power window motor RH (UP, DN). Ground is supplied 쐌 to rear power window motor RH (DN, UP) 쐌 through rear power window switch RH (6, 4) 쐌 to rear power window switch RH (3, 1) 쐌 through main power window and door lock/unlock switch (9, 7). Then, the motor raises or lowers the window until the switch is released or the window is fully closed or open.

AT

AUTO OPERATION

ST

NGEL0102S02

The power window AUTO feature enables the driver to lower the driver’s window without holding the switch in the DOWN position. The AUTO feature is activated by pressing the switch beyond the DOWN position to the AUTO position. The AUTO feature only operates on the downward movement of the driver’s window. The window can be stopped before it is fully open by pressing the window switch to the UP position.

POWER WINDOW LOCK

TF PD AX SU BR

RS BT

NGEL0102S03

The power window lock prevents operation of all windows except the driver’s window. When the lock switch is pressed to lock position, ground of the front power window switch RH and the rear power window switch LH and RH is disconnected in the main power window and door lock/unlock switch. This prevents the front power window motor RH and the rear power window motor LH and RH from operating.

RETAINED POWER OPERATION (WITH POWER DOOR LOCKS)

SC

NGEL0102S04

When the ignition switch is turned to OFF position from ON or START position, power is supplied for 45 seconds 쐌 to power window relay terminal 2 쐌 from smart entrance control unit terminal 46.

EL-177

HA

IDX

POWER WINDOW System Description (Cont’d)

Ground is supplied 쐌 to power window relay terminal 1 쐌 through body grounds M14 and M68. When power and ground are supplied, the power window relay continues to be energized, and the power windows can be operated. The retained power operation is cancelled when the driver or passenger side door is opened.

EL-178

POWER WINDOW Circuit Diagram

Circuit Diagram

NGEL0206

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL802A

EL-179

IDX

POWER WINDOW Wiring Diagram — WINDOW —

Wiring Diagram — WINDOW —

NGEL0104

WEL700A

EL-180

POWER WINDOW Wiring Diagram — WINDOW — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC LEL703

EL-181

IDX

POWER WINDOW Wiring Diagram — WINDOW — (Cont’d)

LEL704

EL-182

POWER WINDOW Wiring Diagram — WINDOW — (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL701A

EL-183

IDX

POWER WINDOW Trouble Diagnoses

Trouble Diagnoses Symptom

Possible cause

NGEL0105

Repair order

None of the power windows can be 1. 7.5A fuse, 40A fusible link and 1. Check 7.5A fuse (No. 20, located in fuse block operated using any switch. M12 circuit breaker [J/B]), 40A fusible link (letter f, located in fuse and 2. Power window relay ground cirfusible link box) and M12 circuit breaker. Turn ignicuit tion switch ON and verify battery positive voltage is 3. Power window relay present at main power window and door lock/unlock 4. Open/short in main power winswitch terminal 2, front power window switch RH dow and door lock/unlock switch terminal 4 and rear power window switch LH and circuit RH terminal 2. 2. Check power window relay ground circuit. 3. Check power window relay. 4. Check W wire between power window relay and main power window and door lock/unlock switch for open/short circuit. Driver side power window cannot 1. Front power window motor LH be operated but other windows can circuit be operated. 2. Front power window motor LH circuit 3. Main power window and door lock/unlock switch

1. Check harness between main power window and door lock/unlock switch and front power window motor LH for open or short circuit. 2. Check front power window motor LH. 3. Check main power window and door lock/unlock switch.

Passenger side power window can- 1. Front power window switch RH not be operated. 2. Front power window motor RH 3. Main power window and door lock/unlock switch 4. Power window circuit

1. Check front power window switch RH. 2. Check front power window motor RH. 3. Check main power window and door lock/unlock switch. 4. Check the following. a. Check harnesses between main power window and door lock/unlock switch RH and front power window switch RH for open/short circuit. b. Check harnesses between front power window switch RH and front power window motor RH for open/short circuit.

Passenger side power window can- 1. Main power window and door not be operated using main power lock/unlock switch window and door lock/unlock switch but can be operated by front power window switch RH.

1. Check main power window and door lock/unlock switch.

One or more rear power windows cannot be operated.

1. 2. 3. 4.

1. 2. 3. 4. a.

Power windows except driver side power window cannot be operated using main power window switch but can be operated by power window switches.

1. Main power window and door lock/unlock switch

1. Check main power window and door lock/unlock switch.

1. Main power window and door Driver’s window AUTO function lock/unlock switch cannot be operated using main power window and door lock/unlock switch.

1. Check main power window and door lock/unlock switch.

Rear Rear Main Rear cuit

power power power power

window window window window

switch motor switch switch cir-

EL-184

Check rear power window switch. Check rear power window motor. Check main power window switch. Check the following. Harnesses between the main power window switch and rear power window switches b. Harnesses between the rear power window switches and rear power window motors for open or short

POWER WINDOW Trouble Diagnoses (Cont’d) Symptom Retained accessory power feature does not operate properly

Possible cause 1. RAP signal circuit 2. Driver or passenger side door switch circuit 3. Smart entrance control unit

Repair order 1. Check harness between power window relay terminal 3 and smart entrance control unit terminal 46 for open/short circuit. 2. Check the following a. Check harness between smart entrance control unit and driver or passenger side door switch for short circuit. b. Check driver or passenger side door switch ground circuit. c. Check driver or passenger side door switch. 3. Replace smart entrance control unit.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-185

IDX

POWER DOOR LOCK Component Parts and Harness Connector Location

Component Parts and Harness Connector Location

NGEL0106

WEL137B

EL-186

POWER DOOR LOCK System Description

System Description

NGEL0107

Power is supplied at all times 쐌 through 40A fusible link (letter f, located in the fuse and fusible link box) 쐌 to circuit breaker terminal + 쐌 through circuit breaker terminal – 쐌 to smart entrance control unit terminal 51. Power is supplied at all times 쐌 through 7.5A fuse [No. 28, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 49, and 쐌 to key switch terminal 1. Ground is supplied 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M14 and M68.

INPUT

GI MA EM LC EC NGEL0107S01

With the key in the ignition key cylinder, power is supplied 쐌 through key switch terminal 2 쐌 to smart entrance control unit terminal 25. With front door LH open, ground is supplied 쐌 to smart entrance control unit terminal 1 쐌 through front door switch LH terminal 2 쐌 through front door switch LH terminal 3 쐌 through body grounds B6 and B10. With front door RH open, ground is supplied 쐌 to smart entrance control unit terminal 2 쐌 through front door switch RH terminal +. With the key inserted in the front door key cylinder switch LH and turned to LOCK, ground is supplied 쐌 to smart entrance control unit terminal 11 쐌 through front door key cylinder switch LH terminal 1 쐌 through front door key cylinder switch LH terminal 2 쐌 through body grounds M14 and M68. With the key inserted in the back door key cylinder switch and turned to LOCK, ground is supplied 쐌 to smart entrance control unit terminal 11 쐌 through back door key cylinder switch terminal 1 쐌 through back door key cylinder switch terminal 2 쐌 through body grounds D402 and D404. With the key inserted in the front door key cylinder switch LH and turned to UNLOCK, ground is supplied 쐌 to smart entrance control unit terminal 10 쐌 through front door key cylinder switch LH terminal 3 쐌 through front door key cylinder switch LH terminal 2 쐌 through body grounds M14 and M68. With the key inserted in the back door key cylinder switch and turned to UNLOCK, ground is supplied 쐌 to smart entrance control unit terminal 10 쐌 through back door key cylinder switch terminal 3 쐌 through back door key cylinder switch terminal 2 쐌 through body grounds D402 and D404. With the main power window and door lock/unlock switch pressed to LOCK, ground is supplied 쐌 to smart entrance control unit terminal 5 쐌 through main power window and door lock/unlock switch terminal 15 쐌 through main power window and door lock/unlock switch terminal 10 쐌 through body grounds M14 and M68. With the door lock/unlock switch RH pressed to LOCK, ground is supplied

EL-187

FE CL MT AT TF PD AX SU BR ST RS BT HA SC

IDX

POWER DOOR LOCK System Description (Cont’d)

쐌 to smart entrance control unit terminal 5 쐌 through door lock/unlock switch RH terminal 6 쐌 through door lock/unlock switch RH terminal 4 쐌 through body grounds M14 and M68. With the main power window and door lock/unlock switch pressed to UNLOCK, ground is supplied 쐌 to smart entrance control unit terminal 4 쐌 through main power window and door lock/unlock switch terminal 11 쐌 through main power window and door lock/unlock switch terminal 10 쐌 through body grounds M14 and M68. With the door lock/unlock switch RH pressed to UNLOCK, ground is supplied 쐌 to smart entrance control unit terminal 4 쐌 through door lock/unlock switch RH terminal 3 쐌 through door lock/unlock switch RH terminal 4 쐌 through body grounds M14 and M68.

OUTPUT Unlock

NGEL0107S02 NGEL0107S0201

Ground is supplied 쐌 to front door lock actuator LH terminal 4 쐌 to front door lock actuator RH terminal 4 쐌 to rear door lock actuator LH terminal 4 쐌 to rear door lock actuator RH terminal 4 and 쐌 to back door lock actuator terminal 1 쐌 through smart entrance control unit terminal 54. FRONT DOOR LH Power is supplied 쐌 to front door lock actuator LH terminal 2 쐌 through smart entrance control unit terminal 55. FRONT DOOR RH Power is supplied 쐌 to front door lock actuator RH terminal 2 쐌 through smart entrance control unit terminal 56. REAR DOOR LH Power is supplied 쐌 to rear door lock actuator LH terminal 2 쐌 through smart entrance control unit terminal 56. REAR DOOR RH Power is supplied 쐌 to rear door lock actuator RH terminal 2 쐌 through smart entrance control unit terminal 56. BACK DOOR Power is supplied 쐌 to back door lock actuator terminal 3 쐌 through smart entrance control unit terminal 56. Then, the doors are unlocked.

Lock

NGEL0107S0202

Ground is supplied 쐌 to front door lock actuator LH terminal 2 쐌 through smart entrance control unit terminal 55 and 쐌 to front door lock actuator RH terminal 2 쐌 to rear door lock actuator LH terminal 2 쐌 to rear door lock actuator RH terminal 2 and

EL-188

POWER DOOR LOCK System Description (Cont’d)

쐌 to back door lock actuator 3 쐌 through smart entrance control unit terminal 56. Power is supplied 쐌 to front door lock actuator LH terminal 4 쐌 to front door lock actuator RH terminal 4 쐌 to rear door lock actuator LH terminal 4 쐌 to rear door lock actuator RH terminal 4 and 쐌 to back door lock terminal 1 쐌 through smart entrance control unit terminal 54. Then, the doors are locked.

OPERATION 쐌 쐌

GI MA EM LC NGEL0107S03

The main power window and door lock/unlock switch and the door lock/unlock switch RH can lock and unlock all doors. With the key inserted in the front door key cylinder LH or the back door key cylinder, turning it to LOCK locks all doors; turning it to UNLOCK once unlocks the corresponding door; turning it to UNLOCK again within 5 seconds of the first unlock operation unlocks all other doors (signal from door key cylinder switch).

Key Reminder

NGEL0107S0301

When performing a door locking operation using the main power window and door lock/unlock switch, the door lock/unlock switch RH, the front door LH lock knob or a keyfob, all the doors will lock and then the front door LH will immediately unlock if the 쐌 key switch is in INSERTED position (key is inserted into ignition key cylinder) and 쐌 either front door switch LH or RH is in OPEN position (door is open).

EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-189

IDX

POWER DOOR LOCK Circuit Diagram

Circuit Diagram

NGEL0108

WEL354A

EL-190

POWER DOOR LOCK Wiring Diagram — D/LOCK —

Wiring Diagram — D/LOCK — FIG. 1

NGEL0109 NGEL0109S01

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

WEL702A

EL-191

IDX

POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)

FIG. 2

NGEL0109S02

WEL703A

EL-192

POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)

FIG. 3

NGEL0109S03

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL704A

EL-193

IDX

POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)

FIG. 4

NGEL0109S04

WEL705A

EL-194

POWER DOOR LOCK Trouble Diagnoses

Trouble Diagnoses

NGEL0110

SYMPTOM CHART 195

196

197

KEY SWITCH (INSERTED) CHECK

Key reminder door system does not operate properly.

X

X

X

Specific door lock actuator does not operate.

X

Power door lock does not operate with door lock and unlock switch (LH and RH) on door trim.

X

Power door lock does not operate with front door key cylinder operation.

X

200

GI

201

LC DOOR LOCK ACTUATOR CHECK

DOOR KEY CYLINDER SWITCH CHECK

EM DOOR LOCK/UNLOCK SWITCH CHECK

SYMPTOM

199

MA

DOOR SWITCH CHECK

)

MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK

REFERENCE PAGE (EL-

NGEL0110S01

X X

EC FE CL MT AT TF

X

PD

X

AX MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK NGEL0110S02 SU Main Power Supply Circuit Check NGEL0110S0201 Terminal (+)

Ignition switch

BR

(−)

OFF

ACC

ON

Ground

Battery voltage

Battery voltage

Battery voltage

M112 - 49 (G) M112 - 51 (W/R) LEL034A

If NG, check the following. 쐌 40A fusible link (letter f, located in fuse and fusible link box) 쐌 7.5A fuse [No. 28, located in fuse block (J/B)] 쐌 Circuit breaker 쐌 Harness for open or short between smart entrance control unit and fuse 쐌 Harness for open or short between circuit breaker and fuse

EL-195

ST RS BT HA SC

IDX

POWER DOOR LOCK Trouble Diagnoses (Cont’d)

Ground Circuit Check

NGEL0110S0202

Terminals (+)

Continuity

Connector

Terminal (wire color)

(-)

M111

43 (B)

Ground

Yes

M112

64 (B)

Ground

Yes

WEL803A

DOOR SWITCH CHECK 1

NGEL0110S05

CHECK DOOR SWITCHES INPUT SIGNAL

Check voltage between smart entrance control unit harness connector M110 terminals 1 (G/R), 2 (G/B) or 3 (R/B) and ground.

LEL028A

Refer to “Wiring Diagram —D/LOCK—”, EL-191. OK or NG OK

䊳

Door switch is OK.

NG

䊳

GO TO 2.

EL-196

POWER DOOR LOCK Trouble Diagnoses (Cont’d)

2

CHECK DOOR SWITCHES

1. Disconnect door switch harness connector. 2. Check continuity between door switch terminals.

GI MA EM LC AEL651C

Continuity: Front door switch LH terminals 2 - 3 Door switch is pressed - No Door switch is released - Yes Front door switch RH, rear door switch LH, or RH, or back door switch terminal + - ground Door switch is pressed - No Door switch is released - Yes

FE CL

OK or NG OK

NG

䊳

䊳

Check the following. 쐌 Front door switch LH ground circuit, front door switch RH or back door switch ground condition 쐌 Harness for open or short between smart entrance control unit and door switch Replace door switch.

MT AT TF

KEY SWITCH (INSERTED) CHECK 1

EC

NGEL0110S06

CHECK KEY SWITCH INPUT SIGNAL

PD

1. Disconnect smart entrance control unit harness connector. 2. Check voltage between smart entrance control unit harness connector M111 terminal 25 (W/G) and ground.

AX SU BR ST LEL010A

Refer to “Wiring Diagram —D/LOCK—”, EL-191.

RS OK or NG

OK

䊳

Key switch is OK.

NG

䊳

GO TO 2.

BT HA SC

EL-197

IDX

POWER DOOR LOCK Trouble Diagnoses (Cont’d)

2

CHECK KEY SWITCH POWER SUPPLY

1. Disconnect key switch harness connector. 2. Check voltage between key switch harness connector terminal 1 and ground.

AEL415B

Battery voltage should exist. Refer to “Wiring Diagram —D/LOCK—”, EL-191. OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following. 쐌 7.5A fuse [No. 28, located in the fuse block (J/B)] 쐌 Harness for open or short between key switch and fuse

3

CHECK KEY SWITCH

Check continuity between key switch terminals 1 and 2.

AEL416B

Continuity Condition of key switch: Key is inserted. Yes Condition of key switch: Key is removed. No OK or NG OK

䊳

Check harness for open or short between smart entrance control unit and key switch.

NG

䊳

Replace key switch.

EL-198

POWER DOOR LOCK Trouble Diagnoses (Cont’d)

DOOR LOCK/UNLOCK SWITCH CHECK 1

=NGEL0110S03

CHECK DOOR LOCK/UNLOCK SWITCH INPUT SIGNAL

GI

1. Disconnect smart entrance control unit harness connector. 2. Check continuity between smart entrance control unit harness connector M110 terminal 4 (BR) or 5 (LG/R) and ground.

MA EM LC EC WEL348A

FE

Refer to “Wiring Diagram —D/LOCK—”, EL-191. OK or NG OK

䊳

Door lock/unlock switch is OK.

NG

䊳

GO TO 2.

CL MT

2

CHECK DOOR LOCK/UNLOCK SWITCH

1. Disconnect door lock/unlock switch harness connector. 2. Check continuity between door lock/unlock switch terminals.

AT TF PD AX AEL642C

SU BR ST RS

AEL556C

OK or NG OK

NG

䊳

Check the following. 쐌 Ground circuit for door lock/unlock switch 쐌 Harness for open or short between door lock/unlock switch and smart entrance control unit

䊳

Replace door lock/unlock switch.

EL-199

BT HA SC

IDX

POWER DOOR LOCK Trouble Diagnoses (Cont’d)

DOOR KEY CYLINDER SWITCH CHECK 1

NGEL0110S07

CHECK DOOR KEY CYLINDER SWITCH INPUT SIGNAL

Check voltage between smart entrance control unit harness connector M110, terminal 10 (Y/R) or 11 (Y) and ground.

WEL328A

Refer to “Wiring Diagram —D/LOCK—”, EL-192. OK or NG OK

䊳

Door key cylinder switch is OK.

NG

䊳

GO TO 2.

2

CHECK DOOR KEY CYLINDER SWITCH

1. Disconnect door key cylinder switch harness connector. 2. Check continuity between door key cylinder switch terminals.

WEL347A

OK or NG OK

䊳

Check the following. 쐌 Door key cylinder switch ground circuit 쐌 Harness for open or short between smart entrance control unit and door key cylinder switch

NG

䊳

Replace door key cylinder switch.

EL-200

POWER DOOR LOCK Trouble Diagnoses (Cont’d)

DOOR LOCK ACTUATOR CHECK 1

NGEL0110S04

CHECK DOOR LOCK ACTUATOR CIRCUIT

GI

Check voltage for door lock actuator.

MA EM LC EC LEL048A

Refer to “Wiring Diagram —D/LOCK—”, EL-193.

FE

OK or NG OK

䊳

GO TO 2.

NG

䊳

Replace smart entrance control unit. (Before replacing smart entrance control unit, perform other procedures indicated in “SYMPTOM CHART”. Refer to “SYMPTOM CHART”, EL-195).

2

CHECK DOOR LOCK ACTUATOR

CL MT AT

1. Disconnect door lock actuator harness connector. 2. Apply 12V direct current to door lock actuator and check operation.

TF PD AX SU WEL833A

BR ST RS BT WEL834A

OK or NG OK NG

䊳 䊳

Check harness for open or short between smart entrance control unit and door lock actuator.

HA SC

Replace door lock actuator.

EL-201

IDX

REMOTE KEYLESS ENTRY SYSTEM Component Parts and Harness Connector Location

Component Parts and Harness Connector Location

NGEL0111

WEL138B

EL-202

REMOTE KEYLESS ENTRY SYSTEM System Description

System Description POWER SUPPLY AND GROUND

NGEL0112 NGEL0112S03

Power is supplied at all times 쐌 through 40A fusible link (letter f, located in the fuse and fusible link box) 쐌 to circuit breaker terminal + 쐌 through circuit breaker terminal – 쐌 to smart entrance control unit terminal 51. With the ignition switch in the ACC or ON position, power is supplied 쐌 through 7.5A fuse [No. 20, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 26. Power is supplied at all times 쐌 through 7.5A fuse [No. 28, located in the fuse block (J/B)] 쐌 to key switch terminal 1, and 쐌 to smart entrance control unit terminal 49. Power is supplied at all times 쐌 through 15A fuse (No. 37, located in the fuse and fusible link box) 쐌 to vehicle security lamp relay terminal 7. Power is supplied at all times 쐌 through 15A fuse (No. 38, located in the fuse and fusible link box) 쐌 to vehicle security lamp relay terminal 5. Power is supplied at all times 쐌 through 15A fuse (No. 32, located in the fuse and fusible link box) 쐌 to horn relay terminals 1 and 5. Ground is supplied 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M14 and M68.

GI MA EM LC EC FE CL MT AT TF PD

INPUTS

NGEL0112S01

With the key switch in the INSERTED (key is in ignition key cylinder) position, power is supplied 쐌 through key switch terminal 2 쐌 to smart entrance control unit terminal 25. With front door LH open, ground is supplied 쐌 to smart entrance control unit terminal 1 쐌 through front door switch LH terminal 2 쐌 through front door switch LH terminal 3 쐌 through body grounds B6 and B10. With front door RH open, ground is supplied 쐌 to smart entrance control unit terminal 2 쐌 through front door switch RH terminal +. With rear door LH or RH open, ground is supplied 쐌 to smart entrance control unit terminal 3 (with vehicle security system) or terminal 2 (without vehicle security system) 쐌 through rear door switch LH or RH terminal +. With the back door open, ground is supplied 쐌 to smart entrance control unit terminal 3 (with vehicle security system) or terminal 2 (without vehicle security system) 쐌 through back door switch terminal + 쐌 through back door switch terminal – 쐌 through body grounds D402 and D404. The remote keyless entry system controls operation of the: 쐌 power door locks 쐌 panic alarm

EL-203

AX SU BR ST RS BT HA SC

IDX

REMOTE KEYLESS ENTRY SYSTEM System Description (Cont’d)

쐌

hazard reminder.

OPERATION PROCEDURE Power Door Lock Operation

NGEL0112S02 NGEL0112S0201

When the keyfob sends a LOCK signal with the key switch in the REMOVED position (key is not in ignition key cylinder), the smart entrance control unit locks all doors. When the keyfob sends an UNLOCK signal once, the smart entrance control unit unlocks the front door LH. Then, if the keyfob sends another UNLOCK signal within 5 seconds, the smart entrance control unit unlocks all other doors.

Key Reminder

NGEL0112S0206

When performing a door locking operation using the main power window and door lock/unlock switch, the door lock/unlock switch RH, the front door LH lock knob or a keyfob, all the doors will lock and then the front door LH will immediately unlock if the 쐌 key switch is in INSERTED position (key is in ignition key cylinder) and 쐌 either front door switch LH or RH is in OPEN position (door is open).

Hazard and Horn Reminder

NGEL0112S0204

When smart entrance control unit receives LOCK or UNLOCK signal from the keyfob with all doors closed, power is supplied 쐌 through smart entrance control unit terminals 47 and 48 쐌 to the hazard warning lamps. Ground is supplied 쐌 to horn relay terminal 2 쐌 through smart entrance control unit terminal 42. Horn relay is now energized, and hazard warning lamps flash and horn sounds as a reminder. The hazard and horn reminder has a horn chirp mode (C mode) and a non-horn chirp mode (S mode). Operating function of hazard and horn reminder Horn chirp mode (C mode)

Lock

Non-horn chirp mode (S mode)

Hazard warning lamps flash

Horn sound

Hazard warning lamp flash

Horn sound

Twice

Once

Twice

—

Unlock

EL-204

REMOTE KEYLESS ENTRY SYSTEM Circuit Diagram

Circuit Diagram

NGEL0113

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL324A

EL-205

IDX

REMOTE KEYLESS ENTRY SYSTEM Wiring Diagram — MULTI —

Wiring Diagram — MULTI — FIG. 1

NGEL0114 NGEL0114S01

WEL706A

EL-206

REMOTE KEYLESS ENTRY SYSTEM Wiring Diagram — MULTI — (Cont’d)

FIG. 2

=NGEL0114S05

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL707A

EL-207

IDX

REMOTE KEYLESS ENTRY SYSTEM Wiring Diagram — MULTI — (Cont’d)

FIG. 3

NGEL0114S02

WEL708A

EL-208

REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses

Trouble Diagnoses SYMPTOM CHART

=NGEL0115 NGEL0115S01

NOTE: 쐌 Always check keyfob battery before replacing keyfob 쐌 Use Remote Keyless Entry Tester J-43241 (follow instructions on tester) to check operation of keyfob before replacing keyfob. Symptom All functions of remote keyless entry system do not operate.

The new ID of keyfob cannot be entered.

Diagnoses/service procedure 1. Keyfob battery check

—

3. Power supply and ground circuit check

211

4. Replace keyfob. Refer to ID Code Entry Procedure.

218

1. Keyfob battery check

210

2. Keyfob check (use Remote Keyless Entry Tester J-43241).

—

3. Power supply and ground circuit check

211

4. Key switch (inserted) check

214

5. Door switch check

213

6. Replace keyfob. Refer to ID Code Entry Procedure.

218

4. Replace keyfob. Refer to ID Code Entry Procedure. Hazard indicator does not flash twice when press- 1. Hazard reminder check ing lock button of keyfob. 2. Keyfob check (use Remote Keyless Entry Tester J-43241).

Panic alarm (horn and headlamps) does not activate when panic alarm button is pressed continuously for more than 1.5 seconds.

214

EM LC EC FE CL MT AT

— 213

TF

218 216

PD

—

3. Replace keyfob. Refer to ID Code Entry Procedure.

218

1. Room lamp operation check

216

2. Door switch check

213

1. Vehicle security operation check. Refer to “PRELIMINARY CHECK”.

229

2. Keyfob check (use Remote Keyless Entry Tester J-43241).

—

3. Replace keyfob. Refer to ID Code Entry Procedure.

MA

210

2. Keyfob check (use Remote Keyless Entry Tester J-43241).

Door lock or unlock does not function 1. Key switch (inserted) check (If the power door lock system does not operate manually, check power door lock system. Refer to 2. Keyfob check (use Remote Keyless Entry Tester J-43241). “Trouble Diagnoses”, EL-195.). 3. Door switch check

Room lamp does not activate properly.

Reference page (EL- )

GI

AX SU BR

218

NOTE: The panic alarm functions of the remote keyless entry system do not activate when the key switch is in INSERTED position (key is in ignition key cylinder). When performing a door locking operation using the main power window and door lock/unlock switch, the door lock/unlock switch RH, the front door LH lock knob, or a keyfob, all the doors will lock and then the front door LH will immediately unlock if: 쐌 the key switch is in INSERTED position (key is in ignition key cylinder), and 쐌 either front door switch LH or RH is in OPEN position (door is open).

ST RS BT HA SC

EL-209

IDX

REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d)

KEYFOB BATTERY CHECK 1

=NGEL0115S02

CHECK KEYFOB BATTERY

Remove battery. Refer to “Keyfob Battery Replacement”, EL-219. Measure voltage across battery positive and negative terminals, (+) and (−).

SEL277V

Voltage [V]: 2.5 - 3.0 NOTE: Keyfob does not function if battery is not installed correctly. OK or NG OK

䊳

Check keyfob battery terminals for corrosion and damage.

NG

䊳

Replace battery.

EL-210

REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d)

POWER SUPPLY AND GROUND CIRCUIT CHECK 1

=NGEL0115S04

CHECK MAIN POWER SUPPLY CIRCUIT FOR CONTROL UNIT

GI

1. Disconnect smart entrance control unit harness connector. 2. Check voltage between smart entrance control unit harness connector M112 terminals 49 (G) and 51 (W/R), and ground.

MA EM LC EC LEL051A

FE

Refer to “Wiring Diagram —KEYLES—”, EL-206. OK or NG

CL

OK

䊳

GO TO 2.

NG

䊳

Check the following. 쐌 40A fusible link (letter f, located in fuse and fusible link box) 쐌 7.5A fuse [No. 28, located in fuse block (J/B)] 쐌 M12 circuit breaker 쐌 Harness for open or short between smart entrance control unit and fuse 쐌 Harness for open or short between smart entrance control unit and circuit breaker

MT AT TF

2

CHECK IGNITION SWITCH ACC CIRCUIT

1. Disconnect smart entrance control unit harness connector. 2. Check voltage between smart entrance control unit harness connector M111 terminal 26 (G) and ground while ignition switch is in ACC or ON position.

PD AX SU BR ST

LEL052A

Refer to “Wiring Diagram —KEYLES—”, EL-206.

RS OK or NG

OK

䊳

GO TO 3.

NG

䊳

Check the following. 쐌 7.5A fuse [No. 20, located in fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse

BT HA SC

EL-211

IDX

REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d)

3

CHECK GROUND CIRCUIT FOR CONTROL UNIT

Check continuity between smart entrance control unit connector M111 terminal 43 (B) and M112 terminal 64 (B) and ground.

WEL332A

Refer to “Wiring Diagram —KEYLES—”, EL-206. OK or NG OK

䊳

Power supply and ground circuits are OK.

NG

䊳

Check ground harness.

EL-212

REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d)

DOOR SWITCH CHECK 1

=NGEL0115S05

CHECK DOOR SWITCH INPUT SIGNAL

GI

Check voltage between smart entrance control unit connector M110 terminals 1 (G/R), 2 (G/B) or 3 (R/B) and ground.

MA EM LC EC LEL028A

Refer to “Wiring Diagram —KEYLES—”, EL-206.

FE

OK or NG OK

䊳

Door switch is OK.

NG

䊳

GO TO 2.

2

CL MT

CHECK DOOR SWITCH

1. Disconnect door switch harness connector. 2. Check continuity between door switch terminals.

AT TF PD AX AEL651C

Continuity: Front door switch LH - terminals 2 and 3 Door switch is pressed - No Door switch is released - Yes Front door switch RH, back door switch or rear door switch LH or RH - terminal + and ground Door switch is pressed - No Door switch is released - Yes

SU BR ST

OK or NG OK

䊳

Check the following. 쐌 Door switch ground circuit (front door LH, back door) or door switch ground condition 쐌 Harness for open or short between smart entrance control unit and door switch

RS

NG

䊳

Replace door switch.

BT HA SC

EL-213

IDX

REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d)

KEY SWITCH (INSERTED) CHECK 1

=NGEL0115S07

CHECK KEY SWITCH INPUT SIGNAL

1. Disconnect smart entrance control unit harness connector. 2. Check voltage between smart entrance control unit harness connector M111 terminal 25 (W/G) and ground.

LEL053A

Refer to “Wiring Diagram —KEYLES—”, EL-206. OK or NG OK

䊳

Key switch is OK.

NG

䊳

GO TO 2.

2

CHECK KEY SWITCH POWER SUPPLY

1. Disconnect key switch harness connector. 2. Check voltage between key switch harness connector terminal 1 and ground.

AEL415B

Battery voltage should exist. Refer to “Wiring Diagram —KEYLES—”, EL-206. OK or NG OK

䊳

GO TO 3.

NG

䊳

Check the following 쐌 7.5A fuse [No. 28, located in the fuse block (J/B)] 쐌 Harness for open or short between key switch and fuse

EL-214

REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d)

3

CHECK KEY SWITCH (INSERTED)

Check continuity between terminals 1 and 2.

GI MA EM AEL416B

Continuity: Condition of key switch: Key is inserted. Yes Condition of key switch: Key is removed. No

LC EC FE

OK or NG OK

䊳

Check harness for open or short between smart entrance control unit and key switch.

NG

䊳

Replace key switch.

CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-215

IDX

REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d)

HAZARD REMINDER CHECK 1

=NGEL0115S09

CHECK HAZARD INDICATOR

Check if hazard indicator flashes with hazard switch. Does hazard indicator operate? Yes

䊳

GO TO 2.

No

䊳

Check “hazard indicator” circuit. Refer to “Trouble Diagnoses”, EL-59.

2

CHECK KEYFOB OPERATION

Check door lock/unlock operation with keyfob. Does door lock/unlock operate? Yes

䊳

GO TO 3.

No

䊳

Check keyfob battery. Refer to “KEYFOB BATTERY CHECK”, EL-210.

3

CHECK HAZARD REMINDER OUTPUT SIGNAL

Measure voltage between smart entrance control unit connector M111 terminals 47 (GY) and 48 (P/B) and ground with CONSULT-II or voltmeter when hazard reminder is operated.

WEL816A

OK or NG OK

䊳

Check harness for open or short between smart entrance control unit and turn signal lamps.

NG

䊳

Replace smart entrance control unit.

INTERIOR ROOM LAMP OPERATION CHECK 1

NGEL0115S10

CHECK INTERIOR ROOM LAMP

Check if the interior room lamp switch is in the “ON” position and the lamp illuminates. Does interior room lamp illuminate? Yes

䊳

GO TO 2.

No

䊳

Check the following. 쐌 Harness for open or short between smart entrance control unit and interior room lamp 쐌 Interior room lamp

EL-216

REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d)

2

CHECK INTERIOR ROOM LAMP CIRCUIT

When interior room lamp switch is in “DOOR” position, check voltage across smart entrance control unit connector M111 terminal 31 (R/B) and ground.

GI MA EM LC EC

LEL055A

Refer to “Wiring Diagram —KEYLES—”, EL-208.

FE

OK or NG OK

䊳

GO TO 3.

NG

䊳

Repair harness between smart entrance control unit and interior room lamp.

3

CL MT

CHECK CONTROL UNIT OUTPUT

Push unlock button of keyfob with key removed and all doors closed, and check voltage across smart entrance control unit connector M111 terminal 31 (R/B) and ground.

AT TF PD AX

LEL056A

SU

OK or NG OK

䊳

Check system again.

NG

䊳

Replace smart entrance control unit.

BR ST RS BT HA SC

EL-217

IDX

REMOTE KEYLESS ENTRY SYSTEM ID Code Entry Procedure

ID Code Entry Procedure

NGEL0117

WEL806A

EL-218

REMOTE KEYLESS ENTRY SYSTEM ID Code Entry Procedure (Cont’d)

NOTE: 쐌 If a keyfob is lost, the ID code of the lost keyfob must be erased to prevent unauthorized use. To erase all ID codes in memory, register one ID code (keyfob) four times. After all ID codes are erased, the ID codes of all remaining and/or new keyfobs must be re-registered. 쐌 When registering an additional remote controller, the existing ID codes in memory may or may not be erased. If four ID codes are stored in memory when an additional code is registered, only the oldest code is erased. If less than four ID codes are stored in memory when an additional ID code is registered, the new ID code is added and no ID codes are erased. 쐌 If you need to activate more than two additional new keyfobs, repeat the procedure “ADDITIONAL ID CODE ENTRY” for each new keyfob. 쐌 Entry of a maximum of four ID codes is allowed. When more than four ID codes are entered, the oldest ID code will be erased. 쐌 If an ID code has already been registered in the memory, the same ID code can be entered in the memory again. Each registration of an ID code counts as an additional code.

GI MA EM LC EC FE CL MT

Keyfob Battery Replacement

NGEL0118

NOTE: 쐌 Be careful not to touch the circuit board or battery terminal. 쐌 The keyfob is water-resistant. However, if it does get wet, wipe it dry immediately. 쐌 After battery replacement, press the keyfob buttons two or three times to check their operation.

AT TF PD AX SU BR ST RS BT

WEL911A

HA SC

EL-219

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM Component Parts and Harness Connector Location

Component Parts and Harness Connector Location

NGEL0119

WEL949A

EL-220

VEHICLE SECURITY (THEFT WARNING) SYSTEM Component Parts and Harness Connector Location (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL139B

EL-221

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM System Description

System Description DESCRIPTION 1. Operation Flow

NGEL0120 NGEL0120S01 NGEL0120S0101

AEL579C

2. Setting the Vehicle Security System

NGEL0120S0102

Initial condition 1) Close all doors. 2) Close hood. Disarmed phase The vehicle security system is in the disarmed phase when any door(s) or hood is opened. The security indicator lamp blinks every second. Pre-armed phase and armed phase The vehicle security system turns into the “pre-armed” phase when hood and all doors are closed and the doors are locked by key or keyfob. (The security indicator lamp illuminates.) After about 30 seconds, the system automatically shifts into the “armed” phase (the system is set). (The security indicator lamp blinks every 2.6 seconds.)

3. Canceling the Set Vehicle Security System

NGEL0120S0103

When the doors are unlocked with the key or keyfob, the armed phase is canceled.

4. Activating the Alarm Operation of the Vehicle Security System

NGEL0120S0104

Make sure the system is in the armed phase. (The security indicator lamp blinks every 2.6 seconds.) When the following operation 1) or 2) is performed, the horn, and headlamps operate intermittently for about 50 seconds. (At the same time, the system disconnects the starting system circuit.) 1) Engine hood or any door is opened before unlocking door with key or keyfob. 2) Door is unlocked without using key or keyfob (applies to early production models).

POWER SUPPLY AND GROUND

NGEL0120S07

Power is supplied at all times 쐌 through 15A fuse [No. 37, located in the fuse block (J/B)] 쐌 to vehicle security lamp relay terminal 7. 쐌 through 15A fuse [No. 38, located in the fuse block (J/B)] 쐌 to security lamp relay terminal 5. 쐌 through 7.5A fuse [No. 28, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 49 쐌 to key switch terminal 1 and 쐌 to security indicator lamp terminal 1.

EL-222

VEHICLE SECURITY (THEFT WARNING) SYSTEM System Description (Cont’d)

With the ignition switch in the ACC or ON position, power is supplied 쐌 through 7.5A fuse [No. 20, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 26. With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 5, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 27. Ground is supplied 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M14 and M68.

INITIAL CONDITION TO ACTIVATE THE SYSTEM

GI MA EM LC NGEL0120S02

The operation of the vehicle security system is controlled by the doors and hood. To activate the vehicle security system, the smart entrance control unit must receive signals indicating the doors and hood are closed and the doors are locked. When a door is open, smart entrance control unit terminal 1, 2, or 3 receives a ground signal from the corresponding door switch. When the hood is open, ground is supplied 쐌 to smart entrance control unit terminal 6 쐌 through hood switch terminal + 쐌 through hood switch terminal – 쐌 through body grounds E12 and E54. When smart entrance control unit receives lock signal from key cylinder or keyfob and none of the described conditions exist, the vehicle security system will automatically shift to armed phase.

VEHICLE SECURITY SYSTEM ACTIVATION (WITH KEY OR KEYFOB USED TO LOCK DOORS)

EC FE CL MT AT

NGEL0120S03

If the key is used to lock doors, ground is supplied to smart entrance control unit terminal 11 쐌 through front door key cylinder switch LH terminal 1 쐌 through front door key cylinder switch LH terminal 2 쐌 through body grounds M14 and M68 or 쐌 through back door key cylinder switch terminal 1 쐌 through back door key cylinder switch terminal 2 쐌 through body grounds D402 and D404. If this signal or lock signal from keyfob is received by the smart entrance control unit, the vehicle security system will activate automatically. Once the vehicle security system has been activated, smart entrance control unit terminal 38 supplies ground to security indicator lamp terminal 2. The security indicator lamp will illuminate for approximately 30 seconds and then blink. The vehicle security system is now in armed phase.

TF

VEHICLE SECURITY SYSTEM ALARM OPERATION

ST

NGEL0120S04

The vehicle security system is triggered by 쐌 opening a door 쐌 opening the hood 쐌 unlocking door without using a key or keyfob. Once the vehicle security system is in armed phase, if the smart entrance control unit receives a ground signal at terminal 1, 2, 3 (door switch) or 6 (hood switch), the horn and headlamps operate intermittently and the starting system is interrupted. With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 5, located in the fuse block (J/B)]. 쐌 to vehicle security relay terminal 2. If the vehicle security system is triggered, ground is supplied 쐌 to vehicle security relay terminal 1 쐌 through smart entrance control unit terminal 40.

EL-223

PD AX SU BR

RS BT HA SC

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM System Description (Cont’d)

With power and ground supplied, starter motor circuit is interrupted. The starter motor will not crank and the engine will not start. Power is supplied at all times 쐌 through 15A fuse (No. 37, located in fuse and fusible link box) 쐌 to vehicle security lamp relay terminal 7. 쐌 through 15A fuse (No. 38, located in fuse and fusible link box) 쐌 to vehicle security lamp relay terminal 5. 쐌 through 15A fuse (No. 32, located in fuse and fusible link box) 쐌 to horn relay terminals 1 and 5. When the vehicle security system is triggered, ground is supplied intermittently 쐌 to vehicle security lamp relay terminal 1 쐌 to horn relay terminal 2 쐌 through smart entrance control unit terminals 39 and 42. The horn and headlamps operate intermittently. The alarm automatically turns off after 50 seconds but will reactivate if the vehicle is tampered with again.

VEHICLE SECURITY SYSTEM DEACTIVATION

NGEL0120S05

To deactivate the vehicle security system, a door must be unlocked with the key or keyfob. When the key is used to unlock the door, smart entrance control unit terminal 10 receives a ground signal 쐌 through front door key cylinder switch LH terminal 3 쐌 through front door key cylinder switch LH terminal 2 쐌 through body grounds M14 and M68 or 쐌 through back door key cylinder switch terminal 3 쐌 through back door key cylinder switch terminal 2 쐌 through body grounds D402 and D404. When the smart entrance control unit receives this signal or an unlock signal from keyfob, the vehicle security system is deactivated. (Disarmed phase)

PANIC ALARM OPERATION

NGEL0120S06

When the remote keyless entry system is triggered, ground is supplied intermittently 쐌 to vehicle security lamp relay terminal 1 and 쐌 to horn relay terminal 2 쐌 through smart entrance control unit terminals 39 and 42. The horn and headlamps operate intermittently. The alarm automatically turns off after 30 seconds or when smart entrance control unit receives any signal from keyfob.

EL-224

VEHICLE SECURITY (THEFT WARNING) SYSTEM Circuit Diagram

Circuit Diagram

NGEL0121

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL709A

EL-225

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM Wiring Diagram — VEHSEC —

Wiring Diagram — VEHSEC — FIG. 1

NGEL0122 NGEL0122S01

WEL710A

EL-226

VEHICLE SECURITY (THEFT WARNING) SYSTEM Wiring Diagram — VEHSEC — (Cont’d)

FIG. 2

NGEL0122S02

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL711A

EL-227

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM Wiring Diagram — VEHSEC — (Cont’d)

FIG. 3

NGEL0122S03

WEL712A

EL-228

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses

Trouble Diagnoses PRELIMINARY CHECK

NGEL0123 NGEL0123S01

The system operation is canceled by turning ignition switch to ACC at any step between START and ARMED in the following flow chart.

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

WEL907A

After performing preliminary check, refer to “SYMPTOM CHART”, EL-230.

BT HA SC

EL-229

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

SYMPTOM CHART

Vehicle security system cannot be set by .... *1 Vehicle security system does not alarm when ...

237

238

239

241

209

DOOR KEY CYLINDER SWITCH CHECK

VEHICLE SECURITY HORN ALARM CHECK

VEHICLE SECURITY HEADLAMP ALARM CHECK

STARTER INTERRUPT SYSTEM CHECK

Check “REMOTE KEYLESS ENTRY” system.

SECURITY INDICATOR LAMP CHECK

5

236

DOOR AND HOOD SWITCH CHECK

4

Vehicle security alarm does not activate.

3

232

X

X

X

All items

X

X

X

Door outside key

X

Keyfob

X

Any door is opened.

X

Any door is unlocked without using key or keyfob.

X

All function

X

Horn alarm

X

Headlamp alarm

X

Starter interrupt

X

Door outside key

X

Keyfob

X

Vehicle security indicator does not turn ON or is not blinking.

Vehicle security system cannot be canceled by ....

2

231

X

SYMPTOM 1

229

POWER SUPPLY AND GROUND CIRCUIT CHECK

)

PRELIMINARY CHECK

REFERENCE PAGE (EL-

NGEL0123S02

X X X

X

X X X X X

X

X : Applicable *1: Make sure the system is in the armed phase.

Before starting trouble diagnoses above, refer to “PRELIMINARY CHECK”, EL-229. Symptom numbers in the symptom chart correspond with those of “PRELIMINARY CHECK”.

EL-230

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

POWER SUPPLY AND GROUND CIRCUIT CHECK NGEL0123S03 Power Supply Circuit Check NGEL0123S0301 Terminals

GI

Ignition switch position

(+)

MA (−)

OFF

ACC

ON

Connector

Terminal (wire color)

M112

49 (G)

Ground

Battery voltage

Battery voltage

Battery voltage

M111

27 (G/W)

Ground

0V

0V

Battery voltage

M111

26 (G)

Ground

0V

Battery voltage

Battery voltage

If NG, check the following. 쐌 7.5A fuse [No. 28, located in fuse block (J/B)] 쐌 10A fuse [No. 5, located in fuse block (J/B)] 쐌 7.5A fuse [No. 20, located in fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse. LEL026A

Ground Circuit Check

NGEL0123S0302

Terminals (+)

Continuity (−)

Connector

Terminal (wire color)

M111

43 (B)

Ground

EM LC EC FE CL MT AT TF PD

Yes M112

64 (B)

Ground

AX LEL008A

SU BR ST RS BT HA SC

EL-231

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

DOOR AND HOOD SWITCH CHECK Door Switch Check 1

=NGEL0123S04 NGEL0123S0401

PRELIMINARY CHECK

1. Turn ignition switch OFF and remove key from ignition key cylinder. 2. Close all doors and hood. “SECURITY” indicator lamp should turn off. 3. Open any door. “SECURITY” indicator lamp should blink every second. OK or NG OK

䊳

Door switch is OK.

NG

䊳

GO TO 2.

2

CHECK DOOR SWITCH INPUT SIGNAL

Check voltage between smart entrance control unit connector M110 terminals 1 (G/R), 2 (G/B), or 3 (R/B) and ground.

LEL028A

Refer to wiring diagram on EL-226. OK or NG OK

䊳

Door switch is OK. Refer to “Hood Switch Check”, EL-234.

NG

䊳

GO TO 3.

EL-232

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

3

CHECK DOOR SWITCH

1. Disconnect door switch harness connector. 2. Check continuity between door switch terminals.

GI MA EM LC AEL651C

Continuity: Front door switch LH - terminals 2 and 3 Door switch is pressed - No Door switch is released - Yes Front door switch RH, back door switch or rear door switch LH or RH - terminal + and ground Door switch is pressed - No Door switch is released - Yes OK or NG OK

䊳

Check the following. 쐌 Door switch ground circuit (Front LH, back door) or door switch ground condition 쐌 Harness for open or short between smart entrance control unit and door switch

NG

䊳

Replace door switch.

EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-233

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

Hood Switch Check 1

=NGEL0123S0402

PRELIMINARY CHECK

1. Turn ignition switch OFF and remove key from ignition key cylinder. 2. Close all doors and hood. “SECURITY” indicator lamp should turn off. 3. Open hood. “SECURITY” indicator lamp should blink every second. OK or NG OK

䊳

Hood switch is OK.

NG

䊳

GO TO 2.

2

CHECK HOOD SWITCH FITTING CONDITION OK or NG

OK

䊳

GO TO 3.

NG

䊳

Adjust installation of hood switch or hood.

3

CHECK HOOD SWITCH INPUT SIGNAL

Check voltage between smart entrance control unit connector M110 terminal 6 (B/P) and ground.

LEL029A

Refer to wiring diagram on EL-226. OK or NG OK

䊳

Hood switch is OK.

NG

䊳

GO TO 4.

EL-234

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

4

CHECK HOOD SWITCH

1. Disconnect hood switch harness connector. 2. Check continuity between hood switch terminals + and –.

GI MA EM LC AEL430B

Continuity: Condition: Pressed No Condition: Released Yes

EC FE OK or NG

OK

䊳

Check the following. 쐌 Hood switch ground circuit 쐌 Harness for open or short between smart entrance control unit and hood switch

NG

䊳

Replace hood switch.

CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-235

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

SECURITY INDICATOR LAMP CHECK 1

=NGEL0123S05

CHECK INDICATOR LAMP OUTPUT SIGNAL

1. Disconnect smart entrance control unit harness connector. 2. Check voltage between smart entrance control unit harness connector M111 terminal 38 (G/OR) and ground.

LEL030A

Refer to “Wiring Diagram —VEHSEC—”, EL-226. OK or NG OK

䊳

Security indicator lamp is OK.

NG

䊳

GO TO 2.

2

CHECK INDICATOR LAMP

Refer to “Wiring Diagram —VEHSEC—”, EL-226. OK or NG OK

䊳

GO TO 3.

NG

䊳

Replace indicator lamp.

3

CHECK POWER SUPPLY CIRCUIT FOR INDICATOR LAMP

1. Disconnect security indicator lamp harness connector. 2. Check voltage between security indicator lamp harness connector terminal 1 and ground.

AEL145C

Does battery voltage exist? Yes

䊳

Check harness for open or short between security indicator lamp and smart entrance control unit.

No

䊳

Check the following. 쐌 7.5A fuse [No. 28, located in fuse block (J/B)] 쐌 Harness for open or short between security indicator lamp and fuse

EL-236

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

DOOR KEY CYLINDER SWITCH CHECK 1

=NGEL0123S07

CHECK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL)

GI

Check voltage between smart entrance control unit connector M110 terminal 10 (Y/R) or 11 (Y) and ground.

MA EM LC EC WEL328A

Refer to “Wiring Diagram —VEHSEC—” EL-227.

FE

OK or NG OK

䊳

Door key cylinder switch is OK.

NG

䊳

GO TO 2.

2

CL MT

CHECK DOOR KEY CYLINDER SWITCH

1. Disconnect door key cylinder switch harness connector. 2. Check continuity between door key cylinder switch connector D9 terminals 1 and 2, and 3 and 2.

AT TF PD AX WEL347A

SU

OK or NG OK

䊳

Check the following. 쐌 Door key cylinder switch ground circuit 쐌 Harness for open or short between smart entrance control unit and door key cylinder switch

NG

䊳

Replace door key cylinder switch.

BR ST RS BT HA SC

EL-237

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

VEHICLE SECURITY HORN ALARM CHECK 1

=NGEL0123S09

CHECK HORN OPERATION

Depress the horn switch to operate horn. OK or NG OK

䊳

GO TO 2.

NG

䊳

Refer to “Wiring Diagram — HORN— “, EL-129

2

CHECK HORN ALARM OPERATION

1. Disconnect smart entrance control unit harness connector. 2. Apply ground to smart entrance control unit harness connector M111 terminal 42 (LG/R).

LEL033A

Refer to “Wiring Diagram —VEHSEC—”, EL-228. OK or NG OK

䊳

Replace smart entrance control unit.

NG

䊳

Check harness for open or short between horn relay and smart entrance control unit.

EL-238

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

VEHICLE SECURITY HEADLAMP ALARM CHECK =NGEL0123S10 1

CHECK VEHICLE SECURITY HEADLAMP ALARM OPERATION

GI

1. Disconnect smart entrance control unit harness connector. 2. Apply ground to smart entrance control unit harness connector M111 terminal 39 (R).

MA EM LC EC LEL422A

FE

Refer to “Wiring Diagram —VEHSEC—”, EL-228. OK or NG OK

䊳

Headlamp alarm is OK.

NG

䊳

GO TO 2.

CL MT

2

CHECK HEADLAMP OPERATION

AT

Do headlamps come on when turning lighting switch ON? Yes

䊳

GO TO 3.

No

䊳

Check headlamp system. Refer to “HEADLAMP”, EL-35.

3

TF

CHECK VEHICLE SECURITY LAMP RELAY

PD

Check vehicle security lamp relay. OK or NG OK

䊳

GO TO 4.

NG

䊳

Replace vehicle security lamp relay.

4

AX SU

CHECK POWER SUPPLY FOR VEHICLE SECURITY LAMP RELAY

BR

1. Disconnect vehicle security lamp relay harness connector. 2. Check continuity between vehicle security lamp relay harness connector E22 terminal 2 (B) and ground.

ST RS BT HA WEL858A

Refer to “Wiring Diagram —VEHSEC—”, EL-228.

SC OK or NG

OK

䊳

GO TO 5.

NG

䊳

Check the following. 쐌 Harness for open between vehicle security lamp relay and ground

EL-239

IDX

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

5

CHECK VEHICLE SECURITY LAMP RELAY CIRCUIT

1. Disconnect vehicle security lamp relay harness connector. 2. Check voltage between vehicle security lamp relay harness connector E22 terminals 3 (R/G) and 5 (Y/B). Battery voltage should exist. 3. Check voltage between vehicle security lamp relay harness connector E22 terminals 6 (R/W) and 7 (Y/G). Battery voltage should exist.

LEL068A

OK or NG OK

䊳

Check harness for open or short between vehicle security lamp relay and smart entrance control unit.

NG

䊳

Check the following. 쐌 Harness for open or short between fuses and vehicle security lamp relay 쐌 Harness for open or short between vehicle security lamp relay and headlamps

EL-240

VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d)

STARTER INTERRUPT SYSTEM CHECK 1

=NGEL0123S11

CHECK STARTER MOTOR INTERRUPT SIGNAL

GI

1. Turn ignition switch ON. 2. Check voltage between smart entrance control unit connector M111 terminal 40 (R/W) and ground.

MA EM LC EC LEL057A

Refer to “Wiring Diagram —VEHSEC—”, 228.

FE

OK or NG

CL

OK

䊳

GO TO 2.

NG

䊳

Check the following. 쐌 10A fuse [No. 5, located in fuse block (J/B)] 쐌 Harness for open or short between vehicle security relay and fuse 쐌 Harness for open or short between smart entrance control unit and vehicle security relay

2

CHECK VEHICLE SECURITY RELAY

MT AT TF

Check vehicle security relay. Refer to “VEHICLE SECURITY RELAY”, 241.

PD

OK or NG OK

䊳

Check system again.

NG

䊳

Replace relay.

AX

Electrical Components Inspection

NGEL0214

VEHICLE SECURITY RELAY

SU

NGEL0214S01

Check continuity between terminals 3 and 4. Condition

Continuity

12V direct current supply between terminals 1 and 2

No

No current supply

Yes

BR ST RS

SEC202B

BT HA SC

EL-241

IDX

SMART ENTRANCE CONTROL UNIT Description

Description

NGEL0124

The following systems are controlled by the smart entrance control unit. 쐌 Warning chime 쐌 Rear window defogger timer 쐌 Power window 쐌 Power door lock 쐌 Remote keyless entry 쐌 Vehicle security 쐌 Room lamp For detailed description and wiring diagrams, refer to the relevant pages for the each system. The control unit receives data from the switches and sensors to control their corresponding system relays and actuators. System

Input

Output

Warning chime

Key switch (Insert) Ignition switch (ON) Lighting switch (1st) Seat belt buckle switch Front door switch LH

Warning chime

Rear window defogger timer

Ignition switch (ON or START) Rear window defogger switch

Rear window defogger relay

Power window

Ignition switch (ON) Door switches

Power window relay

Power door lock

Door lock/unlock switch Key switch (insert) Door switches Door key cylinder switches

Door lock actuator

Remote keyless entry

Key switch (Insert) Ignition switch (ACC) Door switches Antenna (keyfob signal) Door lock/unlock switches

Horn relay Vehicle security lamp relay Door lock actuator Room lamp

Vehicle security

Ignition switch (ACC, ON) Door switches Hood switch Door lock/unlock switches Door key cylinder switch (lock/unlock)

Horn relay Vehicle security lamp relay Vehicle security relay (Starter interrupt) Security indicator lamp

Room lamp

Door switches Ignition switch Key switch (insert)

Room lamp

EL-242

SMART ENTRANCE CONTROL UNIT Circuit Diagram

Circuit Diagram

NGEL0125

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL775A

EL-243

IDX

SMART ENTRANCE CONTROL UNIT Circuit Diagram (Cont’d)

LEL721

EL-244

SMART ENTRANCE CONTROL UNIT Smart Entrance Control Unit Inspection Table

Smart Entrance Control Unit Inspection Table

NGEL0126

Voltage (Approximate values)

GI

Terminal No.

Wire color

1

G/R

Front door switch LH

OFF (Closed) , ON (Open)

12V , 0V

2

G/B

Front door switch RH

OFF (Closed) , ON (Open)

12V , 0V

3

R/B

Rear door switch LH and RH, back door switch

OFF (Closed) , ON (Open)

12V , 0V

4

BR

Main power window and door lock/unlock switch, door lock/ unlock switch RH

Neutral , Unlock

12V , 0V

5

LG/R

Main power window and door lock/unlock switch, door lock/ unlock switch RH

Neutral , Lock

12V , 0V

6

B/P

Hood switch

ON (Open) , OFF (Closed)

0V , 12V

10

Y/R

Front door key cylinder unlock switch LH or back door key cylinder unlock switch

OFF (Neutral) , ON (Unlock)

12V , 0V

11

Y

Front door key cylinder lock switch LH or back door key cylinder lock switch

OFF (Neutral) , ON (Lock)

12V , 0V

14

G/B

Rear window defogger switch

OFF , ON

12V , 0V

25

W/G

Ignition key switch (Insert)

Key inserted , Key removed from ignition key cylinder

12V , 0V

26

G

Ignition switch (ACC)

ACC position

12V

27

G/W

Ignition switch (ON)

Ignition key is in ON position

12V

28

B/P

Seat belt buckle switch

Unfastened , Fastened (Ignition key is in ON position)

0V , 12V

31

R/B

Room lamp

When interior lamp is operated using keyfob. (Interior lamp switch in DOOR position)

12V , 0V

32

R/B

Door ajar indicator lamp

OFF , ON (Ignition key is in ON position)

12V , 0V

37

G/R

Rear window defogger relay

OFF , ON (Ignition key is in ON position)

12V , 0V

38

G/OR

Security indicator lamp

Turns off , Turns on

12V , 0V

39

R

Vehicle security lamp relay

When panic alarm is operated using keyfob or when alarm is activated

12V , 0V

40

R/W

Vehicle security relay (Starter cut)

OFF , ON (Ignition key is in ON position)

12V , 0V

ST

42

R

Horn relay

When panic alarm is operated using keyfob or when alarm is activated

12V , 0V

RS

43

B

Ground

46

G/W

47

Connections

Operated condition

MA EM LC EC FE CL MT

—

Power window relay

Ignition key is in ON position , 45 seconds after ignition key is turned to OFF position

12V , 0V

GY

Turn signal lamp LH

When doors are locked using keyfob

12V , 0V

48

P/B

Turn signal lamp RH

When doors are locked using keyfob

12V , 0V

49

G

Power source (Fuse)

50

R/G

Battery saver (Room lamp)

51

W/R

Power source (C/B)

Turns off , Turns on

PD AX SU

BT

12V

HA SC

12V , 0V —

EL-245

TF

BR

—

—

AT

12V

IDX

SMART ENTRANCE CONTROL UNIT Smart Entrance Control Unit Inspection Table (Cont’d) Terminal No.

Wire color

Connections

54

L

Front door lock actuator LH and RH, rear door lock actuator LH and RH

Main power window and door lock/unlock switch, door lock/unlock switch RH

Front door lock actuator LH

Main power window and door lock/unlock switch, door lock/unlock switch RH

55

56

G/W

L/R

58

L/R

64

B

Voltage (Approximate values)

Operated condition

Front door lock actuator RH, rear door lock actuator LH and RH, back door lock actuator

Main power window and door lock/unlock switch, door lock/unlock switch RH

Lighting switch

1ST, 2ND positions: ON , OFF

Ground

—

EL-246

Lock

12V

Neutral, unlock

0V

Unlock

12V

Neutral, lock

0V

Unlock

12V

Neutral, lock

0V 12V , 0V —

ELECTRICAL UNITS LOCATION Engine Compartment

Engine Compartment

NGEL0129

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL919A

EL-247

IDX

ELECTRICAL UNITS LOCATION Passenger Compartment

Passenger Compartment

NGEL0130

AEL157C

EL-248

ELECTRICAL UNITS LOCATION Passenger Compartment (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT WEL140B

HA SC

EL-249

IDX

HARNESS LAYOUT How to Read Harness Layout

How to Read Harness Layout

NGEL0172

SEL252V

The following Harness Layouts use a map style grid to help locate connectors on the drawings: 쐌 Main Harness 쐌 Engine Room Harness (Engine Compartment) 쐌 Engine Control Harness

TO USE THE GRID REFERENCE 1. 2. 3. 4. 5.

NGEL0172S01

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

NGEL0172S02

Main symbols of connector (in Harness Layout) are indicated below. Waterproof type

Standard type

Connector type Male

Female

쐌 Cavity: Less than 4 쐌 Relay connector 쐌 Cavity: From 5 to 8 쐌 Cavity: More than 9

쐌 Ground terminal etc. —

EL-250

Male

Female

HARNESS LAYOUT Outline

Outline

NGEL0173

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST LEL161A

NOTE: For detailed ground distribution information, refer to “Ground Distribution”, EL-18.

RS BT HA SC

EL-251

IDX

HARNESS LAYOUT Main Harness

Main Harness

NGEL0174

WEL141B

EL-252

HARNESS LAYOUT Main Harness (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL142B

EL-253

IDX

HARNESS LAYOUT Main Harness (Cont’d)

WEL972A

EL-254

HARNESS LAYOUT Engine Room Harness

Engine Room Harness KA24DE Engine Compartment

NGEL0175 NGEL0175S01

GI

NGEL0175S0101

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA

WEL143B

EL-255

SC

IDX

HARNESS LAYOUT Engine Room Harness (Cont’d)

WEL145B

EL-256

HARNESS LAYOUT Engine Room Harness (Cont’d)

Passenger Compartment

NGEL0175S0102

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA WEL146B

SC

EL-257

IDX

HARNESS LAYOUT Engine Room Harness (Cont’d)

VG33E AND VG33ER Engine Compartment

=NGEL0175S02 NGEL0175S0201

WEL147B

EL-258

HARNESS LAYOUT Engine Room Harness (Cont’d)

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL148B

EL-259

IDX

HARNESS LAYOUT Engine Room Harness (Cont’d)

Passenger Compartment

NGEL0175S0202

WEL149B

EL-260

HARNESS LAYOUT Engine Control Harness

Engine Control Harness KA24DE

NGEL0176 NGEL0176S01

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA

WEL932A

EL-261

SC

IDX

HARNESS LAYOUT Engine Control Harness (Cont’d)

WEL150B

EL-262

HARNESS LAYOUT Engine Control Harness (Cont’d)

VG33E

NGEL0176S02

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA LEL158A

SC

EL-263

IDX

HARNESS LAYOUT Engine Control Harness (Cont’d)

WEL151B

EL-264

HARNESS LAYOUT Engine Control Harness (Cont’d)

VG33ER

NGEL0176S05

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA WEL152B

SC

EL-265

IDX

HARNESS LAYOUT Engine Control Harness (Cont’d)

WEL153B

EL-266

HARNESS LAYOUT Engine No. 2 Harness

Engine No. 2 Harness KA24DE

NGEL0177 NGEL0177S01

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA

AEL659C

EL-267

SC

IDX

HARNESS LAYOUT Engine No. 2 Harness (Cont’d)

VG33E

NGEL0177S02

LEL350A

EL-268

HARNESS LAYOUT Engine No. 2 Harness (Cont’d)

VG33ER

NGEL0177S03

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA WEL474A

SC

EL-269

IDX

HARNESS LAYOUT Body Harness

Body Harness

NGEL0180

WEL154B

EL-270

HARNESS LAYOUT Body No. 2 and Chassis Harness

Body No. 2 and Chassis Harness

NGEL0201

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL155B

EL-271

IDX

HARNESS LAYOUT Room Lamp Harness

Room Lamp Harness

NGEL0202

WEL156B

EL-272

HARNESS LAYOUT Front Door Harness

Front Door Harness

NGEL0182

GI MA EM LC EC FE CL MT AT

WEL928A

TF PD AX SU BR ST RS BT HA SC

WEL929A

EL-273

IDX

HARNESS LAYOUT Rear Door Harness

Rear Door Harness

NGEL0183

LEL147A

LEL148A

EL-274

HARNESS LAYOUT Back Door Harness

Back Door Harness

NGEL0199

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA WEL655A

SC

EL-275

IDX

NGEL0144

BULB SPECIFICATIONS Headlamp

Headlamp Item High/Low (Semi-sealed beam)

NGEL0144S03

Wattage (W)

Bulb No.*

65/55

9007 (HB5)

*: Always check with the Parts Department for the latest parts information.

Exterior Lamp Item

NGEL0144S01

Wattage (W)

Bulb No.*

Front fog lamp

55

H3

Front turn signal lamp

27

1156A

Parking lamp

3.8

194

27

3157AK

Stop/Tail lamp

27/7

3057K

Back-up lamp

16

921

License plate lamp

3.8

168

High-mounted stop lamp

12.8

912

Turn signal lamp Rear combination lamp

*: Always check with the Parts Department for the latest parts information.

Interior Lamp Item

NGEL0144S02

Wattage (W)

Bulb No.*

Room lamp

8

82

Map lamp (with compass and thermometer)

8

168

Map lamp (without compass and thermometer)

8

82

*: Always check with the Parts Department for the latest parts information.

EL-276

NGEL0145

WIRING DIAGRAM CODES (CELL CODES) Use the chart below to find out what each wiring diagram code stands for. Refer to the wiring diagram code in the alphabetical index to find the location (page number) of each wiring diagram. Code

Section

Wiring Diagram Name

1STSIG

AT

A/T 1ST Signal

2NDSIG

AT

A/T 2ND Signal

3RDSIG

AT

A/T 3RD Signal

4THSIG

AT

A/T 4TH Signal

A/C

HA

Air Conditioner

AAC/V

EC

IACV-AAC Valve

ABS

BR

Anti-lock Brake System

ASCD

EL

Automatic Speed Control Device

AT/C

EC

A/T Control

Code

Section

Wiring Diagram Name

EC

Fuel Level Sensor Unit

FLS3

EC

Fuel Level Sensor Unit

F/PUMP

EC

Fuel Pump

FICD

EC

IACV-FICD Solenoid Valve

FTTS

EC

Fuel Tank Temperature Sensor

FTS

AT

A/T Fluid Temperature Sensor

FUEL

EC

Fuel Injection System Function (KA24DE)

FUELB1

EC

Fuel Injection System Function (Bank 1) (VG33E and VG33ER)

EC

FUELB2

EC

Fuel Injection System Function (Bank 2) (VG33E and VG33ER)

FE

H/LAMP

EL

Headlamp

HO2S1

EC

Heated Oxygen Sensor 1 (Front) (KA24DE)

HO2S2

EC

Heated Oxygen Sensor 2 (Rear) (KA24DE)

MT

HO2S2H

EC

Heated Oxygen Sensor 2 Heater (Rear) (KA24DE)

AT

HO2SH

EC

Heated Oxygen Sensor 1 Heater (Front) (KA24DE)

TF

ATDIAG

EC

A/T Diagnosis Communication Line

AUDIO

EL

Audio

BA/FTS

AT

A/T Fluid Temperature Sensor and Transmission Control Module (TCM) Power Supply

BACK/L

EL

Back-up Lamp

BYPS/V

EC

Vacuum Cut Valve Bypass Valve

HORN

EL

Horn

CHARGE

SC

Charging System

IATS

EC

Intake Air Temperature Sensor

CHIME

EL

Warning Chime

IGN/SG

EC

Ignition Signal

CIGAR

EL

Cigarette Lighter

ILL

EL

Illumination

CKPS

EC

Crankshaft Position Sensor (OBD)

INJECT

EC

Injector

KEYLES

EL

Remote Keyless Entry System

CMPS

EC

Camshaft Position Sensor KS

EC

Knock Sensor

COMPAS

EL

Compass and Thermometer LPSV

AT

Line Pressure Solenoid Valve

MAFS

EC

Mass Air Flow Sensor

MAIN

AT

Main Power Supply and Ground Circuit

MAIN

EC

Main Power Supply and Ground Circuit

METER

EL

Speedometer, Tachometer, Temp., Oil and Fuel Gauges

MIL/DL

EC

MIL and Data Link Connector

MIRROR

EL

Door Mirror

NONDTC

AT

Non-detectable Items

O2H1B1

EC

Heated Oxygen Sensor 1 (Front) Heater Bank 1 (VG33E and VG33ER)

D/LOCK

EL

Power Door Lock

DEF

EL

Rear Window Defogger

DTRL

EL

Headlamp - With Daytime Light System

ECTS

EC

Engine Coolant Temperature Sensor

EGRC1

EC

EGR Function (KA24DE)

EGRC/V

EC

EGRC - Solenoid Valve (KA24DE)

EGR/TS

EC

EGR Temperature Sensor

ENGSS

AT

Engine Speed Signal

F/FOG

EL

Front Fog Lamp

FLS1

EC

Fuel Level Sensor Unit

GI

FLS2

EL-277

MA EM LC

CL

PD AX SU BR ST RS BT HA SC

IDX

WIRING DIAGRAM CODES (CELL CODES) Code O2H1B2

O2H2B1

O2H2B2

Section

Wiring Diagram Name

EC

Heated Oxygen Sensor 1 (Front) Heater Bank 2 (VG33E and VG33ER)

TP/SW

EC

Throttle Position Switch

TPS

AT

Throttle Position Sensor

Heated Oxygen Sensor 2 (Rear) Heater Bank 1 (VG33E and VG33ER)

TPS

EC

Throttle Position Sensor

TRSA/T

AT

Turbine Revolution Sensor

TURN

EL

Turn Signal and Hazard Warning Lamps

VEHSEC

EL

Vehicle Security System

EC

EC

Heated Oxygen Sensor 2 (Rear) Heater Bank 2 (VG33E and VG33ER)

Code

Section

Wiring Diagram Name

O2S1B1

EC

Heated Oxygen Sensor 1 (Front) Bank 1 (VG33E and VG33ER)

VENT/V

EC

EVAP Canister Vent Control Valve

O2S1B2

EC

Heated Oxygen Sensor 1 (Front) Bank 2 (VG33E and VG33ER)

VSS

EC

Vehicle Speed Sensor

VSSAT

AT

O2S2B1

EC

Heated Oxygen Sensor 2 (Rear) Bank 1 (VG33E and VG33ER)

Vehicle Speed Sensor A/T (Revolution Sensor)

VSSMTR

AT

Vehicle Speed Sensor MTR

O2S2B2

EC

Heated Oxygen Sensor 2 (Rear) Bank 2 (VG33E and VG33ER)

WARN

EL

Warning Lamps

OVRCSV

AT

Overrun Clutch Solenoid Valve

WINDOW

EL

Power Window

PGC/V

EC

EVAP Canister Purge Volume Control Solenoid Valve

WIP/R

EL

Rear Wiper and Washer

WIPER

EL

Front Wiper and Washer

PNP/SW

AT

Park/Neutral Position Switch

PNP/SW

EC

Park/Neutral Position Switch

POWER

EL

Power Supply Routing

PRE/SE

EC

EVAP Control System Pressure Sensor

PST/SW

EC

Power Steering Oil Pressure Switch

ROOM/L

EL

Interior Room Lamp

S/CHGR

EC

Supercharger bypass valve control solenoid valve (VG33ER)

S/SIG

EC

Start Signal

SHIFT

AT

A/T Shift Lock System

SRS

RS

Supplemental Restraint System

SSV/A

AT

Shift Solenoid Valve A

SSV/B

AT

Shift Solenoid Valve B

START

SC

Starting System

STOP/L

EL

Stop lamp

SW/V

EC

MAP/BARO Switch Solenoid Valve

T/TOW

EL

Trailer Tow

TAIL/L

EL

Parking, License and Tail Lamps

TCCSIG

AT

A/T TCC Signal (Lock Up)

TCV

AT

Torque Converter Clutch Solenoid Valve

EL-278

SUPER MULTIPLE JUNCTION (SMJ) Installation

Installation

NGEL0146

Securely fit and lock SMJ connectors. Tighten harness bracket bolt to the specified torque. : 3 - 5 N·m (0.3 - 0.5 kg-m, 26 - 43 in-lb)

GI MA EM LC

WEL860A

EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

EL-279

IDX

SUPER MULTIPLE JUNCTION (SMJ) Terminal Arrangement

Terminal Arrangement

NGEL0147

AEL646B

EL-280

FUSE BLOCK — JUNCTION BOX (J/B) Terminal Arrangement

Terminal Arrangement

NGEL0148

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL913A

EL-281

IDX

FUSE AND FUSIBLE LINK BOX Terminal Arrangement

Terminal Arrangement

NGEL0149

WEL914A

EL-282

JOINT CONNECTOR Terminal Arrangement

Terminal Arrangement

NGEL0198

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC WEL862A

EL-283

IDX

ELECTRICAL UNITS Terminal Arrangement

Terminal Arrangement

NGEL0150

WEL863A

EL-284

QUICK REFERENCE CHAR CHARTT: XTERRA

EQUIPPED WITH KA 24DE ENGINE

ENGINE TUNE-UP DATA Engine model

KA24DE

Firing order

1-3-4-2

Idle speed

2002

BRAKE Unit: mm (in)

rpm

Disc brake

MT (in neutral)

800° ± 50 Pad minimum thickness

Ignition timing (degree B.T.D.C. at idle speed)

Idle mixture screw is preset and sealed at factory

CO% at idle Spark plug

NGK (Double Platinum Tipped)

Type

Standard

mm (in) mm (in)

PFR6G-11

1.1 (0.043)

Number of notches*2

Deflection of new belt

17 (0.67)

10 - 12 (0.39 - 0.47)

8 - 10 (0.31 - 0.39)

Air conditioner compressor

16 (0.63)

10 - 12 (0.39 - 0.47)

8 - 10 (0.31 - 0.39)

Power steering oil pump

17 (0.67)

10 - 13 (0.39 - 0.51)

8 - 10 (0.31 - 0.39)

Generator

N (kg, lb)

Used belt Limit

222.4 (22.7, 50)

Air conditioner compressor

200.2 (20.4, 45)

Power steering oil pump

222.4 (22.7, 50) N (kg, lb)

5 - 6

FRONT WHEEL BEARING Model Item

2WD

Lock nut tightening torque

Tension after adjustment

Tension of new belt

355.8 - 444.8

489.3 - 578.2

(36.3-45.4, 80-100)

(49.9-59.0, 110-130)

355.8 - 444.8

489.3 - 578.2

(36.3-45.4, 80-100)

(49.9-59.0, 110-130)

355.8 - 444.8

489.3 - 578.2

(36.3-45.4, 80-100)

(49.9-59.0, 110-130)

N • m (kg•m, ft-lb)

34 - 39 (3.5 - 4.0, 25 - 29)

Preload (At hub bolt)

N (kg, lb)

New seal

9.8 - 28.4 (1.0 - 2.9, 2.2 - 6.4)

Used seal

9.8 - 23.5 (1.0 - 2.4, 2.2 - 5.3)

REFILL CAPACITIES

78 - 98 (0.8 - 1.0, 11 - 14)

Unit

Cooling system leakage testing pressure

Coolant (with reservoir)

Standard

1,226 (12.5, 178)/300

Minimum

1,030 (10.5, 149)/300

Liter

US measure

73.5

19.4 gal

2WD MT

7.3

7-3/4 qt

With oil filter

3.5

3-3/4 qt

Without oil filter

3.3

3-1/2 qt

Fuel tank

157 (1.6, 23)

kPa (kg/cm 2, psi)

Tightening torque

At pulling force: 196 N (20 kg, 44 lb)

98 (10, 22)

Radiator cap relief pressure kPa (kg/cm 2, psi)

Compression pressure kPa (kg/cm 2, psi)/rpm

296.5 (11.67)

Used belt Deflection after adjustment

Applied pushing force

1.5 (0.059)

Parking brake

Limit

Generator

26.0 (1.024)

Drum repair limit Maximum inner diameter

*1

Drive belt tension

0.07 (0.0028)

Minimum thickness

Lining minimum thickness

–

Drive belt deflection (Cold)

Rotor repair limit Runout

Drum brake

PFR5G-11

Cold

Gap

2.0 (0.079)

20° ± 2°

2WD Engine

N·m

kg-m

ft-lb

Spark plug

20 - 29

2.0 - 3.0

14 - 22

Oil pan drain plug

29 - 39

3.0 - 4.0

22 - 29

(engine overhaul)

4.1

4-3/8 qt

Transmission

Dry engine M/T

2WD

2.0

4-1/4 pt

Final drive

Rear

C200

1.5

3-1/8 pt

Manual steering system Power steering system

FRONT WHEEL ALIGNMENT (Unladen*1) Minimum

Degree minute (Decimal degree) Caster

Degree minute (Decimal degree) Kingpin inclination Degree minute (Decimal degree)

Total toe-in

Left and right difference

45' (0.75°) or less

Minimum

2°04' (2.07°)

Nominal

2°34' (2.57°)

Maximum

3°04' (3.07°)

Left and right difference

45' (0.75°) or less

Minimum

10°23' (10.38°)

Nominal

10°53' (10.88°)

Maximum

11°23' (11.38°)

Minimum

3 (0.12) 4 (0.16)

Maximum

5 (0.20)

Angle (left plus right)

Minimum

15' (0.25°)

Nominal

20' (0.33°)

Inside

Outside

*1 *2

0°33' (0.55°) 1°03' (1.05°)

Distance (A - B) mm (in)

Degree minute (Decimal degree) Full turn *2

Nominal Maximum

Nominal

Degree minute (Decimal degree)

Wheel turning angle

0°03' (0.05°)

Degree minute (Decimal degree)

Maximum

25' (0.42°) Except P265/70R15

P265/70R15

Minimum

32°48' (32.80°)

30°48' (30.80°)

Nominal

34°48' (34.80°)

32°48' (32.80°)

Maximum

34°48' (34.80°)

32°48' (32.80°)

Minimum

31°00' (31.00°)

28°42' (28.70°)

Nominal

33°00' (33.00°)

30°42' (30.70°)

Maximum

33°00' (33.00°)

30°42' (30.70°)

Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.

Lubricant Refrigerant *

*R-134a

2WD Camber

Air conditioning system

0.62

2-3/8 qt

0.9 - 1.0

30.4-33.8 fl oz

0.2

6.8 fl oz

0.6 - 0.7 kg

1.32 - 1.54 lb

QUICK REFERENCE CHAR CHARTT: XTERRA

2002

EQUIPPED WITH VG33E ENGINE

ENGINE TUNE-UP DATA Engine model

BRAKE

VG33E

Firing order

1-2-3-4-5-6

Idle speed

Unit: mm (in)

rpm

Disc brake

MT (in neutral)

750° ± 50

A/T (in “P” or “N” position)

750° ± 50

Ignition timing (degree B.T.D.C. at idle speed)

Pad minimum thickness

10° ± 2° Idle mixture screw is preset and sealed at factory

CO% at idle Spark plug

Type

PFR4G-11

Standard

PFR5G-11

Cold

PFR6G-11

Gap

mm (in)

1.1 (0.043)

Drive belt deflection (Cold)

mm (in)

Generator

Air conditioner compressor Power steering oil pump Drive belt tension

Lining minimum thickness

1.5 (0.059)

Drum repair limit Maximum inner diameter

296.5 (11.67)

Parking brake Number of notches*2 *1

Limit

Deflection after adjustment

Deflection of new belt

11 (0.43)

7 - 8 (0.24 - 0.31)

6 - 7 (0.24 - 0.28)

18 (0.71)

12 - 13 (0.47 - 0.51)

10.5 - 11.5 (0.413 - 0.453)

15 (0.59)

9.5 - 10.5 (0.374 - 0.413)

8 - 9 (0.31 - 0.35)

5 - 6

At pulling force: 196 N (20 kg, 44 lb)

FRONT WHEEL BEARING Model Item

2WD

4WD

Lock nut tightening torque N • m (kg•m, ft-lb)

34 - 39 (3.5 - 4.0, 25 - 29)

—

Used belt Limit

Tension after adjustment

Tension of new belt

226 (23, 51)

554.1-642.4 (56.565.5, 124.6-144.4)

671.8-760.0 (68.577.5, 151.0-170.9)

Air conditioner compressor

196 (20, 44)

495.3-583.5 (50.559.5, 111.4-131.2)

603.1-691.4 (61.570.5, 135.6-155.5)

Power steering oil pump

275 (28, 62)

554.1-642.4 (56.565.5, 124.6-144.4)

671.8-760.0 (68.577.5, 151.0-170.9)

Applied pressed force

26.0 (1.024)

Used belt

N (kg, lb)

Generator

0.07 (0.0028)

Minimum thickness Drum brake

NGK (Double Platinum Tipped) Hot

2.0 (0.079)

Rotor repair limit Runout

N (kg, lb)

Wheel bearing Tightening torque N • m(kg•m, ft-lb) New seal

Preload (At hub bolt)

Retightening torque after loosening wheel 0.5 - 1.5 bearing lock nut (0.05 - 0.15, N•m (kg•m, ft-lb) 0.4 - 1.1) Axial end play mm (in)

N (kg, lb)

98 (10, 22)

Radiator cap relief pressure kPa (kg/cm 2, psi)

9.8 - 28.4 (1.0 - 2.9, 2.2 - 6.4)

Used seal

78 - 98 (0.8 - 1.0, 11 - 14)

78 - 98 (8-10, 58 - 72)

Turning angle degree

9.8 - 23.5 (1.0 - 2.4, 2.2 - 5.3)

0(0) 15° - 30°

Cooling system leakage testing pressure 157 (1.6, 23)

kPa (kg/cm 2, psi) Compression pressure kPa (kg/cm 2, psi)/rpm

Standard Minimum

Tightening torque

Wheel bearing 7.06 - 20.99 preload at wheel (0.72 - 2.14, hub bolt 1.59 - 4.72) N (kg, lb)

1,196 (12.2, 173)/300 883 (9.0, 128)/300 N·m

kg-m

ft-lb

Spark plug

20 - 29

2.0 - 3.0

14 - 22

Oil pan drain plug

29 - 39

3.0 - 4.0

22 - 29

REFILL CAPACITIES

FRONT WHEEL ALIGNMENT (Unladen*1) Camber

Degree minute (Decimal degree) Caster

Degree minute (Decimal degree)

2WD

4WD

Minimum

0°03' (0.05°)

0°06' (0.10°)

Nominal

0°33' (0.55°)

0°36' (0.60°)

Maximum

1°03' (1.05°)

1°06' (1.10°)

Left and right difference

45' (0.75°) or less

45' (0.75°) or less

Unit

Coolant (with reservoir)

2°04' (2.07°)

1°40' (1.67°)

Nominal

2°34' (2.57°)

2°10' (2.17°)

Maximum

3°04' (3.07°)

2°40' (2.67°)

Left and right difference

45' (0.75°) or less

45' (0.75°) or less

Dry engine

Minimum

10°23' (10.38°)

10°18' (10.30°)

Nominal Degree minute (Decimal degree)

10°53' (10.88°)

M/T

A/T

Transfer Final drive

Kingpin inclination

AT & MT

Engine

Transmission

Minimum

Liter

Fuel tank

With oil filter

3.3

3-1/2 qt

3.0

3-1/8 qt

(engine overhaul)

3.8

4 qt

2WD

2.8

5-7/8 pt

4WD

5.1

10-3/4 pt

2WD

8.3

8-3/4 qt

4WD

8.5

9 qt

4WD

2.2

2-3/8 qt

Rear

H233B

2.8

5-7/8 pt

Front

R200A

1.75

3-3/4 pt

Manual steering system Maximum

11°23' (11.38°)

11°18' (11.30°)

Minimum

3 (0.12)

3 (0.12)

Nominal

4 (0.16)

4 (0.16)

Air conditioning system Maximum

5 (0.20)

5 (0.20)

Angle (left plus right)

Minimum

15' (0.25°)

15' (0.25°)

Nominal

20' (0.33°)

20' (0.33°)

Wheel turning angle Degree minute (Decimal degree) Outside Full turn *2

*1 *2

Degree minute (Decimal degree)

Lubricant Refrigerant *

Maximum

Inside

25' (0.42°) Except P265/70R15

Minimum

32°48' (32.80°)

11-5/8 qt

10°48' (10.80°)

Distance (A - B) mm (in)

Degree minute (Decimal degree)

19.4 gal

10.95

Without oil filter

Power steering system

Total toe-in

US measure

73.5

25' (0.42°)

P265/70R15

Except P265/70R15

P265/70R15

30°48' (30.80°)

33°06' (33.10°)

31°00' (31.00°)

Nominal

34°48' (34.80°)

32°48' (32.80°)

35°06' (35.10°)

33°00' (33.00°)

Maximum

34°48' (34.80°)

32°48' (32.80°)

35°06' (35.10°)

33°00' (33.00°)

Minimum

31°00' (31.00°)

28°42' (28.70°)

31°12' (31.20°)

29°00' (29.00°)

Nominal

33°00' (33.00°)

30°42' (30.70°)

33°12' (33.20°)

31°00' (31.00°)

Maximum

33°00' (33.00°)

30°42' (30.70°)

33°12' (33.20°)

31°00' (31.00°)°

Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.

*R-134a

0.62

1-3/8 pt

1.0 - 1.1

33.8 - 37.2 fl oz

0.2

6.8 fl oz

0.6 - 0.7 kg

1.32 - 1.54 lb

QUICK REFERENCE CHAR CHARTT: XTERRA

2002

EQUIPPED WITH VG33ER ENGINE

ENGINE TUNE-UP DATA Engine model

BRAKE

VG33E

Firing order

1-2-3-4-5-6 Unit: mm (in)

Idle speed

rpm

MT (in neutral)

750° ± 50

A/T (in “P” or “N” position)

750° ± 50

Ignition timing (degree B.T.D.C. at idle speed)

Disc brake Pad minimum thickness

10° ± 1° Idle mixture screw is preset and sealed at factory

CO% at idle Spark plug

Type

PFR5G-11

Standard

PFR6G-11

Cold

PFR7G-11

mm (in)

1.1 (0.043)

0.07 (0.0028)

Minimum thickness

26.0 (1.024)

Drum brake

NGK (Double Platinum Tipped) Hot

2.0 (0.079)

Rotor repair limit Runout

Lining minimum thickness

1.5 (0.059)

Drum repair limit Maximum inner diameter

296.5 (11.67)

Parking brake Gap Drive belt deflection (Cold)

mm (in)

Generator

Air conditioner compressor and Power steering oil pump Power steering oil pump Supercharger Drive belt tension

Power steering oil pump Air conditioner compressor and Supercharger Power steering oil pump Applied pressed force

Used belt Limit

Deflection after adjustment

Deflection of new belt

11 (0.43)

7 - 8 (0.24 - 0.31)

6 - 7 (0.24 - 0.28)

16.5 (0.65)

9.5 - 10.5 (0.374 - 0.413)

8.5 - 9.5 (0.33 - 0.39)

15 (0.59)

9.5 - 10.5 (0.374 - 0.413)

8 - 9 (0.31 - 0.35)

N (kg, lb)

Generator

Number of notches*2 *1

5 - 6

At pulling force: 196 N (20 kg, 44 lb)

FRONT WHEEL BEARING Model Item

2WD

4WD

Lock nut tightening torque N • m (kg•m, ft-lb)

34 - 39 (3.5 - 4.0, 25 - 29)

—

Used belt Limit

Tension after adjustment

Tension of new belt

226 (23, 51)

554.1-642.4 (56.565.5, 124.6-144.4)

671.8-760.0 (68.577.5, 151.0-170.9)

294 (30, 66)

730-818 (75.583.5, 166.5-184.1)

838-926 (85.594.5, 188.5-208.4)

275 (28, 62)

554.1-642.4 (56.565.5, 124.6-144.4)

671.8-760.0 (68.577.5, 151.0-170.9)

N (kg, lb)

Wheel bearing Tightening torque N • m(kg•m, ft-lb) New seal

Preload (At hub bolt)

Retightening torque after loosening wheel 0.5 - 1.5 bearing lock nut (0.05 - 0.15, N•m (kg•m, ft-lb) 0.4 - 1.1) Axial end play mm (in)

N (kg, lb)

98 (10, 22)

Radiator cap relief pressure kPa (kg/cm 2, psi)

9.8 - 28.4 (1.0 - 2.9, 2.2 - 6.4)

Used seal

78 - 98 (0.8 - 1.0, 11 - 14)

78 - 98 (8-10, 58 - 72)

Turning angle degree

9.8 - 23.5 (1.0 - 2.4, 2.2 - 5.3)

0(0) 15° - 30°

Cooling system leakage testing pressure 157 (1.6, 23)

kPa (kg/cm 2, psi) Compression pressure kPa (kg/cm 2, psi)/rpm

Standard Minimum

Tightening torque

Wheel bearing 7.06 - 20.99 preload at wheel (0.72 - 2.14, hub bolt 1.59 - 4.72) N (kg, lb)

1,196 (12.2, 173)/300 883 (9.0, 128)/300 N·m

kg-m

ft-lb

Spark plug

20 - 29

2.0 - 3.0

14 - 22

Oil pan drain plug

29 - 39

3.0 - 4.0

22 - 29

REFILL CAPACITIES

FRONT WHEEL ALIGNMENT (Unladen*1) Camber

Degree minute (Decimal degree) Caster

Degree minute (Decimal degree) Kingpin inclination Degree minute (Decimal degree)

Total toe-in

2WD

4WD

Minimum

0°33' (0.05°)

0°06' (0.10°)

Nominal

0°33' (0.55°)

0°36' (0.60°)

Maximum

1°03' (1.05°)

1°06' (1.10°)

Left and right difference

45' (0.75°) or less

45' (0.75°) or less

Minimum

2°04' (2.07°)

1°40' (1.67°)

Nominal

2°34' (2.57°)

2°10' (2.17°)

Maximum

3°04' (3.07°)

2°40' (2.67°)

Left and right difference

45' (0.75°) or less

45' (0.75°) or less

Minimum

10°23' (10.38°)

10°18' (10.30°)

Nominal

10°53' (10.88°)

10°48' (10.80°)

Maximum

11°23' (11.38°)

11°18' (11.30°)

Minimum

3' (0.12°)

3' (0.12°)

Nominal

4' (0.16°)

4' (0.16°)

Maximum

5' (0.20°)

5' (0.20°)

Angle (left plus right)

Minimum

15' (0.25°)

15' (0.25°)

Nominal

20' (0.33°)

20' (0.33°)

Maximum

Inside Wheel turning angle Degree minute (Decimal degree) Outside Full turn *2

*1 *2

Degree minute (Decimal degree)

Coolant (with reservoir)

25' (0.42°) Except P265/70R15

Minimum

32°48' (32.80°)

25' (0.42°)

P265/70R15

Except P265/70R15

P265/70R15

30°48' (30.80°)

33°06' (33.10°)

31°00' (31.00°)

Nominal

34°48' (34.80°)

32°48' (32.80°)

35°06' (35.10°)

33°00' (33.00°)

Maximum

34°48' (34.80°)

32°48' (32.80°)

35°06' (35.10°)

33°00' (33.00°)

Minimum

31°00' (31.00°)

28°42' (28.70°)

31°12' (31.20°)

29°00' (29.00°)

Nominal

33°00' (33.00°)

30°42' (30.70°)

33°12' (33.20°)

31°00' (31.00°)

Maximum

33°00' (33.00°)

30°42' (30.70°)

33°12' (33.20°)

31°00' (31.00°)°

Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.

Liter

AT & MT

Engine Dry engine Transmission

Distance (A - B) mm (in)

Degree minute (Decimal degree)

Unit Fuel tank

M/T

A/T

Transfer Final drive

11-5/8 qt

With oil filter

3.3

3-1/2 qt

3.0

3-1/8 qt

(engine overhaul)

3.8

4 qt

2WD

2.8

5-7/8 pt

4WD

5.1

10-3/4 pt

2WD

8.3

8-3/4 qt

4WD

8.5

9 qt

4WD

2.2

2-3/8 qt

Rear

H233B

2.8

5-7/8 pt

Front

R200A

1.75

3-3/4 pt

Power steering system Lubricant Refrigerant * *R-134a

19.4 gal

10.95

Without oil filter

Manual steering system

Air conditioning system

US measure

73.5

0.62

1-3/8 pt

1.0 - 1.1

33.8 - 37.2 fl oz

0.2

6.8 fl oz

0.6 - 0.7 kg

1.32 - 1.54 lb

ALPHABETICAL INDEX SECTION

IDX

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

ALPHABETICAL INDEX A AAC/V - Wiring diagram.......EC-437, 1009, 1589 ABS - Wiring diagram.................................BR-40 ABS sensor rotor ........................................AX-15 Absolute pressure sensor.........................EC-178 A/C air flow .................................................HA-19 A/C component layout ................................HA-20 A/C compressor clutch removal and installation ...............................................HA-70 A/C compressor description .......................HA-17 A/C compressor precaution ..........................HA-8 A/C compressor special service tool........................................HA-12, 16 A/C control linkage adjustment (manual A/C) ...........................................HA-42 A/C control operation (manual A/C) ...........HA-18 A/C diagnostic work flow (manual A/C)......HA-28 A/C HFC134a (R134a) system precaution..................................................HA-3 A/C HFC134a (R134a) system service tools.........................................................HA-13 A/C HFC134a system service equipment precaution................................HA-8 A/C lubricant (R134a) .................................HA-66 A/C lubrication oil........................................HA-66 A/C operational check ................................HA-29 A/C pressure switch....................................HA-51 A/C relay .....................................................HA-51 A/C service data specification ....................HA-87 A/C switch...................................................HA-18 A/C symptom chart (manual A/C)...............HA-28 A/C trouble diagnoses (manual A/C)..........HA-22 A/C, M - Wiring diagram.............................HA-26 Accelerator control system............................FE-3 Accelerator wire adjustment..........................FE-3 Air bag ..................................................RS-10, 16 Air bag disposal ..........................................RS-21 Air bag precautions........................................GI-3 Air bleeding (hydraulic clutch).......................CL-7 Air bleeding for brake system.......................BR-8 Air cleaner filter replacement ...............MA-21, 32 Air conditioner cut control.........EC-39, 625, 1198 Air flow meter - See Mass air flow sensor ....................EC-168, 761, 1334 Air spoiler, rear ............................................BT-32 Alternator ....................................................SC-37 Angular tightening application................EM-4, 66 Antenna - See Power antenna..................EL-153 Anti-lock brake system - Wiring diagram ...................................................BR-40 ASCD (automatic speed control device) ...................................................EL-155 ASCD - Wiring diagram.............................EL-160 A/T - Wiring diagram - AT - FTS ...............AT-112 A/T - Wiring diagram - AT - MAIN .............AT-101 A/T - Wiring diagram - AT - PNP/SW........AT-106

A/T - Wiring diagram - AT - VSS A/T ........AT-118 A/T control ....................................EC-1019, 1599 A/T diagnosis communication line.............................................EC-1126, 1706 A/T fluid temperature sensor .....................AT-115 A/T shift lock system .................................AT-260 A/T shift lock system - Wiring diagram .....AT-261 A/T Wiring diagram - AT - ENG SS...........AT-122 A/T Wiring diagram AT - 1ST ....................AT-128 A/T Wiring diagram AT - 2ND....................AT-134 A/T Wiring diagram AT - 3RD....................AT-140 A/T Wiring diagram AT - 4TH ....................AT-147 A/T Wiring diagram AT - BA/FTS ..............AT-195 A/T Wiring diagram AT - LPSV..................AT-166 A/T Wiring diagram AT - NONDTC ...........AT-212 A/T Wiring diagram AT - OVRCSV............AT-190 A/T Wiring diagram AT - SSV/A ................AT-171 A/T Wiring diagram AT - SSV/B ................AT-176 A/T Wiring diagram AT - TCCSIG .............AT-159 A/T Wiring diagram AT - TCV....................AT-154 A/T Wiring diagram AT - TPS ....................AT-182 A/T Wiring diagram AT - VSSMTR............AT-201 AT/C - Wiring diagram..................EC-1021, 1601 ATDIAG - Wiring diagram .............EC-1127, 1707 Audio .........................................................EL-144 AUDIO - Wiring diagram ...........................EL-146 Audio and A/C control removal and installation - See Instrument panel..........BT-20 Auto lock free running hub..........................AX-11 Automatic speed control system See ASCD..............................................EL-155 Automatic transmission fluid replacement ............................................MA-40 Automatic transmission number ..................GI-43 Auxiliary air control (AAC) valve..................................EC-434, 1006, 1586 B Back door ....................................................BT-15 Back door opener - See Back door ............BT-15 Back window ...............................................BT-32 Back-up lamp ..............................................EL-50 Back-up lamp switch (M/T).....................MT-8, 40 BACK/L - Wiring diagram ............................EL-50 Ball joint (front) ...........................................SU-17 Basic inspection......................EC-112, 701, 1273 Battery...........................................................SC-4 Battery/Starting/Charging System Tester ............................................SC-7, 16, 29 Baulk ring (M/T)....................................MT-12, 45 Blower motor...............................................HA-37 Blower resistor ............................................HA-37 Body alignment............................................BT-47 Body mounting ............................................BT-46 Boring/horning cylinder block .............EM-47, 119 Brake booster .............................................BR-16

IDX-2

ALPHABETICAL INDEX Brake fluid change........................................BR-6 Brake fluid level..........................................MA-43 Brake fluid level and line check....................BR-6 Brake hydraulic line ......................................BR-9 Brake inspection.........................................MA-43 Brake lines and cables inspection .............MA-43 Brake master cylinder.................................BR-13 Brake pedal.................................................BR-11 Bulb specifications.....................................EL-276 Bumper, front...............................................BT-12 Bumper, rear................................................BT-15 BYPS/V - Wiring diagram ......EC-541, 549, 1113, 1120, 1693, 1700 C Camshaft inspection.............................EM-32, 96 Camshaft position sensor (CMPS) ...............................EC-300, 901, 1481 Canister-See EVAP canister.....EC-40, 626, 1199 Center bearing assembly (propeller shaft) .......................................PD-11 Center bearing disassembly (propeller shaft) .........................................PD-9 Center case (Transfer) ................................TF-12 CHARGE - Wiring diagram.........................SC-27 Charging system.........................................SC-26 Chassis and body maintenance.................MA-38 CHIME - Wiring diagram ...........................EL-106 CIGAR - Wiring diagram ...........................EL-130 Cigarette lighter .........................................EL-130 Circuit breaker .............................................EL-17 CKPS - Wiring diagram...........EC-296, 492, 897, 1073, 1477, 1653 Closed loop control...................................EC-483 Closed loop control (Left bank).................................EC-1064, 1644 Closed loop control (Right bank) ..............................EC-1064, 1644 Closed throttle position switch ................................EC-440, 1012, 1592 Clutch cover ..........................................CL-12, 13 Clutch disc...................................................CL-12 Clutch fluid level .........................................MA-38 Clutch master cylinder ..................................CL-8 Clutch operating cylinder ..............................CL-9 Clutch pedal ..............................................CL-5, 6 Clutch release bearing ................................CL-10 Clutch release mechanism..........................CL-10 Clutch withdrawal lever ...............................CL-10 CMPS - Wiring diagram .........EC-303, 904, 1484 Collision diagnosis ......................................RS-57 Combination lamp, front, removal and installation ................................................BT-12 Combination lamp, rear, removal and installation ................................................BT-32 Combination meter ......................................EL-75

Combination meter removal and installation - See Instrument panel..........BT-20 Combination switch .....................................EL-32 COMPAS - Wiring diagram .........................EL-91 Compass .....................................................EL-90 Component Location (manual A/C) ............HA-22 Compression pressure .........................EM-15, 77 Compressor clutch removal and installation ...............................................HA-70 Compressor description..............................HA-17 Compressor precaution ................................HA-8 Compressor special service tool ..........HA-12, 16 Connecting rod ...................................EM-46, 118 Connecting rod bearing clearance ........................................EM-50, 123 Connecting rod bushing clearance ........................................EM-51, 123 Connector inspection ...................................GI-19 Console box - See Instrument panel ..........BT-20 CONSULT for ABS .....................................BR-49 CONSULT for engine ...............EC-94, 682, 1254 CONSULT-II general information .................GI-38 Control lever (M/T) ...............................MT-13, 47 Control valve (A/T) ....................................AT-293 Converter housing installation ...................AT-272 Coolant mixture ratio ..................................MA-15 Coolant replacement ............................MA-17, 28 Cooling circuit (engine) .........................LC-10, 27 Cooling fan............................................LC-16, 34 Cooling fan control .......EC-275, 485, 1066, 1646 Cooling unit (A/C evaporator).....................HA-85 Counter gear (M/T)...............................MT-12, 45 Counter gear (Transfer) ........................TF-13, 23 Coupling sleeve (M/T) ..........................MT-12, 45 Crank angle sensor built into distributor See Camshaft position sensor .................................EC-300, 901, 1481 Crankcase emission control system See positive crankcase ventilation..............................EC-55, 642, 1215 Crankcase ventilation system See Positive crankcase ventilation .........EC-55 Crankshaft ..........................................EM-48, 120 Crankshaft position sensor (OBD)..........................EC-294, 490, 895, 1475 Crankshaft position sensor (OBD) cog chipping ..........EC-490, 1071, 1651 Crash zone sensor .....................................RS-15 Cruise control - See ASCD .......................EL-155 Cylinder block.....................................EM-44, 115 Cylinder block boring .........................EM-47, 120 Cylinder head .......................................EM-29, 92 Cylinder head bolt tightening ...................EM-105

IDX-3

GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

ALPHABETICAL INDEX D Data link connector for Consult..................................EC-57, 682, 1254 Daytime light system ...................................EL-40 Daytime running light - See Daytime light system..............................................EL-40 DEF - Wiring diagram ...............................EL-134 Detonation sensor - See Knock sensor .................................EC-290, 891, 1471 Diagnosis sensor unit .................................RS-14 Diagnostic trouble code (DTC) for OBD system ................EC-18, 601, 661, 1174, 1233 Diagnostic trouble code (DTC) inspection priority chart.......EC-126, 715, 1288 Differential carrier assembly...........PD-32, 57, 84 Differential carrier disassembly ............PD-46, 70 Differential gear oil replacement ................MA-42 Dimensions ..................................................GI-44 Distributor .................................EC-37, 624, 1197 Distributor ignition (DI) system...................................EC-37, 624, 1197 D/LOCK - Wiring diagram .........................EL-191 Dome light - See Interior lamp....................EL-66 Door glass ...................................................BT-18 Door glass Fitting Adjustment .....................BT-18 Door lock .....................................................BT-18 Door mirror ..................................................BT-45 Door trim......................................................BT-27 Door, front....................................................BT-18 Drive belt inspection.............................MA-16, 26 Drive chain (Transfer) .................................TF-13 Drive pinion diff. inspection ............PD-25, 49, 73 Drive pinion height .........................PD-27, 51, 80 Drive plate runout...............................EM-52, 124 Drive shaft (front) ........................................AX-18 Dropping resistor (A/T) ..............................AT-168 DTC work support ..................EC-104, 693, 1265 DTRL - Wiring diagram ...............................EL-43 E ECM input/output signal .........EC-137, 726, 1299 ECTS - Wiring diagram ...........EC-187, 206, 777, 795, 1350, 1368 EGR control (EGRC) - BPT valve ............EC-320 EGR control (EGRC) - solenoid valve......EC-496 EGR temperature sensor..........................EC-328 EGR/TS - Wiring diagram.........................EC-331 EGRC/V - Wiring diagram ........................EC-498 EGRC1 - Wiring diagram .................EC-312, 506 Electrical diagnoses .....................................GI-22 Electrical ignition system ..........EC-37, 624, 1197 Electrical unit .............................................EL-284 Electrical units location..............................EL-247 Electronic ignition (EI) system ....................EC-37

Engine compartment ...................................BT-48 Engine control circuit diagram .................................EC-31, 618, 1191 Engine control component parts location.........................EC-29, 616, 1189 Engine control module (ECM)................................EC-447, 1024, 1604 Engine control system diagram and chart.................EC-32, 619, 1192 Engine coolant temperature sensor (ECTS) .................................EC-185, 204, 775, 793, 1348, 1366 Engine fail-safe system ..........EC-127, 716, 1289 Engine oil filter replacement ................MA-22, 33 Engine oil precautions ...................................GI-6 Engine oil replacement ........................MA-21, 32 Engine outer component parts.............EM-12, 74 Engine removal ..................................EM-41, 112 Engine room - See Engine compartment ............................................BT-48 Engine serial number...................................GI-43 EVAP canister ..........................EC-40, 627, 1200 EVAP canister purge volume control solenoid valve ..........EC-512, 626, 939, 1080, 1199, 1519, 1660 EVAP canister purge volume control valve..................................EC-366, 512 EVAP canister vent control valve.....................................EC-373, 523, 529, 946, 1092, 1099, 1526, 1672, 1679 EVAP control system (small leak) diagnosis.......................EC-42, 350, 405, 925, 976, 1078, 1505, 1556, 1658 EVAP control system pressure sensor ..................EC-380, 952, 1532 EVAP control system purge flow monitoring diagnosis...........EC-339, 913, 1493 EVAP system close mode ..........................EC-42 EVAP vapor lines inspection ................MA-23, 36 Evaporative emission (EVAP) system...................................EC-40, 626, 1199 Exhaust gas recirculation (EGR) valve ..................................EC-308, 503 Exhaust system.............................................FE-9 Exterior ........................................................BT-32 F Fan switch...................................................HA-36 Fast idle cam (FIC) inspection and adjustment ...........................EC-646, 1219 F/FOG - Wiring diagram..............................EL-52 FICD - Wiring diagram .........EC-593, 1166, 1746 Final drive disassembly ........................PD-45, 69 Final drive pre-inspection .....................PD-45, 69 Final drive removal and installation......PD-45, 69 Finisher, interior - See Trim.........................BT-24

IDX-4

ALPHABETICAL INDEX Floor trim .....................................................BT-24 Flow charts...................................................GI-22 Fluid temperature sensor (A/T) .................AT-115 Fluids ..........................................................MA-13 Flywheel (clutch) ...................................CL-12, 13 Flywheel runout..................................EM-52, 124 FO2H-L - Wiring diagram ...............EC-749, 1322 FO2H-R - Wiring diagram ..............EC-748, 1321 Fog lamp, front ............................................EL-51 Fog lamp, front, removal and installation ................................................BT-12 Fork rod (M/T) ......................................MT-13, 47 Forward clutch ...........................................AT-312 F/PUMP - Wiring diagram .............................EC-582, 1155, 1735 Freeze frame data....................EC-74, 661, 1233 FRO2 - Wiring diagram ............EC-213, 221, 233 FRO2/H - Wiring diagram.........................EC-160 FRO2LH - Wiring diagram ......EC-803, 812, 827, 1377, 1386, 1401 FRO2RH - Wiring diagram ......EC-802, 811, 826, 1376, 1385, 1400 Front axle ......................................................AX-2 Front bumper...............................................BT-12 Front case (Transfer) ............................TF-12, 25 Front combination lamp removal and installation.........................................BT-12 Front disc brake..........................................BR-19 Front door....................................................BT-18 Front drive shaft (Transfer) ...................TF-13, 22 Front final drive disassembly (4WD) ..........PD-20 Front final drive pre-inspection (4WD) .......PD-20 Front final drive removal and installation (4WD)....................................PD-19 Front fog lamp .............................................EL-51 Front fog lamp removal and installation......BT-12 Front heated oxygen sensor (HO2S)..................EC-211, 218, 229, 449, 456 Front heated oxygen sensor (HO2S) (Left bank) ....................................EC-800, 808, 822, 1026, 1035, 1374, 1382, 1396, 1606, 1615 Front heated oxygen sensor (HO2S) (Right bank) ....................................EC-800, 808, 822, 1026, 1035, 1374, 1382, 1396, 1606, 1615 Front heated oxygen sensor (HO2S) heater ....................................................EC-158 Front heated oxygen sensor heater (Left bank) .......................EC-746, 1319 Front heated oxygen sensor heater (Right bank) .....................EC-746, 1319 Front oxygen sensor (O2S) monitor ........................................EC-676, 1247 Front passenger air bag .......................RS-10, 19 Front seat ....................................................BT-37 Front seat belt...............................................RS-4 Front suspension ..........................................SU-2 Front washer..............................................EL-118 Front wiper.................................................EL-118

FUEL - Wiring diagram.....................EC-257, 264 Fuel cut control (at no load & high engine speed) ...............EC-39, 626, 1199 Fuel filler lid .................................................BT-15 Fuel filter .....................................................EC-57 Fuel gauge ..................................................EL-75 Fuel injection system........................EC-255, 262 Fuel injection system (Left bank) ................EC-853, 862, 1427, 1436 Fuel injection system (Right bank) ..............EC-853, 862, 1427, 1436 Fuel injector ..............................................EC-571 Fuel precautions ............................................GI-7 Fuel pressure check.................EC-57, 644, 1217 Fuel pressure regulator ............EC-58, 645, 1218 Fuel pressure release ..............EC-57, 644, 1217 Fuel pump.............................EC-580, 1153, 1733 Fuel pump and gauge...................................FE-7 Fuel pump relay........................................EC-580 Fuel system...................................................FE-4 Fuel tank temperature sensor .................................EC-269, 870, 1444 Fuel tank vacuum relief valve......................................EC-41, 627, 1200 FUELLH - Wiring diagram.....................EC-856, 865, 1430, 1439 FUELRH - Wiring diagram.....................EC-855, 864, 1429, 1438 Fuse.............................................................EL-17 Fuse block .................................................EL-281 Fusible link ..................................................EL-17 G

GI MA EM LC EC FE CL MT AT TF PD AX SU

Garage jack and safety stand......................GI-45 Gauges ........................................................EL-75 Gear components (M/T) .......................MT-12, 45 BR Generator....................................................SC-37 Generator - See Alternator .........................SC-37 Generic scan tool (GST) ........EC-106, 695, 1267 ST Glass ...........................................................BT-18 Grease........................................................MA-13

RS

H

BT Harness connector ........................................EL-6 Harness connector inspection .....................GI-19 HA Harness layout ..........................................EL-250 Hazard warning lamp ..................................EL-55 Headlamp ....................................................EL-35 SC Headlining - See Roof trim..........................BT-30 Heated oxygen sensor (HO2S) (front).......EC-211, 218, 229, 449, 456 EL Heated oxygen sensor (HO2S) heater (front) ............................EC-158

IDX-5

ALPHABETICAL INDEX Heated oxygen sensor (HO2S) heater (rear) ..........................................EC-163 Heated oxygen sensor (rear) .............................EC-237, 245, 463, 473 Heater unit (heater core) ............................HA-84 Height (Dimensions) ....................................GI-44 HFC134a (R134a) system precaution..........HA-3 HFC134a (R134a) system service tools.........................................................HA-13 HFC134a system service equipment precaution..................................................HA-8 High clutch.................................................AT-310 H/LAMP - Wiring diagram ...........................EL-36 Hood ............................................................BT-12 Horn...........................................................EL-129 HORN - Wiring diagram ............................EL-129 How to erase DTC for OBD system...................................EC-86, 673, 1246 Hydraulic lash adjuster inspection..............................................EM-102

Joint connector (J/C) .................................EL-283 Journal bearing assembly (propeller shaft) .......................................PD-11 Journal bearing disassembly (propeller shaft) .......................................PD-10 Jump seat....................................................BT-38 Junction box (J/B) .....................................EL-281

I

Leaf spring (rear) ........................................SU-25 Length (Dimensions)....................................GI-44 License lamp ...............................................EL-48 Lifting points.................................................GI-46 Limited slip diff. adjustment ........................PD-77 Limited slip diff. assembly ..........................PD-78 Limited slip diff. disassembly......................PD-74 Limited slip diff. inspection .........................PD-76 Line pressure solenoid valve ......................................AT-151, 163, 168 Line pressure test (A/T)...............................AT-65 Liquid gasket application .................EM-5, 19, 67 Location of electrical units.........................EL-247 Lock, door....................................................BT-18 Low and reverse brake..............................AT-316 Lubricant (R134a) A/C ................................HA-66 Lubricants ...................................................MA-13 Lubrication circuit (engine)......................LC-5, 20 Lubrication oil A/C.......................................HA-66 Lubrication-locks, hinges and hood latches.....................................................MA-47 Luggage room lamp ....................................EL-66

IACV-AAC valve ...................EC-434, 1006, 1586 IACV-FICD solenoid valve..................................EC-592, 1165, 1745 IATS - Wiring diagram............EC-182, 772, 1345 Identification..................................................HA-4 Identification plate ........................................GI-42 Idle air control (IAC) system.....................EC-434 Idle air control valve (IACV) ...............................EC-434, 1006, 1586 Idle mixture ratio.......................EC-59, 648, 1220 Idle speed.................................EC-59, 648, 1220 IGN/SG - Wiring diagram .....EC-564, 1139, 1719 Ignition control system..........EC-562, 1138, 1718 Ignition timing ...........................EC-59, 648, 1220 ILL - Wiring diagram....................................EL-64 Illumination ..................................................EL-63 INJECT - Wiring diagram .....EC-572, 1145, 1725 Injector ..........................................EC-1144, 1724 Injector removal and installation .............................EC-58, 645, 1218 Instrument panel..........................................BT-20 INT/L - Wiring diagram ................................EL-69 Intake air temparature sensor .................................EC-180, 770, 1343 Intake door control linkage adjustment...............................................HA-42 Intake manifold.....................................EM-12, 74 Interior .........................................................BT-24 Interior lamp ................................................EL-66 J Jacking points ..............................................GI-45

K Keyless entry system - See Multi-remote control system ..................EL-202 Knock sensor (KS) .........EC-290, 291, 891, 1471 Knuckle spindle...........................................AX-16 KS - Wiring diagram .......................EC-892, 1472 L

M MAFS - Wiring diagram..........EC-172, 765, 1338 Magnet clutch .............................................HA-70 MAIN - Wiring diagram...........EC-151, 740, 1313 Main drive gear (M/T)...........................MT-12, 45 Main gear (Transfer) .............................TF-13, 23 Mainshaft (M/T) ....................................MT-12, 45 Mainshaft (Transfer) ..............................TF-13, 20 Maintenance (engine) ..........................MA-16, 26 MAJOR OVERHALL..................................AT-274 Major overhaul (Transfer) ............................TF-11

IDX-6

ALPHABETICAL INDEX Malfunction indicator lamp (MIL)......................................EC-88, 675, 1247 Manual air conditioner Wiring diagram ........................................HA-26 Manual transmission number.......................GI-43 Manual transmission oil replacement.........MA-38 Mass air flow sensor (MAFS)................................EC-168, 761, 1334 Master cylinder (brake)...............................BR-13 Master cylinder (clutch).................................CL-8 Meter ...........................................................EL-75 METER - Wiring diagram ............................EL-80 MIL & Data link connectors circuit.................................EC-598, 1171, 1751 MIL/DL - Wiring diagram ......EC-598, 1171, 1751 MIRROR - Wiring diagram ........................EL-154 Mirror defogger..........................................EL-131 Mirror, door ..................................................BT-45 Mirror, out side ............................................BT-45 Misfire .....................................EC-281, 882, 1462 Mode door control linkage adjustment...............................................HA-39 Model variation.............................................GI-40 Molding - See Exterior ................................BT-32 M/T major overhaul...............................MT-11, 44 M/T removal and installation ..................MT-9, 41 MULTI - Wiring diagram ............................EL-206 Multi-remote control system ......................EL-202 Multiport fuel injection (MFI) system...................................EC-35, 622, 1195 Multiport fuel injection precautions .................................................GI-5 N Neutral position switch..............................EC-556 NVH troubleshooting (AX) ......................AX-4, 29 NVH troubleshooting (BR) ............................BR-5 NVH troubleshooting (CL).............................CL-4 NVH troubleshooting (EM) ...................EM-10, 72 NVH troubleshooting (M/T).....................MT-6, 36 NVH troubleshooting (PD) ............................PD-4 NVH troubleshooting (ST) .............................ST-5 NVH troubleshooting (SU) ............................SU-3 O Oil change (capacity) .................................MA-13 Oil pan (engine) ...................................EM-16, 79 Oil pressure (engine) ..............................LC-6, 21 Oil pump (A/T) ...........................................AT-289 Oil pump (engine) ...................................LC-6, 21 Oil pump regulator valve (engine) ..........LC-7, 23 Oil seal replacement (engine)..............EM-26, 90 Oil seal replacement (front final drive 4WD) ..............................................PD-16

Oil seal replacement (front of final drive) .................................................PD-43, 66 On board diagnostic system...................................EC-73, 660, 1232 Operating cylinder (clutch) ............................CL-9 ORVR (On-board Refueling Vapor Recovery) ...................EC-45, 632, 1205 Out side mirror ............................................BT-45 Overdrive control switch ............................AT-257 Overrun clutch ...........................................AT-312 Overrun clutch solenoid valve ...................AT-192 Oversize piston ..................................EM-48, 120 P Pantograph jack ...........................................GI-45 Park/Neutral position switch ................................EC-556, 1129, 1709 Park/neutral position switch (A/T) ...............................................AT-109, 258 Park/neutral position switch (M/T)....................................................MT-8, 40 Parking brake control..................................BR-27 Parking lamp ...............................................EL-48 PCV (positive crankcase ventilation).............................EC-55, 642, 1215 PCV filter replacement ...............................MA-24 PGC/V - Wiring diagram .........EC-369, 515, 942, 1083, 1522, 1663 Pilot bushing replacement..................EM-54, 126 Pinion bearing preload diff..........................PD-27 Pinion gear height diff. ...................PD-27, 51, 80 Piston assembly .................................EM-52, 124 Piston pin inspection ..........................EM-45, 117 Piston ring inspection .........................EM-46, 117 Piston to bore clearance ....................EM-47, 119 PNP/SW - Wiring diagram .............................EC-559, 1132, 1712 POWER - Wiring diagram ...........................EL-12 Power antenna ..........................................EL-153 Power door lock ........................................EL-186 Power door mirror .....................................EL-154 Power steering fluid level .................MA-45, ST-8 Power steering hydraulic pressure................ST-9 Power steering oil pressure switch ................................EC-588, 1160, 1740 Power steering oil pump .............................ST-18 Power steering system bleeding ...................ST-8 Power supply routing...................................EL-10 Power transistor & ignition coil.....................................EC-562, 1138, 1718 Power window ...........................................EL-176 PRE/SE - Wiring diagram ......EC-383, 954, 1534 Precations for Leak detection dye................HA-4 Precautions (General)....................................GI-3 Pressure plate - See Clutch cover..............CL-12 Pressure test (A/T) ......................................AT-65

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ALPHABETICAL INDEX Propeller shaft ......................................PD-3, 5, 6 Propeller shaft greasing .............................MA-41 Propeller shaft inspection...........................MA-41 Propeller shaft on vehicle service ................PD-7 Propeller shaft vibration................................PD-7 PST/SW - Wiring diagram .............................EC-589, 1161, 1741

RRO2 - Wiring diagram.........................EC-239, 248, 466, 476 RRO2/H - Wiring diagram ........................EC-165 RRO2LH - Wiring diagram ..............EC-837, 847, 1048, 1058, 1411, 1421, 1628, 1638 RRO2RH - Wiring diagram..............EC-836, 846, 1047, 1057, 1410, 1420, 1627, 1637

R

S

Radiator.................................................LC-14, 32 Radiator fan - See Cooling fan.............LC-16, 34 Radio - See Audio .....................................EL-144 Rear air spoiler............................................BT-32 Rear axle.....................................................AX-27 Rear body....................................................BT-46 Rear bumper ...............................................BT-15 Rear case (Transfer) .............................TF-12, 26 Rear combination lamp removal and installation.........................................BT-32 Rear cover packing replacement diff. ....................................................PD-17, 43 Rear drum brake.........................................BR-23 Rear heated oxygen sensor (HO2S).................................EC-237, 245, 463, 473, 833, 843, 1044, 1054, 1407, 1417, 1624, 1634 Rear heated oxygen sensor (HO2S) heater ....................EC-163, 753, 1326 Rear seat.....................................................BT-38 Rear seat belt ...............................................RS-5 Rear side window........................................BT-41 Rear suspension.........................................SU-20 Rear washer ..............................................EL-124 Rear window defogger ..............................EL-131 Rear wiper .................................................EL-124 Refrigerant connection precaution................HA-4 Refrigerant discharging evacuating charging...................................................HA-64 Refrigerant general precaution .....................HA-3 Refrigerant lines..........................................HA-77 Refrigeration cycle ......................................HA-17 Release bearing (clutch) .............................CL-10 Removal and installation (A/T) ..................AT-271 Removal and installation (Transfer) ............TF-10 Reverse clutch...........................................AT-306 Reverse idler shaft (M/T)......................MT-12, 45 Reverse lamp switch (M/T) - See Back-up lamp switch (M/T) .................MT-8, 40 Reverse main gear (M/T) .....................MT-12, 45 Revolution sensor (A/T).............................AT-120 Ring gear diff. inspection ...............PD-25, 49, 73 RO2H-L - Wiring diagram...............EC-756, 1329 RO2H-R - Wiring diagram ..............EC-755, 1328 Road wheel size ..........................................GI-44 Roof trim......................................................BT-30 Room lamp - See Interior lamp...................EL-66

SAE J1930 terminology list..........................GI-51 S/CHGR - Wiring diagram ......................EC-1459 Seal - See Exterior......................................BT-32 Seat belt inspection .........................MA-48, RS-6 Seat belt pre-tensioner .........................RS-10, 15 Seat belt pre-tensioner disposal.................RS-21 Seat belt, front ..............................................RS-4 Seat belt, rear ...............................................RS-5 Seat, front....................................................BT-37 Seat, rear.....................................................BT-38 Self-diagnostic results ..............EC-88, 676, 1247 SHIFT - Wiring diagram ............................AT-261 Shift control (Transfer) ..........................TF-14, 27 Shift control components (M/T) ............MT-13, 47 Shift fork (M/T)......................................MT-13, 47 Shift lever..............................................MT-13, 47 Shift lock system .......................................AT-260 Shift schedule ............................................AT-348 Shift solenoid valve A (A/T)...............................AT-130, 142, 151, 173 Shift solenoid valve B (A/T)...............................AT-130, 135, 151, 178 Shock absorber (front)................................SU-12 Shock absorber (rear).................................SU-24 Side bearing preload (front final drive 4WD) ..............................................PD-26 Side bearing preload diff. ...........................PD-50 Side shaft diff..............................................PD-24 Side trim ......................................................BT-24 Smart entrance control unit.......................EL-242 SMJ (super multiple junction)....................EL-279 Spare tire size..............................................GI-44 Spark plug replacement .......................MA-22, 34 Speedometer ...............................................EL-75 Spiral cable .................................................RS-16 Spot lamp ....................................................EL-66 SRS - See Supplemental Restraint System.....................................RS-10 SRS - Wiring diagram.................................RS-34 S/SIG - Wiring diagram ........EC-577, 1150, 1730 Stabilizer bar (front) ....................................SU-14 Stabilizer bar (rear).....................................SU-26 Stall test (A/T)..............................................AT-62 Standardized relay ........................................EL-8 START - Wiring diagram.............................SC-13 Start signal............................EC-576, 1149, 1729 Starter .........................................................SC-23

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ALPHABETICAL INDEX Starting system ...........................................SC-10 Steering gear, linkage and transfer gear inspection .......................................MA-44 Steering linkage...........................................ST-21 Steering switch ............................................EL-34 Steering wheel and column.........................ST-11 Steering wheel play.......................................ST-6 Steering wheel turning force .........................ST-9 Stop lamp ....................................................EL-49 STOP/L - Wiring diagram ............................EL-49 Striking rod (M/T)..................................MT-13, 47 Sub-gear (M/T) .....................................MT-12, 45 Sunroof ........................................................BT-39 Supercharger ..........................................EC-1456 Supercharger bypass (SCB) valve control solenoid valve .........................EC-1456 Supplemental Restraint System .................RS-10 Supplemental restraint system Wiring diagram ........................................RS-34 Symbols and abbreviations............................GI-9 Symptom matrix chart ............EC-128, 717, 1290 Synchronizer (M/T) ...............................MT-12, 45 System readiness test (SRT) code ......................................EC-75, 662, 1234 T Tachometer..................................................EL-75 Tail lamp ......................................................EL-48 TAIL/L - Wiring diagram ..............................EL-48 TCM circuit diagram ....................................AT-13 TCM inspection table...................................AT-97 Temperature control cable and linkage adjustment ..................................HA-62 TFTS - Wiring diagram...........EC-271, 872, 1446 THEFT - Wiring diagram ...........................EL-226 Theft warning system ................................EL-220 Thermal protector .......................................HA-51 Thermo control amp ...................................HA-52 Thermometer ...............................................EL-90 Thermostat ............................................LC-13, 31 Three way catalyst....................................EC-334 Three way catalyst function (Left bank)...................................EC-908, 1488 Three way catalyst function (Right bank) ................................EC-908, 1488 Three way catalyst precautions .....................GI-5 Throttle bodies .....................................EM-12, 74 Throttle chambers ................................EM-12, 74 Throttle drum adjustment ..............................FE-3 Throttle position sensor (TPS)...................................EC-190, 780, 1353 Throttle position sensor adjustment...........................EC-112, 701, 1273 Throttle position switch.....................AT-187, 258, EC-440, 1012, 1592

Throwout bearing - See Clutch release bearing........................................CL-10 Tie-rod .........................................................ST-21 Tie-rod ball joints .........................................ST-21 Tightening torque of standard bolts .............GI-49 Timing belt..................................................EM-82 Timing chain ...............................................EM-18 Tire rotation ................................................MA-43 Tire size .......................................................GI-44 Tooth contact (front final drive 4WD) .......................................................PD-31 Tooth contact diff. .................................PD-56, 83 Torque converter installation .....................AT-272 Torque convertor clutch solenoid valve ................................AT-156, 163 Torsion bar spring .......................................SU-12 Tow truck towing ..........................................GI-46 Towing point .................................................GI-48 TP/SW - Wiring diagram ......EC-442, 1014, 1594 TPS - Wiring diagram.............EC-195, 785, 1358 Transfer case ..............................................TF-12 Transfer oil replacement ............................MA-40 Transfer serial number.................................GI-43 Transmission case (M/T) ......................MT-11, 44 Transmission serial number.........................GI-43 Tread-FR&RR (Dimensions) ........................GI-44 Trim .............................................................BT-24 Trouble diagnoses .......................................GI-32 Turbine revolution sensor ..........................AT-203 TURN - Wiring diagram...............................EL-57 Turn signal lamp..........................................EL-55 Two trip detection logic ............EC-73, 660, 1232 Two-pole lift..................................................GI-46

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U

SU Under body..................................................BT-50

BR V

ST Vacuum cut valve ...........................EC-626, 1199 Vacuum cut valve bypass valve.....................................EC-539, 546, 626, 1111, 1117, 1199, 1691, 1697 Vacuum hose drawing (Engine control).....................EC-33, 620, 1193 Valve clearance..................................EM-38, 128 Valve guide...........................................EM-33, 97 Valve lifter...................................................EM-37 Valve seat.............................................EM-35, 99 Valve spring........................................EM-37, 101 Vehicle identification number .......................GI-42 Vehicle recovery (freeing a stuck vehicle)............................................GI-48 Vehicle speed sensor (VSS) ................................EC-430, 1002, 1582

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ALPHABETICAL INDEX VENT/V - Wiring diagram................EC-375, 948, 1094, 1102, 1528, 1674, 1682 Viscosity number (SAE) .............................MA-14 VSS - Wiring diagram ..........EC-432, 1004, 1584 W WARN - Wiring diagram..............................EL-95 Warning chime ..........................................EL-103 Warning lamps ............................................EL-94 Washer, front .............................................EL-118 Washer, rear..............................................EL-124 Water pump ..........................................LC-12, 29 Water temperature gauge ...........................EL-75 Weatherstrip - See Exterior.........................BT-32 Wheel alignment (front) ................................SU-6 Wheel balance............................................MA-43 Wheel bearing (front) ....................................AX-5 Wheel bearing (rear)...................................AX-30 Wheel hub (front) ........................................AX-14

Wheel sensors (ABS) ...........................BR-55, 75 Wheel size ...................................................GI-44 Wheelbase (Dimensions).............................GI-44 Wide open & closed throttle position switch ....................EC-190, 780, 1353 Width (Dimensions)......................................GI-44 WINDOW - Wiring diagram.......................EL-180 Window, back ..............................................BT-32 Window, door...............................................BT-18 Window, opera.............................................BT-46 Windshield ...................................................BT-40 WIP/R - Wiring diagram ............................EL-125 WIPER - Wiring diagram...........................EL-120 Wiper, front ................................................EL-118 Wiper, rear.................................................EL-124 Wiring Diagram (Cell code) list .................EL-277 Wiring diagrams ...........................................GI-10 Withdrawal lever (clutch).............................CL-10 Wrist pin - See Piston pin inspection........................................EM-45, 117

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