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
PLEASE HELP MAKE THIS SERVICE MANUAL BETTER! Your comments are important to NISSAN and will help us to improve our Service Manuals. Use this form to report any issues or comments you may have regarding our Service Manuals. Please print this form and type or write your comments below. Mail or fax to: Nissan North America, Inc. Technical Service Information 39001 Sunrise Drive, P.O. Box 9200 Farmington Hills, MI USA 48331 FAX: (248) 488-3910 SERVICE MANUAL:
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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
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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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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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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
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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
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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
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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
SC
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”
SC-2
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
AT TF PD AX SU BR ST RS BT HA
EL
SC-3
IDX
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.
SC-4
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
SC-5
SU BR ST RS BT HA
EL IDX
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.
SC-6
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
SC-7
IDX
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”.
SC-8
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”.
GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA
EL
SC-9
IDX
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.
SC-10
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.
GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA
EL
SC-11
IDX
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.
SC-12
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
EL WSC058
SC-13
IDX
STARTING SYSTEM Wiring Diagram — START — (Cont’d)
VG33E AND VG33ER M/T MODELS
NGSC0005S02
WSC059
SC-14
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
SC-15
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.
LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA
EL
SC-17
IDX
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
EL
SC-19
IDX
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.
SC-20
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
EL
SC-21
IDX
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
SC-22
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
EL
SC-23
IDX
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.
AT TF PD AX SU BR ST RS BT HA
EL
SC-25
IDX
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
GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA
EL WSC056
SC-27
IDX
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
EL
SEL419X
SC-29
IDX
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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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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